JPH1044581A - Production of molded object having intaglio and relief printing display - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a molded object formed by a sheet molding method and having a pattern layer free from strain or deinking provided in the side surface part thereof. SOLUTION: A molded object 10 has an opening part 3 and the surface of at least one of the outside and inside of a pre-printing sheet 12 is constituted of a thermal resin layer and the pre-printing sheet 12 is obtained by pressure forming or vacuum molding. In this case, the intaglis or relief pattern 6 of a mold corresponding to the pattern layer 2 provided in the side surface part 45 of the molded object and the pattern layer 21 of the pre-printing sheet provided so as to estimate deformation at a time of molding are deformed after molding to form a matched intaglis and relief. printing display.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

TECHNICAL FIELD The present invention relates to an uneven surface of a molded article in which a picture layer printed on a molding sheet is formed on the molded article through processing such as stretching and deformation such as heating and drawing. Has a uniform pattern layer, and
It is an object of the present invention to provide a molded article having an uneven printed display provided with a picture layer conforming to the shape of the molded article.

[0002]

DISCLOSURE OF THE INVENTION The present invention provides a molded article produced by a sheet molding method, which has an accurate pattern layer without distortion on the side surface having a concave and convex shape, and a sheet molding method. It is an object of the present invention to provide a molded product having a picture layer in mass production without being limited by the display portion and the shape or size of the molded product.

[0003]

In order to solve the above-mentioned problems, the present invention provides a molded article having an opening, wherein at least one of the outer and inner surfaces of a molding sheet is formed of a thermoplastic resin layer. The pre-printed sheet, in a molded body obtained by pressurized air or vacuum molding, a concave or convex pattern of a mold corresponding to a picture layer provided on the side surface of the molded body, and provided by predicting deformation during molding The pattern layer of the pre-printed sheet is a molded article having a concavo-convex printed display that is deformed and matched after molding. The unevenness of the molded body is a molded body having a fine three-dimensional satin pattern, a one-dimensional rib stand in a stretching direction, or a concave-convex printed display as a picture layer formed in an irregular shape in both vertical and horizontal directions. The molded body has an opening, and at least one surface of the outside and the inside of the molding sheet is obtained by pressurizing or vacuum molding a preprinted sheet composed of a thermoplastic resin layer, and the irregularities are provided. The above molding sheet is in contact with the mold surface
This is a method for producing a molded article having a concavo-convex print display, characterized by molding.

[0004]

2. Description of the Related Art Conventionally, when a molded article is manufactured from a synthetic resin sheet (hereinafter, referred to as sheet molding), the periphery of the molded article is fixed, and if necessary, plug assist is used. In this case, it is performed by a method such as drawing or drawing by pressure forming or vacuum forming. 2. Description of the Related Art A sheet forming method is widely used in which a sheet-like thermoplastic resin is softened by heating or is fixed at normal temperature, and its periphery is fixed, and the sheet is stretched by means of a plug and compressed air or reduced pressure. Such sheet molding is suitable for mass production because the equipment cost of the molding machine is low and the molding speed is high as compared with other molding methods (for example, injection molding).

[0005] The usual method of providing a pattern layer of characters, patterns, figures, images, etc. on a molded article by sheet molding is to directly print on the surface of the molded article, for example, dry offset printing, gravure offset printing, pad printing, silk screen printing. It is performed by a method such as printing, transfer printing, or sticking a label. However, these methods can be performed on a curved surface, which is a secondary surface, of the molded body, but a three-dimensional printed body with a concavo-convex pattern or a special jig or a small-sized one. A dedicated machine was needed. If the shape of the printing surface is uneven or the size is small, there is a problem that it is difficult to perform printing directly from the viewpoint of ink loss and handling. In addition, when a preliminary pattern layer is provided on a sheet having good productivity and subjected to molding, the desired pattern layer cannot be obtained accurately because the sheet in the molded portion, particularly the side portion, does not deform uniformly. was there.

When it is difficult to form a picture layer to be printed on a molded article, a method of simultaneously performing molding and printing [injection molding by inserting a label into a mold (in-mold label method); And transferring the pattern layer by heat and pressure during molding, or by injection molding using several resins of different types or colors. However, these methods are injection molding methods and thus have good dimensional accuracy of the molded body, but are disadvantageous in terms of production cost because of high mold cost and low productivity. In particular, in the method of inserting a label or a transfer film into a mold, an automatic insertion machine may be required, and there is a problem that equipment costs are high. Further, when the surface on which the pattern layer is provided is formed into an uneven shape, the pressure required for printing is not uniform in the above method, so that the transfer of ink cannot form the desired pattern layer, and the label is inserted or pasted. There is a problem in that the label is not stretched and deformed into an uneven shape, so that the surface of the molded article does not match the pattern layer.

Although the above-mentioned in-mold labeling method is applied to sheet molding, an automatic insertion machine is required, which increases the scale and cost of equipment, and causes wrinkles on labels at the time of label insertion. Or the position of the label is shifted, resulting in a large production loss.

As shown in FIG. 1, the pre-printed sheet 12 in the present specification is a single-layer or a multi-layer sheet (not shown) used as a molding sheet, and a preliminary pattern layer 21 provided by predicting deformation after molding. It refers to a sheet printed matter that becomes a picture layer 2 of a desired molded body by being deformed and formed on the molded body by sheet molding. When the molding sheet has a multilayer structure, the pre-printed sheet 12 provided with the preliminary pattern layer 21 provided on at least one surface of the thermoplastic resin is formed with the desired pattern layer 2 on the molded body 10 in which the molding is completed. To display.

[0009]

DESCRIPTION OF THE PREFERRED EMBODIMENTS A molded article 10 provided with a picture layer according to the present invention.
As shown in FIG. 1 (A) and FIG. 2 (A), a preprinted sheet 12 having an opening 3 and having at least one of an outer surface and an inner surface formed of a thermoplastic resin layer is compressed or vacuum formed. Therefore, it is obtained. And FIG.
(C) and the mold 5 shown in FIG. 2 (C) are formed on the surface of the pre-printed sheet 12 that is stretched and formed on the formed body by the contact with the preliminary pattern layer 21. A molded body 10 capable of uniformly forming a printed display corresponding to No. 6. In addition, the uneven shape of the molded body 10 has a fine three-dimensional satin pattern 6 shown in FIG. 1C, a one-dimensional rib stand 66 in the stretching direction shown in FIG. This is a molded product formed by providing a concave and convex print display, which is a pattern layer 62 formed in a convex shape, on a mold. Further, the formed body 10 provided with the pattern layer 2 and / or the formed body provided with the uneven portion 4 has the opening 3 shown in FIGS. 1A and 2A and at least one of the outside and the inside. The pre-printed sheet 12 whose surface is formed of a thermoplastic resin layer is obtained by pressurized air or vacuum forming. Then, the pattern 62 of the concave or convex portion of the mold corresponding to the pattern layer 2 of the molded body and the preliminary pattern layer 21 of the molding sheet provided by predicting the deformation at the time of molding are deformed. Molded article 10 having a concavo-convex print indication that matches
It is a manufacturing method of.

In order to form a molded body 10 having the picture layer 2 shown in FIGS. 1 and 2, the present invention designs the preliminary picture layer 21 in the following manner. That is, for example, on a disc-shaped single-layer base material of an amorphous polyethylene terephthalate (A-PET) sheet having a thickness of 500 μm, concentric and radial straight reference lines 26 are provided on a molding sheet shown in FIG. The pre-printed sheet 12 provided with the preliminary picture layer 21 defining the reference point 27 which is the intersection is created. And the sheet forming machine 9
Then, as shown in FIGS. 4A to 4D, the fixing jig 90
The pre-printed sheet 12 provided with the preliminary picture layer 21 is fixed. After heating the sheet 12 to a temperature at which the sheet 12 can be formed, the plug-driven mold is moved to move the center of the preprinted sheet 12 to the upper and lower molds 91 and 92 and the plug 9.
3 and the center line 94 are matched. Further, the plug 93 and the compressed air 96 were operated, and the plug assist molding was completed using the vacuum 95. The obtained molded body 10 is shown in FIG.
(B) is a flat-bottomed cylindrical shape having a flange forming portion 31 on the side of the opening 3, and the forming side surface 45 is a formed body 10 having an uneven portion (a picture layer formed by a reference point) 4. .

The stretched state of the preprinted sheet is predicted by measuring the reference points 27 of the respective parts of the obtained molded body 10 shown in FIG. This defines the picture layer 21. Hereinafter, the preliminary pattern layer in the present specification is formed by using the one obtained by the above method.

The molding sheet used for the preprinted sheet may have a single-layer or multi-layer structure containing at least a thermoplastic resin layer. Then, the molded body 10 is formed as shown in FIG.
2 and an opening 3 as shown in FIG. 2, the position of which is not explicitly shown in the drawing, but at least one of the molding side exterior 45 and / or the molding side interior 46 is predicted and defined in a stretched state. This is obtained from the preprinted sheet 12 provided with the preliminary pattern layer 21 described above.

According to the present invention, the stretching state of the forming sheet is first predicted, and the degree of distortion of the preliminary picture layer and the display position are set.
The preliminary pattern layer 21 provided on the sheet for molding is formed by removing the ink from the irregular portions 6, the pattern 62, and / or the rib stand 66 of the mold for forming the irregular surface on the molded body 10 without any ink leakage, and the normal desired pattern layer 21 is formed. An uneven portion (such as a satin pattern) 4 can be provided on the outer side of the picture layer 2 and / or the molded body.

The shape of the molded body having an opening is shown in FIGS.
5 is not limited to the flat bottom cylindrical shape shown in FIG.
As shown in (A), (B), (C), (D) or (E), a round-bottom cylindrical molded body 71, a hemispherical molded body 72, a shallow convex molded body 73, and a rectangular parallelepiped molded body 74 Alternatively, all shapes that can be created by sheet stretching and molding such as a polygonal columnar molded body 75 can be manufactured.

When the molded body has a round bottom shape, a hemispherical shape, a shallow convex shape, or the like, the boundary between the molding bottom surface and the molding side surface cannot be clearly defined. However, in the present invention, the molding side surface portion is the body portion of the molded body, and a preliminary pattern layer that is simply obtained by calculating the stretching ratio of the molding sheet is printed. If the pattern layer is not deformed and the drawing unevenness is not taken into account, it means a region in which a picture layer without distortion or misalignment cannot be completed, and includes a region that is not apparent in appearance. The shapes of the flange 31 and the side surface of the molded body have appropriate sizes depending on the use of the molded body, but it is necessary to secure a space where the flange 31 can be fixed during molding.

The preheating of the preprinted sheet 12 is carried out by sandwiching a forming sheet between upper and lower heaters, and directly contacting the heater with the corresponding portion of the forming to heat and soften the sheet. With an interval between them,
There is a non-contact heating method of heating and softening by radiant heat. The contact heating method has a problem that, when heating the forming sheet, there is a problem that the feed temporarily stays and it is difficult to take out a large number of formed bodies, but only a portion corresponding to the forming of the forming sheet is formed. There is a feature that heating is easy. On the other hand, the non-contact heating method can be applied to a continuous sheet or a wide sheet, and can send a forming sheet without stagnation depending on a heating device or a forming device.

[0017] The molded article having the picture layer of the present invention obtained by the above-mentioned method, regardless of the one produced by sheet molding, is a place where stretching unevenness is likely to occur, for example, a molding side portion or a place where the surface shape is complicated. In addition, this is a method that has not existed in the past so that the predicted pattern layer can be displayed. Therefore, it is possible to efficiently mass-produce a molded article having an accurate pattern layer without distortion and displacement by a sheet molding method. The sheet forming machine does not require any special equipment such as an automatic label automatic label inserting machine.

FIG. 1A shows a molded article 1 provided with a rib stand.
FIG. 2A is a perspective view of a molded body 10 having a picture layer 2 provided on an uneven surface according to the present invention. FIG. 1 (B) or FIG.
(B) is a preprinted sheet 12 to be subjected to molding. FIG. 1 (C) or FIG. 2 (C) is a perspective view of a mold for molding the molded body 10.

The pattern layer having no distortion or misalignment is provided with a preliminary pattern layer 21 for designing a distorted preliminary pattern layer 21 pre-printed on a molding sheet having a disk-shaped molding portion shown in FIG. 2 shows a print sheet 12. The preliminary design layer 21 is completed as the design layer 2 of the molded body 10 as a result of being deformed following the elongation of the sheet during sheet formation. The degree of distortion of the preliminary picture layer and the position of the display are determined in consideration of not only the stretching ratio of the molding sheet but also the stretching unevenness.

The molded article of the present invention may have either a single-layer structure or a laminated structure. In the case of a multilayer structure, it is necessary to include a thermoplastic resin layer as a main layer. For example, a picture layer can be provided on the outer thermoplastic resin layer, or a picture layer can be provided on the inner thermoplastic resin layer. In the laminated structure of the multilayer sheet, layers selected in consideration of the use of the molded article and the like are laminated. The laminated sheet of the molded body is
The thermoplastic resin layer may be composed of two or more layers,
For example, the inner surface layer may be a thermoplastic resin layer,
Further, the innermost layer may be a flexible reaction type resin layer or a metal foil layer other than the thermoplastic resin layer. In addition, the picture layer can be protected by providing a thermoplastic resin layer or a picture protection layer made of, for example, a flexible reactive resin layer.

In the case where the preprinted sheet has a laminated structure, it is necessary that the layer including at least the main layer composed of the thermoplastic resin layer and the layer for providing the preliminary pattern layer be formed of the thermoplastic resin layer. .

The thickness of the molding sheet is 50 to 2000 μm
It is. Then, the sheet can be manufactured by forming a film using a known T-die or circular die, or combining an existing sheet or film with dry lamination provided with an adhesive layer or melt extrusion coating as necessary. . Thermoplastic resin layer, polyolefin resin, polystyrene resin, polyester resin, vinyl chloride resin, polyamide resin, polyimide resin,
Examples include polyurethane resins, acrylic resins, ABS, acrylonitrile resins, and cellulose derivatives. In addition to these, as a functional resin, ethylene
Vinyl alcohol copolymer, hygroscopic resin, adhesive resin,
Elastomer, release resin (fluororesin, silicone)
and so on.

A special function can be added to the thermoplastic resin layer by blending other components up to 40% by weight. For example, calcium carbonate, magnesium carbonate, aluminum hydroxide, magnesium hydroxide, zinc oxide, magnesium oxide, aluminum silicate, calcium silicate, zeolite, etc. may be used as a bulking agent, a reduction in calorie combustion, and a flame retardant. it can. In addition, a pigment, metal powder, carbon black, or the like that gives a light-shielding property, an ultraviolet blocking property, a color, or the like can be added.

It is preferable to add an antistatic agent to the thermoplastic resin layer in order to prevent printing stains. Examples of the antistatic agent include an anionic surfactant, a cationic surfactant, an amphoteric surfactant, a nonionic surfactant, and a tetrafunctional silicon partial hydrolyzate. In addition, metal powder, metal oxide powder, metal sulfide, etc., which have been subjected to conductive treatment to prevent dust adhesion and sheet electrification, conductive carbon, bisammonium organic sulfur semiconductor and so on. The antistatic agent may be added to an adhesive layer, a protective layer, or the like, may be added to a material between layers of the molding sheet, or may be applied to the surface.

The adhesive or anchor coating agent used when laminating each layer of the molding sheet includes polyolefin-based, polyethyleneimine-based, polybutadiene-based, organic titanium compound, polyester-based, polyurethane-based, and isocyanate-based ones. . Examples of the adhesive resin include a thermoplastic resin layer having at least one carbonyl group such as a carboxylic acid, a carboxylate, a carboxylic anhydride, a carboxylic amide, and a carboxylic ester in a main chain or a side chain. For example, ethylene-acrylic acid copolymer, ionomer, maleic anhydride-grafted polyethylene, maleic anhydride-grafted polypropylene, acrylic acid-grafted polyolefin, ethylene-vinyl acetate copolymer,
Examples include polyester-based resins and polyamide-based resins. And the multilayer sheet laminated | stacked through these adhesives, an anchor coat agent, and adhesive resin can be formed by a well-known bonding method or co-extrusion processing.

Between each layer of the molding sheet, low density polyethylene, low medium density linear polyethylene, ethylene / vinyl acetate copolymer, ethylene / acrylic acid copolymer, ethylene / acrylic ester copolymer, ionomer, polypropylene And the like can be used as a rigidity adjusting layer of a molding sheet. In this case, the adhesion can be strengthened by using the above-mentioned adhesive or anchor coating agent. In addition, the thickness of the adhesive layer is preferably 1 μm to 10 μm, and the thickness of the adhesive resin layer and the rigidity adjusting layer is preferably 5 to 200 μm.

It is preferable to provide a protective layer on the preliminary picture layer in order to prevent the picture layer from falling off or being contaminated due to friction with the mold during sheet molding and physical and chemical damage when the molded article is distributed. . The protective layer is formed by laminating the above thermoplastic resin layer film, polyester resin, polyolefin resin, acrylic resin, urethane resin, vinyl chloride / vinyl acetate copolymer, polyamide resin, cellulose derivative. A plasticizer is added to a varnish or a water-soluble dispersion obtained by dissolving one or two or more mixed resins in a solvent.
A dispersion of a lubricant, an antistatic agent and other auxiliaries can be applied and used. Further, an acrylic ionizing radiation-curable resin or a highly flexible reaction-curable resin such as a vinylated alkyd can be applied and formed as a protective layer of the picture layer. The thickness of the protective layer is 5 to 8 for the film.
0 μm, and 1 to 50 μm when applied.

[0028]

EXAMPLE A 500 μm thick Denka A-PET (trade name, manufactured by Denki Kagaku Kogyo Co., Ltd.) was used as a molding sheet, and a urethane resin / vinyl chloride / vinyl acetate copolymer (weight ratio: 35/65) was used. , A binder 50 composed of a lubricant
The composition consisting of 50% by weight of carmine 6B and 50% by weight of carmine 6B was screen-printed using an ink prepared with a solvent, and FIG.
The pre-printed sheet 12 provided with the preliminary picture layer 21 in which the stretching ratio was predicted and converted in advance on the molding side surface portion 45 was prepared. Then, as shown in FIGS.
Then, the pre-printed sheet 12 provided with the preliminary picture layer 21 is fixed, heated to a temperature at which the sheet can be molded, and the center line of the molding sheet 12 and the upper mold 9 are fixed by a plug-driven mold.
1. The center line 94 of the plug 92 and the mold 92 provided with the mold 5 having a fine pattern of satin finish were matched. Then, plug assist molding was performed using the plug 93, compressed air (96), and vacuum (95). The obtained molded body 10 is shown in FIG.
As shown in FIG. 2A or FIG. 2A, the picture layer 2 has a flange 31 on the side of the opening 3 and has a good shape without any distortion, which is formed in a predetermined dimension in both the vertical and horizontal directions of the pattern after molding. .

[0029]

[Comparative example]

(Comparative Example 1) Using the same molding sheet as that used for preparing the preprinted sheet of the example, a molded article having a matte fine uneven pattern was similarly produced. Then, characters were printed directly on the surface of the molded body by the dry offset method, and as a result,
The characters in the printed portion did not transfer to the concave portions of the satin finish, and there was ink leakage or a faint state, and a clear picture layer could not be obtained.

(Comparative Example 2) A pattern layer was printed using the same forming sheet as the one prepared in Example 1 without particularly estimating the stretched state of the base material, and the surface was similarly patterned. An uneven molded body having a pattern was prepared. The pattern of the molded product was distorted, and a pattern layer as expected could not be obtained.

[0031]

As described in detail above, the preprinted sheet in which the molded article of the present invention has an opening and at least one of the outer and inner surfaces of the molding sheet is formed of a thermoplastic resin layer. In the molded body obtained by air-pressure or vacuum molding, the concave or convex pattern of the mold corresponding to the pattern layer provided on the side surface of the molded body, and the pattern of the pre-printed sheet provided by predicting deformation during molding The effect was obtained in that the layer was deformed after molding to form a molded article having the same concavo-convex print indication. Then, the uneven shape of the molded article is a fine three-dimensional satin pattern, a one-dimensional rib stand in the stretching direction, or a pattern layer formed in an uneven shape in both the vertical and horizontal directions, the desired uniform and uniform in the desired position at a predetermined position A picture layer could be formed. Further, the molded article pattern layer obtained by contacting the molding sheet with the mold surface provided on the side surface of the mold provided with the concave and convex portions and stretching and molding by pressurized air or vacuum molding shows the concave and convex printed display of the mold. This is a method for producing a molded article that can be reproduced.

[Brief description of the drawings]

FIG. 1A is a perspective view showing the concept of a molded article of the present invention. (B) It is a top view showing the concept of the form of a preprint sheet. (C) It is a perspective view which shows the concept of the metal mold | die which shows the uneven | corrugated pattern of the molded object of this invention.

FIG. 2A is a perspective view showing the concept of a molded article having another shape according to the present invention. (B) It is a top view which shows the concept of the form of the preprint sheet of another shape. (C) It is a perspective view which shows the concept of the metal mold | die which shows the uneven | corrugated pattern of the molded object of another shape.

FIG. 3A is a plan view of a preprinted sheet for explaining a step of designing a preliminary pattern layer. (B) It is a perspective view which shows the molded object obtained from the said molding sheet.

FIG. 4A is a schematic cross-sectional view of a molding machine for explaining an outline of a sheet molding mechanism and a fixing state of a molding sheet. (B) It is the cross-sectional schematic which shows the state which heats the sheet | seat for shaping | molding, and moves a die. (C) It is the cross-sectional schematic which shows the state which the plug and the compressed air were operated, and the sheet | seat for shaping | stretching was extended. (D) is a schematic sectional view showing a state in which molding has been completed using vacuum.

FIG. 5A is a perspective view of a round-bottomed cylindrical body having ribs. (B) It is a perspective view of the hemispherical molded object which has a rib. (C) It is a perspective view of the shallow convex-shaped molded object which has a rib. (D) It is a perspective view of the rectangular parallelepiped molded object which has a rib. (E) It is a perspective view of the polygonal pillar-shaped molded object which has a rib.

[Explanation of symbols]

 10 Molded body 12 Pre-printed sheet 21 Preliminary picture layer 2 Picture layer of molded body 26 Reference line 27 Reference point 3 Opening 31 Flange 4 Irregularities of molded body 45 Side exterior of molded body 46 Side interior of molded body 5 Mold 6 Mold unevenness 62 Mold pattern 66 Rib stand 71 Round bottom cylindrical molded body 72 Hemispherical molded body 73 Shallow convex molded body 74 Rectangular parallelepiped molded body 75 Polygonal columnar molded body 9 Molding machine 90 Fixing jig 91 Mold 92 Lower mold 93 Plug 94 Center line 95 Vacuum 96 Compressed air

Claims (3)

[Claims] 1. A pre-printed sheet having an opening, and at least one of the outer and inner surfaces of a forming sheet formed of a thermoplastic resin layer, is obtained by press-forming or vacuum forming a pre-printed sheet. The concave or convex pattern of the mold corresponding to the pattern layer provided on the side surface of the molded body, and the pattern layer of the pre-printed sheet provided by predicting the deformation during molding were deformed and matched after molding. A molded article having a concavo-convex print indication, characterized by being a thing. 2. The uneven shape of the side surface portion of the molded body has a fine three-dimensional satin pattern, a one-dimensional rib stand in a stretching direction,
Alternatively, a molded article having a concavo-convex print display, which is a picture layer formed in a concavo-convex shape in both vertical and horizontal directions. 3. A molded article obtained by press-pneumatically or vacuum molding a preprinted sheet having an opening, and at least one of the outer and inner surfaces of the molding sheet is formed of a thermoplastic resin layer. A method for producing a molded article having a concave-convex printed display, wherein the molded sheet is stretched and molded by contacting the molding sheet with a mold surface provided with a concave-convex portion.