JPH11309744A - Flexible molded product and its production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a flexible molded product in which an optional uneven place can be painted in a high yield. SOLUTION: A flexible molding simultaneous painting sheet having at least a design layer on a flexible substrate sheet is set in a mold, the mold is closed, a flexible molding resin of 40-100 A-hardness by a JIS hardness tester is injected into the mold and integrated with the painting sheet, the mold is opened, obtaining a flexible molding in which the painting sheet 1 and a flexible resin molded product 2 are bonded together.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a soft molded article painted simultaneously with injection molding. The soft molded article according to the present invention is particularly effective when applied to an emblem to be mounted on a three-dimensional curved surface of an automobile, a home electric appliance or the like, and therefore, the emblem will be described below as an example. The soft molded product according to the present invention is also effective for applications such as front grills and moldings of automobiles. The emblem is
On the surface of panels for household electric appliances such as televisions and audios, and panels for exterior parts of automobiles, decorative articles symbolizing a company emblem, a car name, a car model, and the like in an emblem. Also, since the emblem is for emphasizing the logo design, by providing unevenness with a large unevenness on the surface of the emblem substrate, by forming glittering coloring on all of the outer surface of the convex portion and all of the inner surface of the concave portion, It is common to make the logo design look like it stands out.

[0002]

2. Description of the Related Art When emphasizing mass productivity, these emblems use an injection-molded hard resin molded product as an emblem substrate, and as post-processing, all of the convex and concave portions of the emblem substrate surface and the concave portion inner surface. Are obtained by applying a metallic color plating or spray-coating a metallic pigment paint to form a bright coloring. In addition, emblems are mounted by attaching or embedding, but in recent years, the shape of the surface of a home appliance panel or an exterior panel of an automobile, which is a base on which the emblem is mounted, has been changed due to diversification of designs. Many of them have a more complicated three-dimensional curved surface, but the emblem requires a sense of unity with home appliance panels and exterior panels of automobiles. It must be fitted closely along the surface.

[0003]

However, the unevenness on the surface of the emblem substrate has a large difference in undulation, so that
On the slopes and corners of the recesses on the emblem substrate surface,
Adhesion of the metal color plating or adhesion of the metal pigment ink becomes defective, or the paint runs off, resulting in a high defect rate as a product and an expensive emblem.

Conventionally, since the emblem substrate is formed of a hard resin molded product, if it is bent once so as to have a specific curvature value, it is deformed so as to have another curvature value, and the curvature value after the deformation is obtained. It's difficult to keep them on. In addition, when the degree of change in the curvature value is large, the emblem substrate is cracked, or the emblem substrate is peeled off from the base surface after the emblem substrate is mounted on the base surface due to the spring property of the emblem substrate. In order to solve such a problem, the shape of the emblem substrate may be changed in accordance with the change of the shape of the three-dimensional curved surface of the base surface on which the emblem is to be mounted. A new mold had to be used, resulting in a costly emblem.

[0005] Even in this case, a new problem has arisen. That is, the injection molded resin molded product constituting the emblem substrate undergoes shape deformation due to resin shrinkage when cooled to room temperature after injection molding. In consideration of such shape deformation, the design values of the three-dimensional curved surface on the mold used for injection molding must be calculated.
For that purpose, it is necessary to repeat the production of the mold used for the injection molding several times, which has caused a high cost of the mold used for the injection molding and a delay in delivery of the emblem.

[0006]

In order to achieve the above object, a method for manufacturing a soft molded product according to the present invention comprises mounting a soft-formed simultaneous painting sheet having at least a design layer on a flexible base sheet in a mold. Close the mold, inject the soft molding resin with A hardness of 40-100 by JIS hardness tester into the mold, integrate the soft molding simultaneous painting sheet and the soft molding resin, and open the mold And a soft molded article in which the soft molding simultaneous painting sheet and the soft resin molded article are bonded to each other. The method for producing a soft molded product according to the present invention comprises:
The design layer may have at least a glittering metallic layer, and the soft molded product may be an emblem.

Further, according to the method for producing a soft molded product of the present invention, a simultaneous painting sheet having at least a design layer as a transfer layer on a base sheet is mounted in a mold, and the mold is closed.
A hardness of 40 to 100 by JIS hardness tester in the mold
Injecting the soft molding resin of the above, the molding simultaneous painting sheet and the soft molding resin are integrated, the mold is opened, the base sheet is peeled off, and a soft molded product in which the transfer layer and the soft resin molded product are adhered is obtained. It is characterized by. In the method for producing a flexible molded product according to the present invention, the design layer has at least a glittering metallic layer,
The soft molded article may be an emblem.

Further, the soft molded article of the present invention comprises a soft molded simultaneous painting sheet having at least a design layer on a flexible base sheet, and an A hardness of 40 to 10 measured by a JIS hardness tester.
0 is integrated with the soft resin molded product. The soft molded article of the present invention may be a glittering soft emblem in which at least a glittering metallic layer is formed by a design layer.

Further, the flexible molded article of the present invention is characterized in that a transfer layer transferred from a molded simultaneous painting sheet having at least a design layer as a transfer layer on a base sheet has an A hardness of 40 to 100 measured by a JIS hardness tester. It is characterized by being integrated with a soft resin molded product. The soft molded article of the present invention may be a glittering soft emblem in which at least a glittering metallic layer is formed by a design layer.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the drawings.

FIGS. 1 and 2 are schematic sectional views showing one embodiment of a soft molded product according to the present invention. 3 and 4 are schematic sectional views showing a state where the soft molded product according to the present invention is mounted on a base.

First, a method for manufacturing a soft molded product according to the present invention will be described.

[0013] There are two types of molded simultaneous painting sheets used in the production method of the present invention, depending on the manner of use. One is to mount the simultaneous painting sheet 1 into an injection molding mold, close the mold, inject molding resin into the injection molding mold, and integrate the molding simultaneous painting sheet 1 with the molding resin. And
The mold is opened, and the base sheet 4 and the design layer are bonded together to the soft resin molded product 2 without peeling the base sheet 4 to form a finished product. This is a type used as a simultaneous painting sheet (hereinafter referred to as “insert sheet”).
The other is mounting the simultaneous painting sheet 1 in an injection molding die, closing the mold, injecting molding resin into the injection molding mold, and forming the simultaneous painting sheet 1 and molding resin. Is formed, the mold is opened, the base sheet 4 is peeled off, and only the transfer layer is adhered to the soft resin molded product 2 to obtain a finished product, which is a so-called "in-mold forming method". Simultaneous painting sheet (hereinafter "in-mold sheet")
That. ) Type.

The simultaneous painting sheet 1 used in the production method of the present invention has a base sheet 4 having at least a design layer.

The base sheet 4 includes a polyethylene terephthalate resin film (including a copolymer type and a homo type), an acrylic resin film, a vinyl chloride resin film, a polypropylene resin film, a polyethylene film, and a TPE film (including a thermoplastic elastomer resin). ) May be used as a single film, or a composite film obtained by laminating two or more films selected from the above may be used.

When the simultaneous painting sheet 1 is an insert sheet, a flexible base sheet 4 is used.
For example, 130% to 250% in an atmosphere of 100 ° C.
% Of the base sheet 4 when stretched.
A function is required that does not cause cracks on the film surface, and does not cause a color change such as whitening of the base sheet 4 due to a phase change in the internal structure of the base sheet 4.

The design layer includes a picture layer 5, a glittering metallic layer 7, and the like. The picture layer 5 is for applying a picture to the surface of the molded product. As a material of the picture layer 5, a resin such as a polyvinyl resin, a polyamide resin, a polyester resin, a polyacryl resin, a polyurethane resin, a polyvinyl acetal resin, a polyester urethane resin, a cellulose ester resin, and an alkyd resin is used. It is preferable to use a coloring ink containing a pigment or dye of an appropriate color as a coloring agent as a binder. The thickness of the picture layer 5 is 10 μm to 50 μm.

The glittering metallic layer 7 includes a layer formed by a so-called metal vapor deposition method, a printing layer containing a pigment which produces a glittering color, and a layer made of a metal foil. A layer formed by a so-called metal vapor deposition method has a thickness of 50 °.
There is an indium layer having a thickness of about 800 mm. As a so-called metal evaporation method, there are a vacuum evaporation method, an ion plating method, a sputtering method, an electron beam evaporation method, and the like. Examples of pigments that produce a brilliant color include fine particles of metal particles such as aluminum, titanium, and bronze, pearl pigments obtained by coating mica with titanium oxide, or gold-silver yarn formed by forming a metal deposition layer or a metal foil layer on a resin film. Things can be used.

Hereinafter, a specific example of the layer structure in the case where the molded simultaneous painting sheet 1 is used as an insert sheet will be described. (1) Base sheet 4, picture layer 5, anchor layer 6 before vapor deposition,
Bright metallic layer 7, Post-deposition anchor layer 8, Adhesive layer 9
Are stacked in this order (see FIG. 5). (2) A layer in which a top coat layer, a glittering metallic layer 7, an anchor layer before vapor deposition 6, a base sheet 4, and an adhesive layer 9 are laminated in this order. In this case,
There is a method in which an adhesive layer 9 is formed on one surface of the base sheet 4 and an anchor layer 6, a glittering metallic layer 7, and a top coat layer are formed on the other surface in this order. (3) First base sheet, picture layer 5, anchor layer 6 before deposition, glittering metallic layer 7, anchor layer 8 after deposition, second
One in which each layer of the base sheet and the adhesive layer 9 is laminated in this order. As a manufacturing method in this case, a pattern layer 5, an anchor layer 6 before vapor deposition, a glittering metallic layer 7, an anchor layer 8 after vapor deposition, and an adhesive layer for lamination are formed in this order on one surface of the first base sheet. On the other hand, an adhesive layer (for molding resin) is formed on one surface of the second base sheet. There is a method of laminating the adhesive layer for lamination and the second base sheet together. Further, the first substrate sheet, in which a pattern layer 5, an anchor layer 6 before vapor deposition, a glittering metallic layer 7, and an anchor layer 8 after vapor deposition are laminated in this order on one surface of the first substrate sheet, is laminated with the second substrate sheet. After dry laminating with an agent, there is a method of forming an adhesive layer (for molding resin) on the second base sheet.

Hereinafter, a specific example of the layer structure in the case where the simultaneous forming painting sheet 1 is used as an in-mold sheet will be described. The layers constituting the in-mold transfer layer include a release layer, a picture layer, an anchor layer before vapor deposition, an adhesive layer and the like in addition to the glittering metallic layer. The release layer becomes the outermost layer of the emblem after the release of the base sheet. As the material of the release layer, acrylic resin, polyester resin, polyvinyl chloride resin, cellulose resin, rubber resin,
In addition to polyurethane resins and polyvinyl acetate resins, copolymers such as vinyl chloride-vinyl acetate copolymer resins and ethylene-vinyl acetate copolymer resins may be used. When the release layer requires hardness, a photocurable resin such as an ultraviolet curable resin, a radiation curable resin such as an electron beam curable resin, or a thermosetting resin may be selected and used.

The pre-deposition anchor layer 6 is a resin layer for improving the adhesion between the picture layer 5 and the glittering metallic layer 7, and is, for example, a two-component curable urethane resin, a melamine-based or epoxy-based thermosetting resin. Thermoplastic resins such as a conductive resin and a vinyl chloride copolymer resin can be used.

The post-evaporation anchor layer 8 is a resin layer for enhancing the adhesion between the glittering metallic layer 7 and the adhesive layer 9, and is, for example, a two-part curable urethane resin, a melamine-based or epoxy-based thermosetting resin. Thermoplastic resins such as a conductive resin and a vinyl chloride copolymer resin can be used.

The adhesive layer 9 is for bonding the above-mentioned layers to the surface of the molded product. As the adhesive layer 9, a heat-sensitive or pressure-sensitive resin suitable for the material of the molded article is appropriately used. For example, when the material of the molded article is a polyacrylic resin, a polyacrylic resin may be used. When the material of the molded article is a polyphenylene oxide / polystyrene resin, a polycarbonate resin, a styrene copolymer resin, or a polystyrene blend resin, a polyacryl resin, a polystyrene resin having an affinity for these resins, A polyamide resin or the like may be used. Further, when the material of the molded article is a polypropylene resin, chlorinated polyolefin resin, chlorinated ethylene-vinyl acetate copolymer resin, cyclized rubber, and coumarone indene resin can be used.

Next, injection molding is carried out using the above-mentioned simultaneous painting sheet 1. As the injection molding method applied in the present invention, there are the above-mentioned insert method and in-mold method. The insert method and the in-mold method according to the present invention do not peel off the base sheet 4 of the soft-molding simultaneous painting sheet 1 after performing the injection molding (insert method).
However, there is a difference in that the base sheet 4 of the molded simultaneous painting sheet 1 is peeled off (in-mold method), but the others are common. That is, the molding simultaneous painting sheet 1 is mounted in an injection molding die, the die is closed, and a soft molding resin having an A hardness of 40 to 100 by a JIS hardness tester is injected into the injection molding die. The soft molded simultaneous painting sheet 1 and the soft molding resin are integrated, the mold is opened, and a soft molded product in which the soft molded simultaneous painting sheet 1 and the soft resin molded product 2 are adhered to each other is obtained.

As an example of an injection mold, an injection mold comprising a movable mold having a cavity forming surface having an uneven surface formed by engraving an emblem or lattice-like relief, and a fixed mold having a molding resin injection gate formed therein. The case where a metal mold is used will be described.

First, any one of the above-mentioned simultaneous molding sheets 1 is fed between the movable mold and the fixed mold.
The simultaneous molding painting sheet 1 is brought into close contact with the movable mold such that the base sheet 4 side of the simultaneous molding painting sheet 1 is in contact with the uneven surface of the cavity forming surface of the movable mold. It is preferable to use vacuum suction or the like to make the movable mold come into close contact with the movable mold. Thereafter, the mold is closed, and the simultaneous molding painting sheet 1 is sandwiched between the movable mold and the fixed mold to form a cavity space for filling with the soft molding resin. The cavity space may be such that the softness obtained is a space having a bowed shape (see FIG. 2). Next, a soft molding resin having an A hardness of 40 to 100 by a JIS hardness tester is injected into the cavity space from the gate provided in the fixed mold, and the molding simultaneous painting sheet 1 and the soft molding resin are integrated. , Open the mold. In the case where an insert sheet is used as the simultaneous-painting sheet 1 (insert method), a soft molded article in which the simultaneous-painting sheet 1 and the soft resin molded article 2 are adhered to each other is obtained. Or,
When an in-mold sheet is used as the simultaneous painting sheet 1 (in-mold method), the base sheet 4 is peeled off to obtain a soft molded article in which the transfer layer and the soft resin molded article 2 are bonded.

A of the soft molding resin by a JIS hardness tester
Hardness is a numerical value in the JIS-6301 standard.
As a soft molding resin, A hardness 4 by JIS hardness tester
The reason for using the thing of 0-100 is as follows. This is because a material having an A hardness of less than 40 according to a JIS hardness tester is too soft and has poor wear resistance and weather resistance, and is unsuitable for emblems. On the other hand, when the hardness is larger than 100 according to the JIS hardness tester, there is a problem such as difficulty in deformation as shown in the related art.

A hardness of 40 to 10 by JIS hardness tester
Examples of the soft molding resin of No. 0 include a thermoplastic elastomer resin and a synthetic rubber latex. As the thermoplastic elastomer resin, there are thermoplastic elastomer resins such as olefin elastomer resin, styrene elastomer resin, urethane elastomer resin, polyester elastomer resin, nylon elastomer resin, vinyl chloride elastomer resin, etc. If emphasis is placed on polyester, a polyester elastomer is preferred. Examples of the synthetic rubber latex include SBR (styrene butadiene latex) and NBR. In the thermoplastic elastomer resin or the synthetic rubber latex, an ultraviolet inhibitor may be dispersed in a resin constituting them in order to improve light resistance.

The obtained soft molded product can be used as a glittering soft emblem, a glittering soft front grill, a side molding or the like of an automobile. When used as a brilliant soft emblem, the soft molded product may be mounted by deforming to follow the shape of the base surface to be mounted (see FIG. 3).
The mating concave portion 3 for fitting the glittering soft emblem may be formed in advance on the base surface, and the glittering soft emblem may be fitted into the fitting concave portion 3 (see FIG. 4). The base 10 includes a surface exhibiting a three-dimensional curved surface such as a home appliance panel, a car exterior panel, a hood, a trunk lid, and a door. When the obtained soft molded product is used as a glittering soft front grill, it is preferable that only the fitting portion of the glittering soft front grill be deformed and fitted to the shape of the fitting concave portion or the fitting convex portion of the automobile front portion, for example. . The brilliant soft front grill is soft and therefore safe for manual mounting work, and is also effective because it can contribute to absorbing shock when a person or an object collides.

[0030]

According to the method for producing a soft molded article of the present invention,
Soft molding such as glittering soft emblem by so-called "insert molding method" or "in-mold molding method" using a simultaneous molding painting sheet and a soft molding resin having an A hardness of 40 to 100 by a JIS hardness tester. Since the product is manufactured, even if the unevenness of the unevenness of the molded product surface is large, it can be painted at any place of the unevenness,
It is possible to obtain a soft molded product having a high non-defective product rate and a reduced cost.

The soft molded article of the present invention is made of a soft molded resin having an A hardness of 40 to 100 according to a JIS hardness tester, and a soft insert sheet is integrally adhered to the surface, or an in-mold sheet. Since the transfer layer is transferred, a part or the whole of the soft molded product can be bent freely. Therefore, no matter how the shape of the three-dimensional curved surface of the base surface on which the emblem or the like is to be mounted or the shape of the fitting portion is changed, a soft molded product produced by the same mold can be used. Therefore, for example, even if the shape of the three-dimensional curved surface of the base surface on which the emblem or the like should be mounted changes,
There is no need to newly raise a mold used for injection molding and re-produce a new emblem substrate. Therefore, the emblem has a reduced production cost.

Further, even if the resin molded product undergoes deformation such as resin shrinkage, the soft resin molded product can be deformed, so that the production of the mold used for injection molding is repeated many times. There is no need to perform it, and the cost of the mold used for injection molding and the delivery of the emblem will not be delayed.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view showing one embodiment of a soft molded product according to the present invention.

FIG. 2 is a schematic sectional view showing one embodiment of a soft molded article according to the present invention.

FIG. 3 is a schematic cross-sectional view showing one embodiment of a state in which the soft molded product according to the present invention is mounted on a base surface.

FIG. 4 is a schematic cross-sectional view showing one embodiment in a state where the soft molded product according to the present invention is mounted on a base surface.

FIG. 5 is a schematic cross-sectional view showing an example of a simultaneous-painting sheet used when manufacturing the flexible molded product according to the present invention.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 Simultaneous painting sheet 2 Soft resin molded article 3 Fitting recess 4 Base sheet 5 Picture layer 6 Anchor layer before vapor deposition 7 Bright metallic layer 8 Anchor layer after vapor deposition 9 Adhesive layer 10 Base

Claims (6)

[Claims] 1. A soft molding simultaneous painting sheet having at least a design layer on a flexible base sheet is mounted in a mold, the mold is closed, and an A hardness of 4 according to a JIS hardness tester is set in the mold.
Inject a soft molding resin of 0-100, integrate the soft molding simultaneous painting sheet and the soft molding resin, open the mold, and form a soft molding product in which the soft molding simultaneous painting sheet and the soft resin molding are bonded. A method for producing a soft molded article, characterized by being obtained. 2. A molding simultaneous painting sheet having at least a design layer in a transfer layer formed on a base sheet is mounted in a mold, the mold is closed, and A is set in the mold by a JIS hardness tester. A soft molding resin having a hardness of 40 to 100 is injected, the molding simultaneous painting sheet and the soft molding resin are integrated, the mold is opened, the base sheet is peeled off, and the transfer layer and the soft resin molding are bonded to each other. A method for producing a soft molded article, characterized by obtaining a molded article. 3. The design layer has at least a glittering metallic layer, and the soft molded product is an emblem.
The method for producing a soft molded article according to the above. 4. A soft molded simultaneous painting sheet having at least a design layer on a flexible base sheet and a molded product made of a soft molded resin having an A hardness of 40 to 100 by a JIS hardness tester are integrated. A soft molded article characterized by the following. 5. A transfer layer formed on a base sheet, wherein the transfer layer is transferred from a molded simultaneous painting sheet having at least a design layer, and an A hardness of 40 to 1 measured by a JIS hardness tester.
A soft molded article characterized by being integrated with a molded article made of the soft molded resin of No. 00. 6. The soft molded product is an emblem, wherein the design layer has at least a glittering metallic layer.
The soft molded article according to 1.