JPS60210432A - Plastic mirror and manufacture thereof - Google Patents

Abstract

PURPOSE:To provide a plastic mirror excellent in the durability with a lighter weight, safety, scrutch resistance, haze proofing, antistatic and antireflective property easily imparted by mounting a thermoplastic resin film or sheet with one side thereof partly converted to a mirror in a cavity section blanked in a shape of a mirror with the partly mirror-converted surface inward. CONSTITUTION:A polycarbonate resin film 5 partly having a mirror coat 11 on one side and having a functional film 12 such as hard coat film on the opposite side previously mounted on dies 8 and 8' for plastic mirror molding thermally melts integral with a melt polycabonate resin layer 6 flowing through a runner 3 and a gate 4. The fixing of polycarbonate resin films or sheets 5, 5' and 5'' having the mirror film and the functional film such as hard coat film on respective sides in the die cavity is done handily by static electricity, sucking force by vacuum or the like and other widely accepted methods.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a novel plastic mirror and its terminology. In particular, it has excellent durability, light weight, safety, as well as scratch resistance, anti-fog property, antistatic property and It is possible to provide plastic mirrors easily imparted with antireflection properties.

Conventionally, mirrors are made by depositing metal on one side of inorganic glass or plastic to form a mirror, then applying a coating to protect the mirror metal to form a plate crystal, and then converting it into metal, wood, resin, etc. It is manufactured by being integrated into the frame, handle, etc. by gluing it.

Inorganic glass has disadvantages such as being heavy, breaking, limited shapes and colors, and low productivity, so in recent years,
Synthetic resin materials are becoming widely used.

When using a synthetic resin material, it has disadvantages such as being more easily scratched than inorganic glass, and it is usually necessary to apply a hard coat to impart scratch resistance.

Plastic mirrors can be molded by injection molding, flat mirrors are manufactured by extrusion plates or casting materials, and curved plastic mirrors are manufactured by hot oiling. When using injection molding, it is necessary to use a highly fluid molding material, and since highly fluid molding materials generally have poor impact resistance and solvent resistance, they are difficult to use when forming functional films such as hard coats. Cracks occur or
There are drawbacks such as easy deterioration of physical properties after coating with a functional film. If the plate is manufactured by hot oiling, the shape is limited and optical distortion is likely to occur.

Similarly, these plastic mirrors are often used under high humidity and tend to fog, and for this reason they are coated with anti-fog paint. Usually, antifogging paint is applied after plastic mirrors are molded, but there are drawbacks such as cranking during coating and physical property deterioration after coating.

Furthermore, conventional mirrors and plastic mirrors require a protective coating to protect the metal part of the mirror, which has the disadvantage of requiring a large number of steps, as well as the fact that the protective coating tends to deteriorate. There were drawbacks such as the need to take

The present invention provides a plastic mirror and a method for manufacturing the same that improves or overcomes the drawbacks of conventional methods.

That is, the present invention is a plastic mirror in which a frame, a handle, etc. are integrally formed, which is made by laminating a thermoplastic plastic film or sheet with one side partially mirrored and a resin layer formed by injection molding. In a preferred embodiment, the outer surface of a portion of the mirror is a thermoplastic plastic coated with one or more functional films selected from a hard coat film, an anti-fog film, an antistatic film, an anti-reflection film, etc. The mirror and functional film are composed of a partially mirrored thermoplastic film or sheet on one side and a hard coat film, an anti-fog film, an antistatic film, and a film or sheet on one side, respectively. 1 selected from anti-reflection films, etc.
It is composed of a thermoplastic film or sheet coated with a seed or two or more types of functional films.

In addition, such a plastic mirror can be produced by (11) a step of punching a thermoplastic plastic film or sheet partially mirrored on one side into the same shape as the mirror, (2) creating a mirror-shaped punched piece; The process of attaching the piece to a part of the cavity corresponding to the mirror part of the mirror molding mold with the partially mirrored surface inside (
3) closing the mold and injecting molten resin at high pressure using injection molding means to integrally mold the resin layer, frame, handle, etc.; and (4) taking out the molded product from the mold. In a preferred embodiment, a thermoplastic plastic film or sheet partially mirrored on one side is punched out in the same shape as the mirror to create a mirror-shaped punched piece, and the punching process comprises: The step of attaching the piece to a part of the cavity corresponding to the mirror part of the mirror mold with the partially mirrored surface inside is carried out at the same time as the step of closing the mold.

First, in order to facilitate understanding of the present invention, the present invention will be explained using drawings.

FIG. 1 is an example of a perspective view of a plastic mirror molded according to the present invention, and FIG.
' is a sectional view at '.

FIG. 3 is an enlarged view of part B in FIG.
A polycarbonate resin film 5, which is partially coated with a mirror coat 11 and a functional film 12 such as a hard coat film on the opposite side, and a resin layer 6 formed by injection molding of molten polycarbonate resin are laminated together. and is firmly heat-sealed by the welding section 7. In addition, in the case of Fig. 3, attaching a film made of ordinary transparent or opaque polycarbonate resin to the opposite side of the mold to which the mirror film-forming film has been attached may cause molding shrinkage of the molding resin. This is a preferable method since it is effective in eliminating distortion. In addition, Fig. 4 shows B in Fig. 2.
It is an enlarged view of another example of a polycarbonate resin film 5' having a mirror coat 11 partially applied on one side and a polycarbonate resin film 5'' having a functional film 12 such as a hard coat film applied on one side. This is an example in which two sheets of polycarbonate resin film or sheet are used, and in this case as well, the transparent resin N6 formed by injection molding of molten polycarbonate resin is laminated and integrated, and is firmly heat-sealed by the welding part 7. Furthermore, the fourth
The figure is an explanatory view schematically showing the injection molding process according to the present invention, in which a mirror coat 11 is partially applied to one side of the plastic mirror molding mold 8.8°, and a hard coat film etc. is applied to the opposite side. The polycarbonate resin film 5 coated with the functional film 12 is thermally fused and integrated with the molten polycarbonate resin layer 6 flowing through the runner 3 and gate 4.

Here, fixing a polycarbonate resin film or sheet 5.5°, 5'°, etc. on one side with a functional film such as a mirror film or a hard coat film to the mold cavity is as follows.
This can be easily carried out using static electricity, suction force such as vacuum, or other conventionally known methods.

Thermoplastic plastic films or sheets coated with a functional film such as a mirror film or a hard coat film on one side are made of thermoplastic plastics such as polycarbonate resin, polycarbonate resin-polybutylene terephthalate resin composition, polymethyl methacrylate (PMM), etc.
A) Normal thickness of acrylonitrile-styrene copolymer (0 AS resin), transparent plastics such as polystyrene, 100 to 1,000μ, preferably 20
A film or sheet of 0 to 500 .mu.m is formed by a conventionally known method, for example, in the case of mirroring, by vapor deposition of aluminum or other metal. In addition, in the case of a hard coat, by coating with a hard coating agent such as epoxy resin, acrylic resin, amino resin, polysiloxane, etc., and then curing with heat or ultraviolet rays, etc., in the case of an anti-fog film, Coat with water-soluble resin coating agent,
Then, by curing with means such as heat or ultraviolet rays, an antistatic film and an antireflection film are similarly formed by vapor deposition of a conventionally known antistatic paint, antireflection paint, antistatic layer, or antireflection layer. Moreover, these functional membranes can also be made into composite membranes having two or more types of functions at the same time.

Next, examples of thermoplastic plastics used in the injection molding of the present invention include those similar to the pluslacs used for functional films such as the mirror coat and hard coat films described above.

Plus-rank plastics used for films or sheets with functional films such as mirror coats and hard coat films formed on one side and thermoplastics used for injection molding are usually the same type of plastics with thermal adhesive and optical properties. It is preferable from the viewpoint of physical uniformity that the melt viscosity of the pluslac used for the film or sheet is higher than that of the thermoplastic plastic used for injection molding, that is, it has a higher molecular weight. It is preferable to prevent the film or sheet from losing its shape due to molten resin, and in the case of polycarbonate resin, a film or sheet with a molecular weight of 25,000 or more on which a hard coat film or an anti-fog film is formed on one side is injection molded. molecules!
15,000 to 25,000 is preferably used.

Note that it is also possible to use different polymers for these thermoplastic plastic films or sheets and for injection molding; in this case,
Heat for injection molding 1 For the purpose of promoting heat fusion with the plastic transparent resin and for the purpose of preventing the film from melting and losing its shape due to the injection molded resin, a primer coat - e.g. Apply a higher molecular weight material of the same type as the resin used for the application, or other thermoplastic resins with adhesive properties that have less melt flow, or heat- or ultraviolet-curable paints, on the opposite side of the hard coat or anti-fog coat. is good. In addition, the mirror coated surface does not require a primer coat for adhesion to the injection molded resin layer, but if durability is required due to usage conditions etc., a primer coat for adhesion may be applied. It is also one of the preferred embodiments to use as appropriate as desired.

Furthermore, plastic films or sheets coated with a functional film such as a mirror coat or hard coat film on one side,
Alternatively, dyes and pigments, ultraviolet absorbers, infrared absorbers, compounds with photochromic properties, etc. can be added to plastics for injection molding to impart special properties. In the case of the embodiment shown in the figure, it is also possible to use an opaque resin to which opaque additives such as inorganic fillers are added for reinforcement, dimensional stability, and other purposes.

As described above, the present invention provides a highly economical plastic that is easily endowed with excellent durability, lightness, safety, as well as scratch resistance, antifogging properties, antistatic properties, antireflection properties, etc. It can provide mirrors. In addition, in a preferred embodiment of the method for manufacturing the plastic mirror of the present invention, (1) it is lightweight because it is molded from polycarbonate resin;
Excellent impact resistance and high safety.

■A polycarbonate resin film or sheet coated with a hard coat film, anti-fog film, etc. on one side, and a polycarbonate resin film or sheet coated with a mirror film on one side are heat-sealed and integrated with the molten polycarbonate resin layer in an injection mold. Therefore, plastic mirrors with the desired surface characteristics can be obtained without going through special mirror treatment or painting processes, resulting in excellent productivity and eliminating the defects that tend to occur in post-processing processes such as painting. disappears.

■It is extremely easy to select and use mirror films and special functional films, and it is also easy to combine them with transparent or opaque molding resins, so post-processing (painting, sputtering, etc.) Impossible plastic mirrors are easily obtained.

It has such characteristics.

Examples will be explained below.

Example 1 An acrylic primer was coated on one side of an extruded polycarbonate film (500 mm x 600 mm) with a molecular weight of 30,000 and a thickness of 200 μm by a wire barcode method and dried. Next, a silicone top coat was applied onto the primer by a wire barcode method and cured at 130°C for 1 hour. Then, on the opposite side of this film, a metal mirror film was formed in a conventional manner using a spackling method on a portion corresponding to a portion of the mirror of the desired mirror design shape.

The hard coat film and partial mirror film forming film obtained above were cut out into the shape of a plastic mirror shown in FIG. 1, and fitted into a partial mirror cavity of the plastic mirror having the shape shown in FIG. Next, a polycarbonate resin having a molecular weight of 23,000 was injection molded. The obtained framed plastic mirror is in good condition, with the non-mirror part film and molded resin completely heat-fused, and the mirror film part encapsulated, with no damage or abnormal appearance to the hard coat film or mirror film. It was something.

Example 2 A hard coat film and a partial mirror film forming film obtained in the same manner as in Example 1 were cut out into a mirror shape and placed in the same mold cavity as in Example 1 except that there was no flat part. I installed it. Next, an ultra high flow polycarbonate resin having a molecular weight of 16,000 was injection molded.

In the obtained framed plastic mirror, the non-mirror part film and the molded resin were completely heat-fused, and no damage or abnormal appearance was observed in the hard coat film and mirror film that encapsulated the mirror film part. , and had good impact strength.

For comparison, when the molded product was molded without attaching the film, the molded product cracked or cracked due to the ejection force when released from the mold, and it was impossible to make it into a mirror.

[Brief explanation of the drawing]

Fig. 1 is a perspective view of the plastic mirror of the present invention, Fig. 2 is a sectional view taken along line AA' in Fig. 1, Fig. 3 is a partial enlarged view of part B in Fig. 2, and Fig. 4 is Fig. 2. FIG. 5 is an enlarged view illustrating another embodiment of part B, and FIG. 5 is a schematic diagram illustrating a state of injection molding of the plastic mirror of the present invention. The numbers in the diagram are: 1 Nibrush Stick Mirror 2 Varnish Blue 3; Runner
4; Gate 5.5°, 5″: Mirror film, plastic film or sheet with functional film 6: Injection molded resin layer 7: Fusion part 11: Mirror film 12: Functional film 8.8°: Mold Show 8

Claims (1)

[Claims] 1. A plastic mirror with integrally molded frame, handle, etc., which is made by laminating a thermoplastic plastic film or sheet partially mirrored on one side and a resin layer formed by injection molding. 2. The outer surface of a part of the mirror is a hard coat film, an anti-fog film,
Claim 1 consisting of a thermoplastic plastic film or sheet coated with one or more functional films selected from antistatic films, antireflection films, etc.
Plastic mirror 3 described in Section 3, one or more types of thermoplastic plastic film or sheet partially mirrored on one side and one or more types selected from a hard coat film, a heat protection film, an antistatic film, an antireflection film, etc. on one side. A plastic mirror 4 according to claim 2, in which a part of the outer layer of the mirror is constituted by two thermoplastic plastic films or sheets, one of which is partially coated with a thermoplastic film or sheet. The mirrored thermoplastic plastic film or sheet is made of polycarbonate resin with a molecular weight of 25,000 or more, and the resin layer, frame, handle, etc. formed by injection molding is made of a polycarbonate resin with a molecular weight of 15,000 or more.
0 to 25,000 polycarbonate resin according to claim 1.2 or 3; +11 A thermoplastic plastic film or sheet partially mirrored on one side is formed into a mirror shape. (2) a step of attaching the punched piece to a part of the cavity corresponding to the mirror part of the mirror mold with the partially mirrored surface on the inside; 3) closing the mold and injecting molten resin at high pressure using injection molding means to integrally mold the resin layer, frame, handle, etc.; and (4) taking out the molded product from the mold. Manufacturing method 6 for a plastic mirror, in step (1) of creating a mirror-shaped punched piece, a thermoplastic plastic film or sheet partially mirrored on one side and a hard coat film, an anti-fog film, or an antistatic film on one side. A patent for a process of punching out a thermoplastic plastic film or sheet coated with one or more functional films selected from a film and an anti-reflection film into the same shape as a mirror to create a mirror-shaped punched piece. Method 7 for producing a plastic mirror according to claim 5, a thermoplastic plastic film or sheet partially mirrored on one side, and optionally a hard coat film, an antifogging film, an antistatic film, an antireflection film, etc. on one side. A process of punching out a thermoplastic plastic film or sheet coated with one or more functional films selected from the above into a mirror-shaped punched piece in the same shape as the mirror, and using the punched piece with a mirror-molding metal. The plastic mirror according to claim 5 or 6, wherein the step of mounting the partially mirrored surface on the inside in a part of the cavity corresponding to the mirror part of the mold is carried out at the same time as the step of closing the mold. Manufacturing method