JPS6128902A - Plastic antidazzle mirror and its production - Google Patents

Abstract

PURPOSE:To obtain a plastic antidazzle mirror or the like having excellent durability and economy by adhering and laminating a film for forming a half-mirror film with a primer coat having a hard coat film on one side and a film for forming a mirror film with a primer coat to a resin layer to be injection-molded in such a manner that the respective surfaces of said films are made non-parallel. CONSTITUTION:The polycarbonate resin film 5 which is formed with the mirror coat 11 over the entire one surface and further the primer coat 15 for adhesion thereon, the polycarbonate resin film 5' which is formed with the half coat 12 over the entire one surface and further the primer coat 15 thereon and the half coat film 13 on the opposite surface and the resin layer 6 formed of the molten polycarbonate resin by injection molding are laminated and united to one body and are securely thermally welded by a primer for adhesion and the film end. The polycarbonate resin having >=25,000mol.wt. is used for the film or sheet and said resin having 15,000-25,000mol.wt. is used for injection molding in the case of using the polycarbonate resin as the film or sheet and injection molding material.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a novel plastic anti-glare mirror and a method for manufacturing the same.
It is possible to provide plastic anti-glare mirrors that are easily imparted with safety, scratch resistance, anti-fog properties, anti-static properties, anti-reflection properties, and the like.

[Conventional technology and its problems] Traditionally, mirrors are made by depositing metal on one side of inorganic glass or plastic to form a mirror, and then applying a coating to protect the mirror metal to form a plate crystal. This is manufactured by fitting it into a frame or handle made of metal, wood, resin, etc. and integrating it with adhesive.

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 a synthetic resin material is used, 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 are molded either by injection molding or by hot oiling of an extrusion plate or casting plate. 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. There are drawbacks such as cranking and physical property deterioration after coating with a functional film.

Further, since the anti-glare mirror of the present invention has a prism shape with non-parallel surfaces, it is difficult to form the thick portion and thin portion in a well-balanced manner, resulting in poor productivity. If the plate is damaged by heat and oil, its shape is restricted, making it unsuitable for use as a normal anti-glare mirror, and it also has the disadvantage of being prone to optical distortion.

Furthermore, conventional mirrors and plastic mirrors require a protective coating to protect the metal of the mirror portion, which has the disadvantage of requiring many steps.

[Means for solving problems]

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 provides a thermoplastic plastic film or sheet that is entirely mirrored with an adhesive primer layer formed on one mirrored surface. A frame in which a thermoplastic plastic film or sheet and a resin layer formed by injection molding are adhered and laminated by the adhesive primer layer, and the mirror surface and the half mirror surface are non-parallel. It is a plastic anti-glare mirror with integrally molded parts and a mounting part, and in a preferred embodiment, the outer surface of the half mirror part is made of one material selected from a hard coat film, an anti-fog film, an antistatic film, an anti-reflection film, etc. The thermoplastic film or sheet is made of a thermoplastic plastic film or sheet coated with one or more functional films, and further includes a fully mirrored thermoplastic plastic film or sheet with an adhesive primer layer formed on one mirrored surface. A resin layer formed by injection molding, consisting of a fully half-mirrored thermoplastic plastic film or sheet with an adhesive primer layer formed on one half-mirrored surface, and a polycarbonate resin having a molecular weight of 25,000 or more; The frame, attachment parts, etc. are made of polycarbonate resin with a molecular weight of 15,000 to 25,000.

In addition, such a plastic anti-glare mirror is made of a thermoplastic plastic film or sheet that is fully mirrored with an adhesive primer layer formed on one mirrored surface, and an adhesive primer formed on the half mirrored surface of one side. A step of punching out a layered thermoplastic plastic film or sheet that has been made into a half-mirror over the entire surface into the same shape as the mirror to create a mirror-shaped punched piece; (2) inserting the punched piece into the mirror part of a mirror molding mold; (3) The mold is closed and molten resin is injected at high pressure by an injection molding means to laminate and integrally mold the resin layer part, frame, mounting part, etc. and (4) taking out the molded product from the mold. In a preferred embodiment, the manufacturing method includes the step (1) of creating a mirror-shaped punched piece and the step of inserting the punched piece into a mold cavity. This consists of simultaneously carrying out the step (2) of mounting the mold on the tee and 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. 2 is an example of an overall view of a plastic anti-glare mirror molded according to the present invention, and FIG. 1 is a cross-sectional view taken along line A-A in FIG.

In FIG. 2, the resin injected through the sprue 2, runner 3, and gate 4 forms a film whose inner surface is a half mirror with a primer coat and whose outer surface is coated with a hard coat film, and a mirror film whose inner surface is coated with a primer coat. The primer layer and the film end are tightly heat-sealed and integrated, and the mirror attachment part is formed in a cylindrical shape on the side surface. In addition, in FIG. 1, a polycarbonate resin film 5 is coated with a mirror coat 11 on the entire surface of one side, and a primer coat 15 for adhesion is applied thereon, a half mirror coat 12 is applied on the entire surface of one side, and a primer coat 15 is further applied on the entire surface of the polycarbonate resin film 5. A polycarbonate resin film 5'' with a hard coat film 13 applied on the opposite side and a resin layer 6 formed by injection molding of molten polycarbonate resin are laminated and integrated, and the primer for adhesion and the edges of the film are firmly heat-fused. It was worn.

Here, a plastic film or sheet 5.51 such as a polycarbonate resin having a half-mirror film, a mirror film, a primer coat thereon, and, if desired, a functional film such as a hard coat film on the opposite side, is used. Fixing to the mold cavity can be easily carried out using static electricity, suction force such as vacuum, or other conventionally known methods.

A thermoplastic plastic film or sheet having a mirror film, a half-mirror film, a ply-roo coat thereon, and a functional film such as a hard coat film on the opposite side is a thermoplastic plastic film or sheet, for example, polycarbonate. Resin, polycarbonate resin - polybutylene terephthalate resin composition, polymethyl methacrylate (PMMA), acrylonitrile-styrene copolymer (AS resin), transparent plastics such as polystyrene - normal thickness, 100 to 1,000 Inn, Preferably, a 200 to 500 mm film or sheet is formed by a conventionally known method, for example, in the case of half-mirroring or mirroring, aluminum or other metal is vapor-deposited. 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, By coating with a water-soluble resin-based coating agent and then curing by means such as heat or ultraviolet rays, antistatic films and antireflective films can be formed using conventionally known antistatic paints, antireflective paints, antistatic layers, etc. The antireflection layer is formed by vapor deposition, etc. Further, these functional membranes can also be made into composite membranes having two or more functions at the same time.

In addition, the adhesive primer layer to be formed on the full mirror-coated metal surface and the full half-mirror coated metal surface has adhesion to the vapor-deposited metal and is heat-fused to the injection molded resin. Any material may be used as long as it can withstand high temperatures during molding. These include functional acrylate resins, phenolic resins,
Epoxy resin, unsaturated polyester resin, cyanate ester resin (commonly known as triazine resin, RT resin, etc.)
etc., and one or a mixture of two or more of these as the main component, and as appropriate, homo- or copolyacrylates, diene rubbers, polyvinyl alcohol, polyvinyl acecures, polycarbonate, polyester,
Heat- or photo-curable or crosslinkable resin compositions that are compositions modified with polyamides, polyphenylene ethers, polysulfones and other thermoplastic resins; homo- or copolyacrylates, polyester copolymers, polyamides, polyphenylenes Resins that have adhesive properties with ethers, polysulfones, and other metals, especially their high molecular weight products, and these.

It is formed by applying a solution such as a composition containing as a main component by a conventional method and drying or curing the solution.

Next, examples of the thermoplastic plastic used in the injection molding of the present invention include those similar to the materials of the plus rank film or sheet used for the functional films such as the mirror coat and hard coat film described above.

Plus rank type used for adhesive primer-coated mirror films, half-mirror films, and films or sheets with a functional film such as a hard coat film formed on the other side if desired, and thermoplastics used for injection molding. The melt viscosity of a plus rank for use in film or sheeting may be the same as or different from that of plastics, and is determined solely by the primer used and the desired physical properties of the product; It is preferable to use a polycarbonate resin with a higher viscosity than that in order to prevent the film or sheet from losing its shape due to the molten resin during injection molding, and when polycarbonate resin is used as the film or sheet and injection molding material, the film or sheet has a molecular weight of 25. 000 or more, with a molecular weight of 15.000 to 25.0 for injection molding.
It is better to use 00.

In addition, a plastic film or sheet with a half-mirror coat or mirror coat with a primer coat for adhesion and, if desired, a functional film such as a hard coat film on the opposite side (=outer surface), or a plastic film or sheet for injection molding. By adding dyes and pigments, ultraviolet absorbers, infrared absorbers, compounds with photochromic properties, etc. to plastics,
It is also possible to impart special performance.

〔Example〕

Examples will be explained below.

Example-1 A piece of extruded polycarbonate film (500vm x 600mm) having a molecular weight of 30,000 and a thickness of 200fm.

An acrylic primer was applied to the surface using the 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, a metal half-mirror film was formed on the opposite surface by sputtering in a conventional manner.

A toluene/methyl ethyl ketone solution of a resin whose main component is a thermoplastic polyester copolymer modified with an epoxy resin for adhesion was applied onto the half-mirror vapor-deposited film of this film, and dried and cured at 120°C (hereinafter referred to as A). .

In addition, the extrusion molded product has a molecular weight of 30,000 and a thickness of 200μ.
A metal mirror film is formed on one side of a polycarbonate film (500 cranes x 600 m) by a conventional method by sputtering, and on top of that a toluene/epoxy resin-modified adhesive resin whose main component is a thermoplastic polyester copolymer is applied.
A methyl ethyl ketone solution was applied, dried and cured at 120°C (hereinafter referred to as B).

Production of a plastic anti-glare mirror The primer-coated half-mirror film-forming film (A) and primer-coated mirror film-forming film (B) of the single-sided hard coat film obtained above were used to prepare the plastic anti-glare mirror shown in FIG. It was punched into a shape and attached to the mirror cavity of a plastic anti-glare mirror having the shape shown in Figure 1. Next, a polycarbonate resin having a molecular weight of 23,000 was injection molded.

The obtained plastic anti-glare mirror with attachment part is completely heat-sealed to the molded resin through the primer coat for adhesion between the half mirror part and the mirror part.
The film and mirror film were encapsulated, and the product was in good condition with no abnormalities observed in appearance.

〔Effect of the invention〕

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 is possible to provide anti-glare mirrors. In addition, in a preferred embodiment of the method for manufacturing the plastic anti-glare mirror of the present invention, (1) it is lightweight because it is molded from polycarbonate resin;
Excellent impact resistance and high safety.

■The half-mirror coated surface and mirror-coated surface become the inner surface, and are heat-sealed and integrated with the molten polycarbonate resin layer in the injection mold using a primer, so the desired surface characteristics can be achieved without going through a special mirror treatment or painting process. This results in plastic mirrors having excellent productivity, and eliminates the occurrence of mechanical defects that occur in post-processing processes such as painting processes.

■It is extremely easy to select and use half-mirror films, mirror films, and special functional films, and it is also easy to select and use molding resins, so there is no need for post-processing (painting, splintering, sagging, etc.). Possible f.

A plastic anti-glare mirror can be easily obtained.

■Since the mold is equipped with a half-mirror film, mirror film, or special functional film, molding is easy with no appearance defects or optical distortions.

It has such characteristics.

[Brief explanation of drawings]

FIG. 2 is a fA1 view of the plastic anti-glare mirror of the present invention. FIG. 1 is a sectional view taken along the line AA' in FIG. The numbers in the diagram are as follows: 1: Plasti-Tsuku anti-glare mirror, 2: Nisblue-3: Runner, 4: Gate, 5: Full mirror film with Niibrimer coating, 5°: Opposite side with single-sided functional film. Half mirror film with primer coat, 6: injection molded resin layer, 7: film edge, 11: mirror film, 1
2: half mirror film, 13: functional film, 15: adhesive primer coat. Patent applicant: Mitsubishi Gas Chemical Co., Ltd. Representative (patent attorney) Sadafumi Tebori, 1 diagram, 2 diagrams ゛ 40

Claims (1)

[Scope of Claims] 1. Fully mirrored thermoplastic plastic film or sheet with an adhesive primer layer formed on one mirrored surface, and entire surface with an adhesive primer layer formed on one half mirrored surface. A half-mirror thermoplastic plastic film or sheet and a resin layer formed by injection molding are bonded and laminated using the adhesive primer layer, and the mirror surface and the half-mirror surface are non-parallel. A plastic anti-glare mirror with integrally molded parts. 2. The outer surface of the half mirror portion is made of a thermoplastic plastic film or sheet coated with one or more functional films selected from hard coat films, antifogging films, antistatic films, antireflection films, etc. A plastic anti-glare mirror according to claim 1. 3. A fully mirrored thermoplastic plastic film or sheet with an adhesive primer layer formed on one mirrored surface and a fully half mirrored thermoplastic film or sheet with an adhesive primer layer formed on one half mirrored surface. Plastic film or sheet with a molecular weight of 2
5,000 or more polycarbonate resin, and the resin layer formed by injection molding, the frame, the attachment part, etc. are made of polycarbonate resin with a molecular weight of 15,000 to 25,000. Or the plastic anti-glare mirror described in item 2. 4. (1) Fully mirrored thermoplastic plastic film or sheet with an adhesive primer layer formed on one mirrored surface and an entire half mirrored entire surface with an adhesive primer layer formed on one half mirrored surface. A process of punching out the thermoplastic plastic film or sheet into the same shape as the mirror to create a mirror-shaped punched piece, (2) inserting the punched piece into a cavity part corresponding to the mirror part of a mirror molding mold. (3) closing the mold and injecting molten resin at high pressure using an injection molding means to laminated and integrally mold the resin layer portion, frame, mounting portion, etc., and (4)
A method for producing a plastic anti-glare mirror, including the step of taking out a molded product from the mold. 5. The method according to claim 4, which comprises performing the step (1) of creating a mirror-shaped punched piece and the step (2) of mounting the punched piece in a mold cavity at the same time when the mold is closed. manufacturing method for plastic anti-glare mirrors.