KR100888656B1 - Film for in-mold forming, preparation method thereof and preparation method for synthetic resin wares and metal plates using the same - Google Patents

Abstract

The present invention relates to an in-molding film, a method for manufacturing the same, and a method for manufacturing a synthetic resin product and a metal plate using the same, and more particularly, to apply a film layer, a pattern layer, a release layer, a thermosetting resin, a thermoplastic resin, or an ultraviolet curable resin. It relates to an in-mold film, characterized in that it comprises a surface layer, a printing layer and an adhesive layer formed by the method, a method for producing the same, and a method for producing a synthetic resin product and a metal plate using the same.

According to the present invention, it is difficult to implement by the conventional spray coating method or silk screen printing method, it is possible to provide a synthetic resin product having a high hardness to prevent the occurrence of scratches and excellent wear resistance. In addition, it is possible to apply a variety of designs using various printing methods, it is possible to provide a better appearance of the product.

Description

In-mold molding film, method for manufacturing same, and method for manufacturing synthetic resin product and metal plate using same {FILM FOR IN-MOLD FORMING, PREPARATION METHOD THEREOF AND PREPARATION METHOD FOR SYNTHETIC RESIN WARES AND METAL PLATES USING THE SAME}

The present invention relates to an in-molding film for producing a synthetic resin product having a high hardness, preventing scratches, and having an excellent wear resistance, a method for manufacturing the same, and a method for manufacturing a synthetic resin product and a metal plate using the same.

In-mold molding is a technology for applying to mobile phone covers, control panels, interior and exterior materials of automobiles, control panels and components of various electronic products, as well as synthetic resin products with decorative surfaces. Compared to the process that has been carried out in several stages, such as the stage and the post-processing stage, it is a technology that can produce a synthetic resin product decorated with complex printing or graphics and patterns with only one injection molding process.

Specifically, the in-mold molding method forms a variety of printed layers on the back of the base film such as polyethylene terephthalate (PET), polycarbonate (PC; polycarbonate), and then put them in a mold together with the synthetic resin injection molding and injection It is the technique of manufacturing the synthetic resin product which the film in which the printing layer was formed adhere | attached and installed by molding.

As a method of manufacturing a synthetic resin product using a conventional in-mold molding method, first, a shape or a figure desired by a user on a top surface of the film layer 10 that forms the surface of the final synthetic resin product by using a method such as silk screen printing After printing to form a printed layer, there is a method of manufacturing a synthetic resin product by inserting a film on which the printed layer is formed into a mold and injecting a synthetic resin injection molding into an upper surface of the printed layer. Alternatively, a release layer is formed on the back side of the film layer, a print layer is formed on the back side of the release layer, and then it is inserted into a mold, and a synthetic resin injection molding is injected into the top side of the printing layer and injection molded. When injection molding is completed, there is a method of removing the film layer and forming a UV hard coating layer to impart wear resistance thereto. As another method, there is a method of forming a UV hard coating layer on the upper surface of the film layer, forming a printing layer on the back side of the film layer, inserting it into a mold, and injecting a synthetic resin injection molding into the back side of the printing layer. . In addition, in the above methods, an adhesive layer may be further formed on the top or the bottom of the printing layer.

The manufacturing method of the synthetic resin product using the in-mold molding method can realize various designs and colors as well as three-dimensional surface by using various printing methods on the upper or rear surface of the film layer. Since it is manufactured, there is an advantage of manufacturing a synthetic resin product without a bonding line. In addition, since the injection molding is made with only one process at the same time as the decoration of the surface, the process is shortened, thereby saving time and reducing production costs.

On the other hand, synthetic resin products manufactured using the conventional in-mold molding method has the following problems.

First, the hardness of the film layer forming the outside of the synthetic resin product is a lot of scratches, especially in the case of polyethylene terephthalate film used a lot as a film layer, the hardness is less than 2H has a problem that a lot of scratches occur particularly. . In addition, when the resin layer applied to form a layer that becomes the surface of the synthetic resin product, such as a print layer or a surface layer, is completely cured to have a hardness (strength) to secure scratch resistance, the planar surface of the in-molding process If a deformation is applied, such as forming, bending, stretching or shrinking to a curved surface, the crack may be broken due to failure to withstand the deformation. Therefore, the printing layer or coating layer on the surface of the in-mold molding or in-mold transfer film should be made of a material having excellent elongation to withstand the hardness or deformation.

As a method for solving this problem, a method of providing a wear resistance by increasing the surface hardness has been proposed by forming a UV hard coating layer on a synthetic resin product manufactured by in-mold molding or in-mold transfer method. Specifically, after the injection molding is completed to form a UV hard coating layer on the surface of the film layer to form the surface of the final synthetic resin product or to remove the film layer and to form a UV hard coating layer on the surface of the release layer for protecting the printed layer The method has been proposed. However, these methods may impart abrasion resistance to the final synthetic resin product, but have the disadvantage that additional processes must be performed, and environmental pollution and pollution produced during the additional process after the injection molding process are produced. The high failure rate of the product is a new problem. As another method of forming the UV hard coating layer, there is a method of forming the UV hard coating layer on the upper surface of the film layer first, followed by injection molding.However, in order to prevent cracking, the elongation must be lowered to secure the elongation and the scratch resistance of the surface. Since it is necessary to adjust the hardness in order to secure the high, this method of solving the problems by adjusting the mutually opposite physical properties also did not solve the above-mentioned problems.

On the other hand, the metal plate is generally used to process the raw materials by cutting, bending or drawing, and then coated or plated with individual products, but metal cans, bottle caps, electronic products or cosmetics. The metal sheet for surface decoration such as a case is capable of expressing various printings by performing the printing process first and the machining process later, and it is possible to manufacture them at high production and low manufacturing cost.

However, a metal plate manufactured by such a method, for example, a cosmetic case or a digital camera, has a problem in that a surface having a high hardness cannot be manufactured even though it is a product requiring a lot of scratch resistance. That is, since the surface with high hardness is broken during the bending or drawing process, it is necessary to paint separately after the processing to obtain the surface with high hardness.

Therefore, the present invention solves the problems of the prior art described above, to prevent the occurrence of scratches due to the high hardness, in-molding film for providing a synthetic resin product and a metal plate having an excellent wear resistance, a manufacturing method thereof and synthetic resin using the same It is an object to provide a method for producing a product and a metal plate.

The present inventors apply a composition for forming a surface layer comprising any one of a thermosetting resin, a thermoplastic resin, a thermally reactive curing agent, or an ultraviolet curable resin to form a surface layer, and in-mold it with a synthetic resin injection product or a metal sheet raw material to form a synthetic resin product. A metal plate was produced. As a result, the surface layer exhibits a soft property with sufficient elongation in the dry state before it is cured, so that it can withstand the deformation, such as forming, bending, stretching or shrinking into curved surfaces during in-mold injection molding. Even below the curing temperature, the shape may be first formed by a vacuum molding machine or a thermoforming machine. In addition, the surface layer is cured by using the temperature and pressure of the injection molding during the injection molding, wherein the hardness is completely cured (crosslinking) by a certain time corresponding to heat, seconds and tens of seconds generated during the in-mold injection molding process It becomes possible to secure the hardness characteristic which can become high and exhibits scratch resistance. This uses the properties of the thermosetting resin and the properties of the thermally reactive curing agent, even if the film layer, which has a lot of scratches, such as polyethylene terephthalate, which has formed on the surface of the conventional product, is removed or not with the release layer, Or it was confirmed that the surface layer formed from the resin containing the thermally reactive curing agent to form the surface of the final product can improve the wear resistance, based on this, to complete the present invention.

In the present invention, the film for in-mold molding, the film layer; A pattern layer formed on the back of the film layer; A release layer formed on the back surface of the pattern layer; A surface layer formed by applying a composition for forming a surface layer comprising any one of (i) a thermosetting resin, (ii) a thermoplastic resin, a thermally reactive curing agent, and (i) an ultraviolet curable resin on the back surface of the release layer; A print layer formed on the back surface layer; And it provides an in-mold forming film comprising an adhesive layer formed on the back of the printing layer.

The thermosetting resin is a melamine resin, and may be one or more selected from the group consisting of methylated melamine resin, butylated melamine resin, urea resin, urea melamine resin, and benzoguanamine resin.

The thermoplastic resin is an acrylic polyol resin, and the thermally reactive curing agent may be a block isocyanate.

The ultraviolet curable resin may include a conventional two-component curable resin and a photoinitiator.

In another aspect, the present invention provides a method for producing an in-mold molding film, comprising: a first step of forming a pattern layer on a rear surface of a film layer; Forming a release layer on a rear surface of the pattern layer; A third step of forming a surface layer by applying a composition for forming a surface layer comprising any one of (i) a thermosetting resin, (ii) a thermoplastic resin, a thermally reactive curing agent, and (i) an ultraviolet ray-curable resin on the back surface of the release layer; A fourth step of forming a printed layer on the back surface layer; And a fifth step of forming an adhesive layer on the rear surface of the printing layer.

The present invention also provides a method for producing a synthetic resin product using the in-mold molding film, comprising: (I) a first method of manufacturing a film for in-molding molding including a film layer, a pattern layer, a release layer, a surface layer, a printing layer, and an adhesive layer. step; (II) inserting the prepared film into a mold; (III) a third step of injecting a synthetic resin injection product into the back of the inserted film, curing the surface layer and simultaneously injection molding; And (IV) removing the release layer from the injection molded synthetic resin product.

In addition, the present invention provides a method for producing a metal plate using an in-mold molding film, comprising: (I) a first step of manufacturing a film including a film layer, a pattern layer, a release layer, a surface layer, a printing layer, and an adhesive layer; (II) a second step of attaching the prepared film to the surface of the metal plate and processing; And (III) a third step of curing the surface layer by heat-treating the processed metal plate.

According to the present invention, by securing an excellent hardness that can not be obtained in the conventional in-mold molding method, it is possible to provide a synthetic resin product and a metal plate that prevents the occurrence of scratches and has an excellent wear resistance. Especially where wear resistance is required, That is, when manufacturing a synthetic resin component used in a place where a lot of friction inevitably occurs during the operation of the machine, the properties of the thermosetting resin, the properties of the thermoplastic resin and the heat-reactive curing agent, or the properties of the UV-curable resin at the frictional site as in the present invention When manufactured by in-mold molding method or by depositing or plating metal to form a thin film having high wear resistance, in-mold injection molding has an effect of obtaining a plastic material component that can satisfy wear resistance and friction resistance.

Figure 2 shows a schematic process diagram for explaining the manufacturing method of the film for molding in-mold according to the present invention.

The film layer 10 is a layer used as a substrate for forming a pattern, polyethylene terephthalate (PET), polycarbonate (PC; polycarbonate), polyvinyl alcohol (PVA; polyvinyl alcohol), nylon (nylon) and It can be 1 or more types chosen from the group which consists of a film of these mixture materials.

It is preferable that the film layer 10 is 12-188 micrometers in thickness.

The pattern layer 20 is a layer for forming a pattern to decorate the surface layer 40 which forms the surface of the final product, and is formed on the rear surface of the film layer 10.

The pattern for decorating the surface layer may be various designs such as wood grain, stone pattern, hair line, hologram, mat, and the like, and may adjust gloss.

The pattern layer 20 may include a printing method such as silk-screen printing, (micro) gravure printing, or the like for forming a pattern layer; Coating methods such as microgravure, roll coating and comma coating; Or it can be formed by patterning to a desired design using processing methods, such as a roll brush processing and a press process. The composition for forming the pattern layer is at least one solvent selected from the group consisting of acrylic polyol resins, isocyanate curing agents, toluene, methylethylketone (MEK) and ethylcellusolve. It includes, and may further include additives such as silica, nitrocellulose. At this time, each component may be used by adjusting the content according to the method and the thickness of the pattern layer for forming a pattern layer.

The release layer 30 is a layer for separating the film layer 10 and the pattern layer 20 from the surface layer 40 which forms the surface of the final product after injection molding is completed. The back surface of the pattern layer 20 Is formed.

The release layer 30 may be formed using a silicone cured product, but it is preferable to use a material that is not imparted with re-coating due to its strong chemical resistance, and the film itself may be separated from the pattern layer or the film layer itself. It may be. Specifically, one kind selected from the group consisting of release materials such as various silicones, waxes, cellulose acetates, or nitrocelluloses, or acrylic modified silicone resins, melamine resins, and alkyd resins. It can form using the composition for mold release layer containing the above resin.

The release layer forming composition is a release agent or resin 45 to 75% by weight, 20 to 50% by weight of at least one solvent selected from the group consisting of toluene, methyl ethyl ketone and isopropyl alcohol, and 1 to 15 catalyst or acid catalyst curing agent It may include weight percent. The release layer forming composition is applied to the back surface of the pattern layer 20 using a method such as microgravure coating, roll coating, dip coating, or spray coating, and has a temperature of 130 to 220 ° C., preferably 150 to 200 ° C. At the appropriate time to dry for a release layer 30 can be formed.

The surface layer 40 is a layer which forms the surface of the final synthetic resin product, and is formed on the rear surface of the release layer 30.

The surface layer 40 can be formed using the composition for surface layer formation containing any one of (i) thermosetting resin, (ii) thermoplastic resin, a thermally reactive hardening | curing agent, or (iv) ultraviolet curable resin.

The thermosetting resin (i) may be a melamine resin, and a solution type melamine resin for normal heat treatment paints that can be used for aqueous and oily materials can be used. As a specific example, 1 or more types chosen from the group which consists of methylated melamine resin, butylated melamine resin, urea resin, urea melamine resin, and benzoguanamine resin can be used. Melamine resin can be used in combination with conventional oil- and oil-based alkyd resin, wherein the alkyd resin may be included in up to 50% by weight relative to the total content of the surface layer-forming composition. The composition for forming a surface layer containing a melamine resin includes 10 to 90% by weight of melamine resin, 5 to 80% by weight of one or more solvents selected from the group consisting of toluene, methylethylketone and isopropyl alcohol, and 5 to 12 acid catalyst curing agents. It may include weight percent.

The composition for forming a surface layer comprising the thermoplastic resin and the thermally reactive curing agent (ii) is at least 50% by weight of an acrylic polyol resin, at least one solvent and a block isocyanate curing agent selected from the group consisting of toluene, methyl ethyl ketone and isopropyl alcohol. It may include. In this case, the content of the block isocyanate may be adjusted so that the ratio of the [OH] group of the acrylic polyol and the [NCO] group of the block isocyanate as a curing agent is a desired value.

The composition for forming a surface layer containing the ultraviolet curable resin (i) includes acrylic polyol resin 25 to 35% by weight, acrylic oligomer 25 to 35% by weight, isocyanate curing agent 5 to 15% by weight, photoinitiator 3 to 7% by weight, toluene, 20 to 40% by weight of one or more solvents selected from the group consisting of methyl ethyl ketone and isopropyl alcohol.

The photoinitiator may be used a conventional photoinitiator used in the ultraviolet curable resin, specifically 1-hydroxycyclohexylphenyl ketone, 2-hydroxy-2-methyl-1-phenylpropan-1-one, hydroxydimethylaceto Phenone, bis (2,4,6-trimethylbenzoyl) -phenylphosphineoxide, 2,2-dimethoxy-1,2-diphenylethan-1-one, 2,4,6-trimethylbenzoyl-diphenyl- Phosphine oxide or benzophenone can be used.

The surface layer forming composition may further include additives such as colorants, slip agents, antifoaming agents, leveling agents, and matting agents. The composition for forming the surface layer is applied to the back surface of the release layer 30 using a method such as microgravure coating, roll coating, dip coating or spray coating and dried at a temperature of 60 to 90 ° C., preferably 70 to 80 ° C. The surface layer 40 can be formed. In the case of forming the surface layer by drying, the surface layer is cured using the temperature and pressure of the injection molding during the injection molding by the in-mold molding method together with the synthetic resin injection molding or metal plate raw material for manufacturing the final product, thereby preventing cracks from occurring. can do. It is preferable that a surface layer is 2-30 micrometers in thickness.

The print layer 50 is a layer for implementing colors and pictures, and is formed on the rear surface of the surface layer 40. The print layer 50 may be formed by using all of the usual natural drying type, ultraviolet curing type, thermosetting ink or coating agent, and the like, and colorants may be used together to implement color.

In the case where the printing layer 50 is a single color, the same and uniform color may be realized by using the front printing method or the coating method. In the case of printing a picture, a design having excellent resolution may be realized by using various printing methods. have. At this time, the printing method or the coating method may use the same method as in the formation of the pattern layer 20, in addition to the offset printing method, the inkjet sublimation transfer method may be used.

The printing layer 50 may be formed by depositing particles such as aluminum paste, copper paste, pearl, or the like by the sputtering method. At this time, the ink may be applied alone or in a separate coating (printing) to form a deposition primer, and printing and deposition may be simultaneously applied. The printing layer 50 may be formed directly on the adhesive layer by using a resin for forming the following adhesive layer 60. The printed layer has a thickness of 1 to 100 μm, preferably 1 to 30 μm.

The adhesive layer 60 is a layer for improving the adhesiveness to which the in-molding film is attached to an injection molded product or a metal plate of a synthetic resin product, and is formed on the rear surface of the printing layer 50.

The adhesive layer 60 is a hot melt and heat-reactive adhesive having excellent heat adhesion and adhesion with various synthetic resin injection molding materials or metal plates, and may be polyacryl, polyester, polyurethane, ethylene vinyl acetate, polycarbonate, polyethylene, polypropylene, polystyrene, It can be formed using a polymer resin capable of thermal fusion, such as acrylonitrile-butadiene-styrene or various rubber adhesives, and a heat-adhesive acrylic resin adhesive. These materials melt well by solvent or heat.

The material for forming the adhesive layer may be selected and used according to the type of the injection molding material. For example, in the case of the polycarbonate injection molding material, an acrylic resin and a polycarbonate resin may be mixed and used. High resin can be used. The adhesive layer forming material may be applied to the back surface of the printing layer 50 using a method such as microgravure coating, roll coating, dip coating or spray coating, and dried to form the adhesive layer 60.

The present invention provides a method for producing a synthetic resin product using an in-mold molding film.

First, to explain a method of manufacturing a synthetic resin product using a film for molding in-mold comprising a surface layer formed by applying a thermosetting resin or a surface layer forming composition comprising a thermoplastic resin and a thermally reactive curing agent according to the present invention in FIG. A schematic process diagram is shown.

Method for producing a synthetic resin product using the in-mold molding film of the present invention shown in Figure 1, (I) film layer (10); Pattern layer 20; Release layer 30; (Iii) a surface layer 40 formed by applying a composition for forming a surface layer containing a thermosetting resin or (ii) a thermoplastic resin and a thermally reactive curing agent; Printed layer 50; And a first step of manufacturing the in-molding film 100 including the adhesive layer 60; (II) inserting the manufactured film into the mold 90; (III) a third step of injecting a synthetic resin injection product 70 into the back surface of the inserted film, curing the surface layer and simultaneously injection molding; And (IV) removing the release layer 30 from the injection molded synthetic resin product 110.

In the third step, the surface layer included in the in-mold molding film is cured, and at the same time, the in-mold molding film and the synthetic resin injection molded product are injection molded. At this time, the surface layer is completely cured using the temperature and pressure of the injection molding, it is possible to prevent the occurrence of cracks. The synthetic resin injection may be used acrylonitrile-butadiene-styrene, polypropylene, polystyrene or polycarbonate. The third step is preferably performed at a temperature of 150 to 220 ℃.

The fourth step is to remove the film layer, which has a lot of scratches, with the release layer, so that the surface layer completely cured in the third step forms the surface of the final synthetic resin product. These surface layers are high in hardness and can improve the wear resistance of the final synthetic resin product surface.

Another method for producing a synthetic resin product using the in-mold molding film of the present invention, (I) film layer (10); Pattern layer 20; Release layer 30; (Iii) a surface layer 40 formed by applying a composition for forming a surface layer containing an ultraviolet curable resin; Printed layer 50; And a first step of manufacturing the in-molding film 100 including the adhesive layer 60. (II) inserting the manufactured film into the mold 90; (III) a third step of injecting a synthetic resin injection product 70 into the back surface of the inserted film to simultaneously cure the surface layer and to perform injection molding; (IV) a fourth step of removing the release layer 30 from the injection molded synthetic resin product 110; And (V) a fifth step of irradiating the synthetic resin product 110 from which the release layer has been removed with ultraviolet rays to second harden the surface layer.

In the fifth step, the second step is completely cured by photocoupling of the photoinitiator by irradiating ultraviolet rays to the surface layer having the elongation in the soft state by primary curing by chemical bonding of the isocyanate, a thermally reactive curing agent in the third step. .

In another aspect, the present invention provides a method for producing a synthetic resin product by applying a composition for forming a surface layer.

The manufacturing method of the synthetic resin product of this invention shown in FIG. 3 is apply | coated to (I) the thermosetting resin or (ii) the composition for surface layer formation containing a thermoplastic resin and a thermally reactive hardening | curing agent on the upper surface of the film 10, A first step of forming the surface layer 40; (II) forming a printed layer 50 on the back of the film layer 10; (III) inserting the film on which the print layer 50 is formed into the mold 90; And (IV) injecting a synthetic resin injection product 70 into the back surface of the printed layer 50 of the inserted film, curing the surface layer and simultaneously injection molding the fourth step.

Another method for producing a synthetic resin product of the present invention, (I) the first step of forming a surface layer 40 by applying a composition for forming a surface layer containing (i) UV curable resin on the upper surface of the film (10); (II) forming a printed layer 50 on the back of the film 10; (III) inserting the film on which the print layer 50 is formed into the mold 90; (IV) a fourth step of injecting a synthetic resin injection product 70 into the back surface of the printed layer 50 of the intercalated film to cure the surface layer first and to simultaneously perform injection molding; And (V) a fifth step of irradiating the injection-molded synthetic resin product 110 with ultraviolet rays to second harden the surface layer.

The present invention provides a method for producing a metal plate using a film for in-molding molding.

Method for producing a metal plate according to the present invention, (I) film layer; Pattern layer; Release layer; (Iii) a surface layer formed by applying a composition for forming a surface layer containing a thermosetting resin or (ii) a thermoplastic resin and a thermally reactive curing agent; Printed layer; And a first step of manufacturing a film including an adhesive layer. (II) attaching the manufactured film to a metal plate and processing it; And (III) heat treating the processed metal plate to cure the surface layer and adhere the adhesive layer.

The second stage of processing may be carried out at temperatures below 100 ° C. and under appropriate pressure. At this time, the release process or wax treatment to the outer surface layer other than the surface layer of the film may facilitate the processing process.

The third step of heat treatment may be performed at 150 to 200 ℃.

The method may further include removing the release layer between the second and third steps or after the third step.

Another method for producing a metal plate according to the present invention, (I) film layer; Pattern layer; Release layer; (Iii) a surface layer formed by applying a composition for forming a surface layer containing a thermosetting resin or (ii) a thermoplastic resin and a thermally reactive curing agent; A first step of producing a film comprising a printed layer; (II) a second step of forming an adhesive layer on the upper surface of the metal plate; (III) attaching the fabricated film to the metal plate on which the adhesive layer is formed and processing the third step; And (IV) heat-treating the processed metal plate to cure the surface layer and adhere the adhesive layer.

According to another aspect of the present invention, there is provided a method of forming a surface layer by applying (i) a thermosetting resin or (ii) a composition for forming a surface layer containing a thermoplastic resin and a thermally reactive curing agent to an upper surface of a film. Stage 1; (II) forming a printing layer and an adhesive layer on the back of the film; (III) a third step of attaching and processing the film having the adhesive layer formed on the metal plate; And (IV) heat-treating the processed metal plate to cure the surface layer and adhere the adhesive layer.

According to another aspect of the present invention, there is provided a method of forming a surface layer by applying (i) a thermosetting resin or (ii) a composition for forming a surface layer containing a thermoplastic resin and a thermally reactive curing agent to an upper surface of a film. Stage 1; (II) a second step of forming a printing layer on the back of the film; (III) forming a adhesive layer on the upper surface of the metal plate; (IV) attaching the fabricated film to the metal plate on which the adhesive layer is formed and processing the fourth step; (V) a fifth step of heat-treating the processed metal plate to cure the surface layer and adhere the adhesive layer.

Synthetic resin products produced in this way can be used for cell phone covers, control panels, interior and exterior materials of automobiles, control panels of various electronic products, air conditioner cases, elevator interior materials. In addition, the metal plate may be used as a component of an electronic product for applying to a place where a lot of friction occurs during operation, for example, a component that operates when a shutter of a digital camera is operated.

Hereinafter, preferred examples are provided to aid the understanding of the present invention, but the following examples are merely for exemplifying the present invention, and it will be apparent to those skilled in the art that various changes and modifications can be made within the scope and spirit of the present invention. It is natural that such variations and modifications fall within the scope of the appended claims.

Example 1

<Production of Film>

Polyethylene terephthalate (PET) film was used as the film layer.

To form the pattern layer, 50 parts by weight of acrylic polyol resin polymerized from 34 parts by weight of methyl methacrylate, 0.5 parts by weight of methyl methacrylate, 0.3 parts by weight of benzoyl peroxide, 50 parts by weight of toluene, and 15.2 parts by weight of ethyl acetate, toluene 20 5 parts by weight of silica is added to 100 parts by weight of a resin composition consisting of 10% by weight of ethylenemethane diisocyanate (HMDI) having a weight%, 20% by weight of methyl ethyl ketone and a proportion of isocyanate groups [NCO] of 20 to 23%. To prepare a composition for forming a pattern layer. This was applied to the back of the PET film using a micro gravure printing method (mat), dried at 80 ℃ and aged at 72 ℃ for 72 hours to form a pattern layer. At this time, the glossiness of the pattern layer was 12.

In order to form a release layer, a composition for forming a release layer comprising 50 wt% of silicon, 20 wt% of toluene, 27 wt% of methyl ethyl ketone, and 3 wt% of mono-n-butyl tin oxide as a catalyst Prepared. This was applied to the back side of the pattern layer using a microgravure printing method, and dried at 150 ° C. to form a release layer having a thickness of 0.5 μm.

To form the surface layer, 50% by weight of melamine resin (CYMEL303), 25% by weight of alkyd resin, 10% by weight of toluene, 15% by weight of isopropyl alcohol, and 10% by weight of p-toluene sulfonic acid as an acid catalyst The composition for surface layer formation containing was prepared. This was applied to the back surface of the release layer using a microgravure printing method, and dried at 80 ° C. to form a surface layer having a thickness of 10 μm.

In order to form a printed layer, a composition for forming a printed layer including 20 wt% of an acrylic resin, 35 wt% of toluene, 35 wt% of methyl ethyl ketone, and 10 wt% of carbon black was prepared. This was applied to the back surface of the surface layer by a microgravure printing method and dried to form a black print layer.

An acrylic pressure-sensitive adhesive was applied to the back of the printed layer and dried to form an adhesive layer.

<Production of Synthetic Resin Products>

The prepared in-mold molding film was inserted into a mold, and an injection molded ABS resin was injected into the adhesive layer portion of the film, followed by injection molding at 200 ° C. After injection molding was completed, the product was separated from the mold, and the release layer was removed to prepare a final ABS resin product.

Example 2

When the pattern layer is formed in Example 1, a pattern layer including 30% by weight of acrylic polyol, 10% by weight of nitrocellulose, 15% by weight of toluene, 15% by weight of methyl ethyl ketone, 10% by weight of ethylcellulose, and 20% by weight of isocyanate A composition for forming was prepared, which was applied using a gravure printing method, and dried at 60 ° C., to thereby form a hologram pattern layer having a thickness of 2 μm.

Example 3

When forming the release layer in Example 2 to prepare a composition for forming a release layer comprising 50% by weight of melamine resin (CYMEL 303), 25% by weight alkyd resin, 10% by weight toluene, 15% by weight isopropyl alcohol, It was applied in the same manner as in Example 2 except that the coating was applied using a microgravure printing method and dried at 150 ° C. to form a release layer.

Example 4

50 weight% of an acrylic polyol resin polymerized from 34 weight parts of methyl methacrylate, 0.5 weight part of methyl methacrylic acid, 0.3 weight part of benzoyl peroxide, 50 weight part of toluene, and 15.2 weight part of ethyl acetate when forming the surface layer in Example 3 To prepare a composition for forming a surface layer comprising 30% by weight of toluene, 10% by weight of methyl ethyl ketone, 10% by weight of hexamethylene diisocyanate (HMDI) having a proportion of blocked isocyanate groups [NCO] of 6 to 7%, and The microgravure printing method was applied and dried at 80 ° C., except that a surface layer was formed.

Example 5

30 weight% of an acrylic polyol resin polymerized from 34 weight parts of methyl methacrylate, 0.5 weight part of methyl methacrylic acid, 0.3 weight part of benzoyl peroxide, 50 weight part of toluene, and 15.2 weight part of ethyl acetate when forming the surface layer in Example 1 Preparing a surface layer composition comprising 30% by weight of an acrylic oligomer (epoxyacrylate, CYTEC EB606), 10% by weight of isocyanate (HMDI), 4% by weight of photoinitiator (benzophenone), 26% by weight of solvent (TMPTA), The film was prepared in the same manner as in Example 1, except that it was coated using a microgravure printing method and dried at 80 ° C. to form a surface layer.

The prepared film was inserted into a mold, and the injection of ABS resin was injected into the adhesive layer of the film, followed by injection molding at 200 ° C. After the injection molding was completed, the product was separated from the mold, the release layer was removed, and the final ABS resin product was prepared by irradiating the ultraviolet ray thereto.

Example 6

Polyethylene terephthalate (PET) film was used as the film layer.

50% by weight of melamine resin (CYMEL303), 25% by weight of alkyd resin, 10% by weight of toluene, 15% by weight of isopropyl alcohol, 10% by weight of p-toluene sulfonic acid as an acid catalyst to form the surface layer To prepare a composition for forming a surface layer comprising a. This was applied to the upper surface of the film layer using a microgravure printing method, and dried at 80 ℃ to form a surface layer having a thickness of 10 ㎛.

In order to form a printed layer, a composition for forming a printed layer including 20 wt% of an acrylic resin, 35 wt% of toluene, 35 wt% of methyl ethyl ketone, and 10 wt% of carbon black was prepared. This was applied to the back of the film layer by a microgravure printing method and dried to form a black print layer.

The prepared film was inserted into a mold, and an injection molded ABS resin was injected into the print layer of the film, followed by injection molding at 200 ° C. After injection molding was completed, the product was separated from the mold to prepare a final ABS resin product.

Example 7

A film was prepared in the same manner as in Example 1.

The prepared film was attached to the surface of the metal plate and processed by applying an appropriate pressure at a temperature of 80 ° C. After removing the release layer from the processed metal plate, it was heat treated at 180 ° C to prepare a final metal plate.

1 is a schematic process diagram for explaining a method of manufacturing a synthetic resin product using an in-mold molding film according to the present invention.

Figure 2 is a schematic process diagram for explaining the manufacturing method of the film for in-molding according to the present invention.

3 is a schematic process chart for explaining a method of manufacturing a synthetic resin product according to the present invention.

* Description of Major Symbols in Drawings *

10: film layer, film 20: pattern layer

30: release layer 40: surface layer

50: printed layer 60: adhesive layer

70: synthetic resin injection molding 80: UV hard coating layer

90: mold 100: film for in-mold molding

110: synthetic resin products

Claims (24)

As a film for in-mold molding, Film layer; A pattern layer formed on the rear surface of the film layer; A release layer formed on a rear surface of the pattern layer; A surface layer formed by applying a composition for forming a surface layer comprising any one of (i) a thermosetting resin, (ii) a thermoplastic resin, a thermally reactive curing agent, and (i) an ultraviolet curable resin on the back surface of the release layer; A printing layer formed on the rear surface of the surface layer; And In-mold molding film comprising an adhesive layer formed on the back of the printing layer. The method of claim 1, The film layer is an in-mold molding film, characterized in that at least one selected from the group consisting of polyethylene terephthalate, polycarbonate, polyvinyl alcohol, nylon and a film of a mixture material thereof. The method of claim 1, The composition for forming a surface layer containing the thermosetting resin (i) includes 5 to 80 wt% of at least one solvent selected from the group consisting of 10 to 90 wt% of melamine resin, toluene, methyl ethyl ketone and isopropyl alcohol, and an acid catalyst. An in-mold molding film comprising 5 to 12 wt% of a curing agent. The method of claim 3, The melamine resin is at least one member selected from the group consisting of methylated melamine resin, butylated melamine resin, urea resin, urea melamine resin, benzoguanamine resin and alkyd resin. The method of claim 3, The composition for forming a surface layer comprising the thermosetting resin (iii) further comprises an alkyd resin in an amount of up to 50% by weight based on the total content of the composition. The method of claim 1, The composition for forming a surface layer comprising the thermoplastic resin and the thermally reactive curing agent (ii) is at least 50% by weight of an acrylic polyol resin, at least one solvent and a block isocyanate curing agent selected from the group consisting of toluene, methyl ethyl ketone and isopropyl alcohol. In-molding film, characterized in that it comprises a. The method of claim 1, The composition for forming a surface layer containing the ultraviolet curable resin (i) includes acrylic polyol resin 25 to 35% by weight, acrylic oligomer 25 to 35% by weight, isocyanate curing agent 5 to 15% by weight, photoinitiator 3 to 7% by weight, and toluene , 20 to 40% by weight of one or more solvents selected from the group consisting of methyl ethyl ketone and isopropyl alcohol. As a manufacturing method of the film for in-molding, A first step of forming a pattern layer on the back of the film layer; Forming a release layer on a rear surface of the pattern layer; A third step of forming a surface layer by applying a composition for forming a surface layer comprising any one of (i) a thermosetting resin, (ii) a thermoplastic resin, a thermally reactive curing agent, and (i) an ultraviolet curable resin on the back surface of the release layer; A fourth step of forming a printed layer on the back surface layer; And And a fifth step of forming an adhesive layer on a rear surface of the printing layer. The method of claim 8, The second step is at least one release material selected from the group consisting of silicone, wax, cellulose acetate and nitrocellulose, or at least one resin selected from the group consisting of acrylic modified silicone resins, melamine resins and alkyd resins. To 75% by weight, toluene, methyl ethyl ketone and isopropyl alcohol, 20 to 50% by weight of at least one solvent selected from the group consisting of, and 1 to 15% by weight of the catalyst or acid catalyst curing agent is applied a composition for forming a release layer Method for producing a film for in-molding, characterized in that carried out by. The method of claim 8, The composition for forming a surface layer containing the thermosetting resin (i) includes 5 to 80 wt% of at least one solvent selected from the group consisting of 10 to 90 wt% of melamine resin, toluene, methyl ethyl ketone and isopropyl alcohol, and an acid catalyst. A method for producing an in-molding film, comprising 5 to 12 wt% of a curing agent. The method of claim 10, The melamine resin is at least one member selected from the group consisting of methylated melamine resin, butylated melamine resin, urea resin, urea melamine resin, benzoguanamine resin and alkyd resin. The method of claim 10, The composition for forming a surface layer containing the thermosetting resin (iii) further comprises an alkyd resin in an amount of up to 50% by weight based on the total content of the composition. The method of claim 8, The composition for forming a surface layer comprising the thermoplastic resin and the thermally reactive curing agent (ii) is at least 50% by weight of an acrylic polyol resin, at least one solvent and a block isocyanate curing agent selected from the group consisting of toluene, methyl ethyl ketone and isopropyl alcohol. Method for producing a film for in-molding molding comprising a. The method of claim 8, The composition for forming a surface layer containing the ultraviolet curable resin (i) includes acrylic polyol resin 25 to 35% by weight, acrylic oligomer 25 to 35% by weight, isocyanate curing agent 5 to 15% by weight, photoinitiator 3 to 7% by weight, and toluene , 20 to 40% by weight of one or more solvents selected from the group consisting of methyl ethyl ketone and isopropyl alcohol. The method of claim 8, The fifth step is characterized in that the polyacryl, polyester, polyurethane, ethylene vinyl acetate, polycarbonate, polyethylene, polypropylene, polystyrene, acrylonitrile-butadiene-styrene or acrylic resin pressure sensitive adhesive coating The manufacturing method of the film for in-molding molding which makes it. As a method of manufacturing a synthetic resin product using an in-mold film, (I) a film layer; Pattern layer; Release layer; (Iii) a surface layer formed by applying a composition for forming a surface layer containing a thermosetting resin or (ii) a thermoplastic resin and a thermally reactive curing agent; Printed layer; And a first step of manufacturing an in-molding film including an adhesive layer; (II) inserting the prepared film into a mold; (III) a third step of injecting a synthetic resin injection product into the back of the inserted film, curing the surface layer and simultaneously injection molding; And (IV) a fourth step of removing the release layer from the injection-molded synthetic resin product. As a method of manufacturing a synthetic resin product using an in-mold film, (I) a film layer; Pattern layer; Release layer; (Iii) a surface layer formed by applying a composition for forming a surface layer containing an ultraviolet curable resin; Printed layer; And a first step of manufacturing an in-molding film including an adhesive layer; (II) inserting the prepared film into a mold; (III) a third step of injecting a synthetic resin injection molding product into the back of the inserted film, and simultaneously curing the surface layer by injection molding; (IV) a fourth step of removing the release layer from the injection molded synthetic resin product; And (V) a method of manufacturing a synthetic resin product, comprising the step of irradiating ultraviolet rays to the synthetic resin product from which the release layer is removed, and curing the surface layer secondaryly. The method according to claim 16 or 17, The third step is a method for producing a synthetic resin product, characterized in that carried out at a temperature of 150 to 220 ℃. delete delete delete As a manufacturing method of a metal plate, (I) a film layer; Pattern layer; Release layer; (Iii) a surface layer formed by applying a composition for forming a surface layer containing a thermosetting resin or (ii) a thermoplastic resin and a thermally reactive curing agent; Printed layer; And a first step of manufacturing a film including an adhesive layer. (II) attaching the manufactured film to a metal plate and processing it; And (III) A method for producing a metal plate, comprising the step of heat-treating the processed metal plate to cure the surface layer and to bond the adhesive layer. The method of claim 22, The process of the second step is carried out at a temperature of less than 100 ℃, the heat treatment of the third step is a method of manufacturing a metal plate, characterized in that carried out at 150 to 200 ℃. delete

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