TWI626146B - Forming method for forming film and film, mold and molded article including film and forming method thereof - Google Patents

Abstract

The present invention provides a film, a method for forming the film, and the like to maintain a good appearance and to prevent the occurrence of cracks.

The upper mold and the lower mold are clamped in a state in which the film is fixed and heated between the upper mold and the lower mold of the forming mold, and the pressing member is pressed against the outer side of the convex portion of the lower mold to press the film for initial shaping. Further, the film is subjected to secondary shaping at least on the outer side of the convex portion of the lower mold by the pressure of the gas introduced from the upper mold side, thereby maintaining a good appearance and realizing a film and a film which are surely prevented from being cracked. Forming method, etc.

Description

Forming method for forming film and film, mold and molded article including film and forming method thereof

The present invention relates to a film, a molding method for thermoforming a film into a desired three-dimensional shape, a molding die, and a three-dimensional shaped article (molded article) using the film. In particular, the present invention can be suitably used for including a hard coat film or the like. The manufacture of decorative molded articles.

The decorative molded article (colored molded article) or the in-mold molded article is emphasized from the side of productivity, design, and functionality. Examples of the object to be applied include containers for external use of mobile phones, automobile-related components, medical machine tools, electronic products, home electric appliances, building materials, lotions, cosmetics, and the like.

Patent Document 1 does not have a resin molded article having a good appearance such as a mirror surface or a pressed surface, and is formed by forming a film layer on the surface thereof, applying a coating, or the like, and forming it without using a large-sized apparatus capable of withstanding a high pressure such as an injection molding method. Revealed as follows. That is, a mold for vacuum/pressure forming is disclosed, the mold having: a supporting means for supporting the mold member in a state of ensuring space between the inner surface of the forming surface of the mold member having the forming surface; And heating the molding surface to a Vicat softening temperature (T) ° C or higher of the sheet-like resin to be molded; and cooling means supplying a cooling medium to the space to cool the molding surface to the sheet-like resin Vicat softening temperature (T) -10 ° C or less.

Patent Document 2 discloses a technique in which the opening portion 2 which can form a square shape is simple, and the fitting member such as a decorative frame is simple, and a special operation such as a cooling time is not required to prevent warpage, and the following is disclosed. That is, a mold for pressure forming is disclosed to obtain a hollow pot-shaped molded product having a pot shape which is recessed at the periphery of the opening and which has a rectangular circumference, and is characterized in that the opening of the mold is formed corresponding to the periphery of the opening. The peripheral edge portion of the opening causes the sides to bulge outwardly, whereby the sides of the open circumference are linearly positioned as the shape of the formed material is cooled and deformed.

However, as an example of the shaping of the conventional pressure forming method, the outline of the mold arranged horizontally is as follows.

(1) The sheet is fixed by a holder of the sheet.

(2) The holder of the sheet is moved to the heating zone, and infrared heating is performed from above to soften the sheet at a higher temperature than the Tg.

(3) The holder of the sheet is moved to the core, and the mold is clamped to prepare for sheet formation, and pressurized air is introduced.

(4) The sheet rapidly reaches the surface of the contact core by the pressurized air, and when it contacts the surface of the core, it is rapidly cooled to have a Tg or less of the resin, and is fixed to the shape along the surface shape of the core.

(5) After the pressurized air or the like is discharged, the shaped article is taken out.

In this way, the use includes having a substantially vertical relative to the bottom surface In the case of a mold of a core of a straight upright portion, a local extension is produced to allow the bottom surface of the shaped sheet (film) to be finally shaped.

Since the resin molded article has a problem that it is easily damaged on the surface, a hard-coated sheet is often used as a countermeasure against damage, but the hard coat hard extension is small, and when the limit elongation is exceeded, cracking is likely to occur. . When the molding is carried out by the above-described molding method, the coating layer is also extended to the same portion as the film is stretched, so that cracks are concentrated in the vicinity of the outer shape of the molded article or the bottom surface of the hole. Therefore, there is a curvature which makes it gentle in shape, or a design which reduces the rising height to prevent cracking of the hard coat layer.

Moreover, the hardness is lowered to cause a certain degree of sacrifice in the damage prevention performance, and the hard coat layer which uses the lift-extension property can be implemented even if the shape is raised by a substantially vertical shape (generally less than 4 mm), but it is not effective. Increasing the damage of the surface of the resin has the problem of damaging the hard coat layer even when it is costly.

[Previous Technical Literature]

[Patent Literature]

[Patent Document 1] Japanese Patent Laid-Open No. Hei 10-193449

[Patent Document 2] Japanese Patent Laid-Open Publication No. 2004-142403

The present inventors focused on cracks concentrated in the vicinity of the bottom surface. It is generated according to the mechanism at the time of shaping. That is, the final extended portion is the problem caused by local extension.

It can be known that when only the pressure air is shaped, only the vicinity of the root portion of the bottom portion is partially extended. On the other hand, when the shape is not pressed without using pressurized air, the mold is pressed, and on the contrary, the top surface is locally localized. Extends to cause cracking. It can be seen that when all the faces are pressed, the contact with the mold, especially for the top surface of the sheet which requires strict quality of the design, is entrained in the air, and the surface of the mold is transferred to the sheet when the degree of polishing of the mold is low. The appearance deteriorates.

Accordingly, it is an object of the present invention to provide a mold sheet which maintains good appearance, such as a mold which can be formed without cracking even if a hard coat layer having damage resistance is used, a molding method, and the like, and which provides an outer shape or hole. A film or sheet having a high rise in shape or a curvature which can reduce the curvature of the top surface side and which is not limited in design, and a molded article including the same. As described above, the present invention provides a hard coat layer for the purpose of preventing damage resistance, and can be suitably used in the formation of a hard coat layer or the like which is relatively prone to cracking.

SUMMARY OF THE INVENTION The present invention has been made in view of the results of a research on a forming method in which a hard coat film formed by a press-form forming does not cause hard coat cracking.

That is, the present invention is as follows.

(1) A film characterized in that it is subjected to a scratch resistance test on the surface of a film before forming (based on ASTM D 2486-79, using a pig hair brush) At least 450 sheets of the scratch-off hard coat layer having a scratch of 10 or less are formed, and a film of the outer side of the convex portion of the lower mold of the molding die used for molding is formed. The elongation of the second region (end portion) is 100% or less with respect to the first region (thick portion) of the film disposed on the convex portion.

(2) A film formed by a molding method using a molding die, the molding die comprising: a lower die having a convex portion; and an upper die having a position outside the convex portion when the mold is closed a pressing member; and a fixing frame, the film is fixed between the upper mold and the lower mold, and the forming mold is used to form the film into a predetermined three-dimensional shape, and is characterized in that: a heating step is performed to press the upper mold When the member is retracted, the film is fixed to the fixing frame and heated to soften it; in the initial shaping step, when the upper mold and the lower mold are closed, the pressing member is advanced to push the film at least outside the convex portion. In order to perform the initial shaping and the secondary shaping step, the film is subjected to secondary shaping at least outside the convex portion of the lower mold after the mold clamping by the pressure of the gas introduced from the upper mold side.

(3) A film formed by a molding method using a molding die, the molding die comprising: a lower die having a concave portion for forming a hole and/or a recess for a molded article on a surface thereof. a convex portion; an upper mold having a pressing member positioned outside the convex portion when clamping; and a fixing frame fixing the film between the upper mold and the lower mold, and forming the film into a predetermined three-dimensional shape using the forming mold , characterized by: In the heating step, the film is fixed to the fixing frame in a state where the pressing member of the upper mold is retracted, and then heated and softened; in the initial shaping step, when the upper mold and the lower mold are closed, the pressing member is pressed. Advancing at least the outer side of the convex portion to press the film for initial shaping; and secondary forming step, by the pressure of the gas introduced from the upper mold side, at least on the outer side of the convex portion of the lower mold after the mold clamping Secondary shaping.

(4) The film according to the above (2) or (3), characterized in that the elongation of the second region (end portion) of the film formed on the outer side of the convex portion during molding is relative to the film disposed on the convex portion The elongation of the first region (thick portion) is 100% or less.

(5) The film according to (2) or (3) above which is characterized in that it is a hard coat film having a hard coat layer.

(6) The film according to the above (1) or (5), wherein the printed hard coat layer is applied to the surface on the side opposite to the hard coat layer.

(7) A molded article comprising the film according to any one of the above (1) to (6).

(8) A method of forming a film, which comprises using a molding die, the molding die comprising: a lower die having a convex portion; and an upper die having a pressing member positioned outside the convex portion at the time of clamping; and a fixing frame And fixing the film between the upper mold and the lower mold, and forming the film into a predetermined three-dimensional shape by using the molding die, characterized in that the heating step is performed, and the film is fixed in a state in which the pressing member is retracted. After fixing the frame, heating is performed to soften it; In the initial shaping step, when the upper mold and the lower mold are closed, the pressing member is advanced to press the film at least on the outer side of the convex portion to perform initial shaping; and the secondary forming step is performed from the upper mold side The pressure of the introduced gas is subjected to secondary shaping at least on the outside of the convex portion of the lower mold after the mold clamping.

(9) A method of forming a film, which is a mold for molding, comprising: a lower mold having a convex portion provided with a concave portion for forming a hole and/or a concave portion in a molded article; and an upper mold having a pressing member positioned outside the convex portion at the time of clamping; and a fixing frame for fixing the film between the upper mold and the lower mold, and forming the film into a predetermined three-dimensional shape by using the forming mold, characterized in that: In the heating step, the film is fixed to the fixing frame in a state where the pressing member of the upper mold is retracted, and then heated and softened; in the initial shaping step, when the upper mold and the lower mold are closed, the pressing member is pressed. Advancing at least the outer side of the convex portion to press the film for initial shaping; and secondary forming step, by the pressure of the gas introduced from the upper mold side, at least on the outer side of the convex portion of the lower mold after the mold clamping Secondary shaping.

(10) The molding method according to (8) or (9) above, wherein the pressing member is advanced, and pressurized air is introduced within one second after the start of the initial shaping step to start the secondary forming step.

(11) The method for molding a film according to (8) or (9) above, wherein the gas is pressurized air.

(12) A method of forming a film according to (8) or (9) above, wherein the film is a hard coat film having a hard coat layer.

(13) The method for molding a film according to the above (12), wherein the film is a hard coat layer printed on a surface opposite to the hard coat layer.

(14) The method for molding a film according to the above (8) or (9), wherein in the initial shaping step, the fixing frame is fitted to the upper mold and the lower mold at the time of mold clamping.

(15) The method for molding a film according to the above (8) or (9), wherein a gas introduction hole is formed in the upper mold, and a gas is introduced into the film from the gas introduction hole in the secondary forming step. surface.

(16) A method of molding a molded article, characterized in that the film formed by the method according to (8) or (9) above is a hard coat film which is printed on a surface opposite to the hard coat layer, and The forming method includes: a processing step of processing the hard coat film corresponding to the shape of the injection molding cavity; and an embedding step of embedding the hard coat film in the cavity of the injection molding die so that the hard coat surface is in contact with the cavity to form In the film substrate and the molding step, the film substrate and the injection molding material are integrated by injection molding to form a molded article.

(17) A molding die comprising: a lower die having a convex portion; an upper die having a pressing member positioned outside the convex portion at the time of clamping; and a fixing frame fixing the film between the upper die and the lower die .

(18) The molding die according to the above (17), wherein the lower mold is provided with a concave portion for forming a hole and/or a concave portion in the molded article.

(19) The molding die according to the above (17), wherein the pressing member has an inner surface having a shape substantially similar to that of the convex portion.

(20) The molding die according to the above (17), wherein in the secondary forming step, a gas introduction hole is formed in the upper mold to introduce a gas into the surface of the film.

(21) The molding die according to the above (17), wherein the difference between the inner diameter of the pressing member and the outer diameter of the convex portion is (thickness (mm) of the film before molding × 2) +1 mm Up to 4mm.

(22) The molding die according to the above (17), wherein the pressing member is operated by a cylinder or a hydraulic cylinder, and the cross-sectional shape of the pressing member of the pressing film is chamfered and/or crowned. The film does not contact the top surface on the convex portion in the initial shaping step and the secondary shaping step.

According to the present invention, it is possible to enlarge a film or a sheet, in particular, a sheet having a hard coat layer, a shape range of designing the shaped article and the in-mold molded article, and the like, and providing a film or sheet which does not cause cracking and Three-dimensional shaped products (molded products) and the like.

10‧‧‧上模

12‧‧‧ Pressurized air introduction hole (air introduction hole)

15‧‧‧Activity ring (pushing member)

20‧‧‧Down

22‧‧‧ core (protrusion)

24‧‧‧Rising Department

30‧‧‧Sheet fixing frame (fixed frame)

32‧‧‧Sheet or film

40‧‧‧Squeezing die

Fig. 1 is a cross-sectional view showing a first embodiment of the mold for pressure forming of the present invention.

Fig. 2 is a schematic top view showing a movable ring and a core of a mold for pressure forming.

Figure 3 is a view showing that the frame is fixed by the upper mold and the lower mold. A cross-sectional view of a state in which the ring is advanced and the heated sheet is initially shaped.

Fig. 4 is a cross-sectional view showing a state in which pressurized air is introduced to indicate secondary shaping.

Fig. 5 is a cross-sectional view corresponding to Fig. 3 showing a second embodiment of the mold for pressure forming.

Hereinafter, the description of the configuration of the present invention, the construction of the molding method, and the like will be described.

(1) film or sheet

The thickness of the above film or sheet of the present invention used above is preferably from 0.05 to 1.2 mm, and the surface layer is preferably a hard coat layer.

The height of the molded article obtained in this case is also based on the elongation property of the hard coat layer, but in the scratch resistance test (based on ASTM D 2486-79, using a pig hair brush and traveling 450 times with a load of 450 g), The resulting scratch is a scratch-resistant practical hard coat layer of 10 or less, and a molded article having a height of substantially vertical upright wall height of 4 mm or more and a maximum height of 15 mm which cannot be obtained in the current state can be produced.

According to the molding method of the present invention, in order to obtain a maximum limit using the hard coat layer extending property so that the top surface or the rising surface becomes a circular product, a height of about twice the height can be produced. Furthermore, the above hard coat layer (layer) was subjected to a scratch resistance test (based on ASTM D 2486-79, using a pig hair brush and a load of 450 g round trip 200 times) to produce a scratch at 5 The following is better, and it is better to use 3 or less.

Examples of the film or sheet include (1) a transparent sheet using a transparent plastic material, and (2) a resin having an impact resistance or a moderate heat resistance as a base layer, and a hard surface is formed on one or both sides thereof. On the transparent multilayer sheet of the resin layer, (3) a sheet or a multilayer sheet of a hard coat layer is formed on one or both sides of the sheet of the above (1) or (2).

In the present invention, a printing layer or a metallized layer having design properties or the like may be appropriately formed on the inner surface as appropriate.

The transparent plastic material used for the film or sheet may, for example, be an aromatic polycarbonate, an amorphous polyolefin (representative example: alicyclic polyolefin), poly(meth)acrylate, polyfluorene, cellulose acetate. Polystyrene, amorphous polyester (representative example: alicyclic polyester), transparent polyamide, polyethylene terephthalate resin, and the like, and a transparent resin formed from the compositions. Among these, a resin to be used for optics is preferred, and examples thereof include an aromatic polycarbonate, a (meth) acrylate, a styrene-(meth) acrylate copolymer resin, and a hydrogenated styrene-(methyl) group. Composition of acrylate copolymer resin (hydrogenated benzene ring of styrene component to form partial alicyclic ring), transparent polyamine and aromatic polycarbonate and amorphous polyester (representative example: alicyclic polyester) Wait.

Aromatic polycarbonate (PC) from the point of impact resistance, strength, heat resistance, durability or bending workability to use 2,2-bis(4-hydroxyphenyl)alkane or 2,2-(4- a diphenolic propane compound represented by a hydroxy-3,5-dihalophenyl)alkane and preferably a polymer produced by a conventional method, and may also include a structural unit whose polymer skeleton is derived from a fatty acid diol Or an ester-bonded structural unit, especially a diol made of 2,2-bis(4-hydroxyphenyl)propane Aromatic polycarbonate is preferred.

The amorphous polyester resin to be used as a composition with an aromatic polycarbonate is, for example, a dicarboxylic acid component typified by 1,4 cyclohexanedicarboxylic acid and cyclohexane dimethanol dibenzoate. The esterification or transesterification reaction is carried out for the diol component represented by the reaction and other minor components as needed, and then the polymerization catalyst is appropriately added to gradually depressurize the reaction vessel, and the obtained method of the copolymerization reaction is obtained by a conventional method. .

The alicyclic dicarboxylic acid or an ester-forming derivative thereof may, for example, be 1,2-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid or 1,4-cyclohexanedicarboxylic acid or 1, 4-decalin dicarboxylic acid, 1,5-decalin dicarboxylic acid, 2,6-decalin dicarboxylic acid, 2,7-decalin dicarboxylic acid, and ester-forming derivatives thereof.

The polyimine resin to be used in the present invention is, for example, a conventional transparent transparent polyimide resin for optical use, and the heat distortion temperature of one of the indexes of heat resistance is, for example, in the range of 100 to 170 ° C, and examples thereof include aromatic polyfluorene. An imide resin, an alicyclic polyimide resin, an aliphatic polyimine resin, and the like. The balance between mechanical strength, chemical resistance, transparency, and the like is preferably an alicyclic polyimide resin, but two or more kinds of polyimine resins may be combined. Examples of the above polyimine resin include GLILAMID TR FE5577, XE 3805 (manufactured by EMS), NOVAMID X21 (manufactured by Mitsubishi Engineering PLASTIC), and Toyobo NYLON T-714E (manufactured by Toyobo Co., Ltd.), but are not limited thereto.

The (meth) propylene resin is a single polymer of various (meth) acrylates represented by polymethyl methacrylate (PMMA) or methyl methacrylate (MMA), or PMMA or MMA and the other one. A monomeric copolymer or the like is added, and a plurality of the resins may be mixed. Among these, a (meth) acrylate having a cyclic alkyl structure excellent in low birefringence, low hygroscopicity, and heat resistance is preferred. Examples of the above (meth) propylene resin are, for example, ACRYPET (manufactured by Mitsubishi Rayon), DELPET (manufactured by Asahi Kasei Chemicals), and PARAPET (manufactured by KURARAY), but are not limited thereto.

The base material layer of the above (2) is a layer for retaining the basic physical properties, and the resin to be used is a representative example of the high impact resistance, and examples thereof include an aromatic polycarbonate, an aromatic polycarbonate, and an amorphous poly The composition of the ester resin.

The hard resin layer formed on one side or both sides of the base material layer is exemplified by copolymerization of (meth) acrylate, styrene-(meth) acrylate copolymer resin, hydrogenated styrene-(meth) acrylate. a resin (a alicyclic ring of a styrene component is hydrogenated to form a partial alicyclic ring), a copolymerized aromatic polycarbonate such as 2,2-(4-hydroxy-3,methylphenyl) alkane, or an aromatic polycarbonate The ester resin includes a (meth)acrylic resin copolymerized with a (meth)acrylic monomer having a compatible aromatic ring, a composition of an aromatic polycarbonate resin, and the like, and a (meth)acrylic resin and hydrogenated styrene. The (meth) acrylate copolymer resin (the styrene component is hydrogenated to form a partial alicyclic ring) is preferred.

These improvements from weather resistance are usually used in combination with UV absorbers.

The film or sheet is usually produced by extrusion or co-extrusion, and is preferably selected from the range of 0.05 mm to 1.2 mm in thickness.

In the case of a multilayer sheet, the thickness of the hard resin layer formed on one or both sides of the base sheet is thinner than half the thickness of the multilayer sheet, and it is preferable that Choose from 0.03mm~0.1mm. When the thickness is too thin, the hardness of the pencil hardness or the like is lowered, and when the thickness is too thick, the effect of improving the hardness is lost, so that the deterioration of the characteristics of the base sheet becomes large, which is not preferable.

Also, the hard coat treatment is performed during or after the extrusion. It is usually excellent in abrasion resistance or fingerprint resistance (fingerprint wiping property), but it is necessary to have thermoforming imparting a predetermined three-dimensional shape, and therefore it is preferable to select a hard coat layer which exhibits predetermined thermoformability.

As the hard coat layer, a compound which forms a conventional crosslinked film such as a propylene type, an anthraquinone type, a melamine type, a polyurethane type, or an epoxy type can be selected. Further, as the curing method, a conventional method such as ultraviolet curing, thermosetting, or electron beam hardening can be used. In the case of the surface as the surface side, it is preferable to form a pencil hardness H or more, and it is preferable to use a propylene-based or urethane acrylate-based copolymer from the balance with the heat-formability.

The hard coat layer is formed by a usual method, a coating method such as a roll coating method, a dip coating method, a transfer method, or the like.

As the propylene-based compound, a cross-linking polymerizable compound having at least two (meth)acryl fluorenyloxy groups (acryloyl fluorenyl group and/or isobutylene fluorenyl group, the same applies hereinafter) in the molecule can be used. The residue of the propylene hydrazine group is a hydrocarbon or a derivative thereof, and may include an ether bond, a thioether bond, an ester bond, a guanamine bond, a urethane bond or the like in the molecule. Further, as a component imparting heat formability, the molecular weight may suitably include a long chain component of one thousand to several thousands.

The multilayer sheets used in the present invention typically have a design printed layer on the inside.

The multilayer sheet used in the present invention preferably has a hard coat layer from the operability or the inner surface suitable for printing or metallization of the inner surface. In an appropriate case, the inner surface side has a hard coat layer/printing layer on the base resin, and the molded resin is sprayed thereon to carry out heat welding. According to this point, in the case where the printing layer is necessary in the portion where the stretching is necessary, the printing ink is firmly adhered to the hard coat layer to have a moderate elongation property, and the molding resin to be used is preferably selected for thermal fusion. Furthermore, even if the hard coat treatment is not performed on one side, it can be used without any problem.

(2) Forming method of film or sheet

The method for producing a film of the present invention uses a mold described later. Specifically, a molding die is preferably used, and a film having a predetermined three-dimensional shape to produce a three-dimensional shaped article is preferably formed by using a mold for pressure forming, and the sheet is fixed to the fixing frame by heating (heating step) After the mold is clamped at the same time, the movable ring is advanced, the film or the thin surface is initially formed on the bottom surface of the lower mold (the initial forming step), and secondly, the pressurized air introduced from the pressurized air introduction hole is introduced. The step of completely forming the above-mentioned film or sheet into a secondary shape of a core shape or a concave shape at the time of molding (secondary forming step).

On the other hand, the conventional manufacturing steps are as follows.

(i) Holding the sheet with the sheet holder.

(ii) Moving toward the heating zone together with the holder of the sheet, infrared heating is performed from above, and the sheet is heated to be softer than the Tg.

(iii) clamping the mold by the upper mold and the lower mold fitting sheet The preparation of the sheet is formed while introducing pressurized air.

(iv) the sheet is fixed by pressurized air from a portion in contact with the surface of the core (below Tg of the resin), and the non-contact portion is rapidly extended to be in contact with the surface of the core to be fixed along the core or the recess. Shaped shape of the surface. Finally, only the sheet near the bottom surface of the non-contact portion partially extends.

(v) After the pressurized air or the like is discharged, the shaped article is taken out.

The method for forming a film of the present invention (the method for producing a three-dimensional shaped article) differs from the manufacturing steps of the above (i) to (v) in the following points.

‧ The heating sheet fixed to the holder (fixing frame) at the time of mold clamping is formed by oblique bending between the core and the ring by the movable ring (the sheet at this time is substantially not extended), To correspond to the rising portion or the recess of the mold.

(temporary shaping)

‧The gas is then preferably introduced by pressing the air, pushing the sheet toward the core and shaping it. At this time, the sheet shape is gradually formed along the core shape (including the concave portion), and the lower portion of the rising portion finally becomes the most extended shape.

According to the molding method of the present invention described above, the following effects can be obtained. that is,

‧The bottom edge of the film is not cooled by contact with the core (including the concave portion) during the introduction of the pressure. Therefore, the shape of the bottom portion of the raised portion of the formed sheet can be shaped to the bottom surface. It is less than 1mmR.

‧With the amount extended by the secondary shape, the area is less than normal, so The uniform thickness of the whole can also make the hard coating uniformly extend.

‧In general, even a PET film that cannot be shaped in the formation of pressure forming can be formed by pressing with a ring of oil or the like.

The method for producing a three-dimensional shaped article of the present invention uses the novel pressure forming mold as described above, and can be used in a range in which the pressure of the pressurized air is referred to as a low pressure, and conventional conditions can be used.

Infrared heating can also be carried out using a conventional near-infrared heater or a far-infrared heater.

In the present invention, the elongation of the second region (end portion) of the film on the outer side of the convex portion of the lower mold of the molding die used for molding is formed with respect to the first region (thickness) of the film disposed on the convex portion. The wall portion has an elongation of 100% or less, preferably 50% or less, and more preferably 40% or less. In this case, in the peripheral portion of the film, that is, in the case of molding, a mold including a core having a substantially vertical rising portion with respect to the bottom surface is used, that is, it is known that the local extension of the bottom surface of the formed film can be suppressed (see paragraph [0005] ]).

The above elongation is calculated as follows. In other words, the first region (thick portion) and the second region (end portion) of the film before molding are printed with a scale line of 1 mm intervals in advance, and the film is formed. The first region (thick portion) and the second region (end portion) of the film which was formed and stretched were respectively measured, and the intervals ([X] mm and [Y] mm) of the marks extending most in the molding were measured. The elongation is calculated by the following formula.

Elongation (%) = ([Y] (mm) - 1 (mm)) / ([X] (mm)) × 100

(Note: [X] = interval of the scale after the extension of the first area, [Y] = interval of the scale after the extension of the second area)

(3) Formed product and forming method thereof

According to the present invention, a film or sheet which is formed into a predetermined shape by heat is applied, for example, a multilayer film is attached to a mold for injection molding, and a molding resin material can be injection molded to produce a molded article.

The resin molding material is required to be thermally welded to the heat-formed multilayer sheet.

In this case, although it is also possible to perform hot-melting well, as described above, generally, the inner surface of the multilayer film is designed by printing, and a protective layer for forming a heat-welding layer having both the injection molding resin and the injection molding resin can be used. The bottom layer.

Specific examples of the molded article which can be produced by using the film of the present invention include, for example, an exterior component of a mobile phone, a car-related component, a medical machine tool, an electronic product, a home appliance product, a building material, a lotion, or a cosmetic container. Toys, etc.

(4) mold

The difference in size between the inner diameter of the pressing member and the outer diameter of the convex portion is (thickness (mm) × 2 of the film before forming) +1 mm to 4 mm, preferably 1.5 mm to 4 mm.

Hereinafter, a first embodiment of the mold for pressure forming of the present invention will be described with reference to Figs. 1 to 4 .

Fig. 1 is a schematic view showing an embodiment of a mold for pressure forming of the present invention. The die forming mold 40 shown in Fig. 1 includes an upper die 10 having a pressurized air introduction hole 12, a lower die 20 having a core 22, and a fixed film or sheet 32 by the upper die 10 and the lower die 20 Composed The fixing frame 30 is housed in the upper mold 10 before forming. The movable ring 15 is formed by advancing the film heated at the time of initial shaping to a position abutting on the lower end of the lower mold 20 or the concave portion 23 of the core 22, and then introducing the pressure by the pressurized air introduction hole 12. After the secondary pressure is formed, the pressure of the air has an action mechanism that moves back to the position before the molding. In the first drawing, a hydraulic cylinder is used as the operating mechanism, but the present invention is not limited thereto.

Fig. 2 is a schematic top view showing the same configuration as that of the pressure forming mold shown in Fig. 1 and showing a state in which the movable ring 15 is initially shaped.

FIG. 3 is a schematic view showing a state in which pressurized air is introduced from the pressurized air introduction hole 12 and the initial shaping is performed.

The mold for pressure forming (hereinafter referred to as the mold) 40 of the present invention includes the upper mold 10, the lower mold 20, and the fixed frame 30. The lower mold 20 has a core 22 (convex portion) including a rising portion 24 that is substantially perpendicular to the bottom surface 20S. On the bottom surface 20S of the lower mold 20, a recess 23 is formed between the core 22 and the fixed frame 30. The upper mold 10 has a movable ring 15 (urging member). The movable ring 15 is advanced and retractable in the vertical direction as indicated by an arrow A, and surrounds the periphery of the core 22 at the time of initial shaping (see FIG. 3) to be described later, and presses the sheet or film 32 into the core 22 and the recess 23.

The movable ring 15 has a ring front end surface 15T which has a cross-sectional shape of a chamfered shape or a crown shape and which does not damage the sheet when pressed into the sheet.

The chamfer shape and the amount of chamfering are 0.5 to 2 mm C, and the crown shape is 0.5 to 2 mm R. The above setting does not hurt the life. A sheet or film 32 of the rising surface at the time of press-fitting of the movable ring 15, for example, a hard coat sheet.

The secondary shaping after initial shaping with respect to the sheet or film 32 (see Fig. 4) is carried out with pressurized air. In particular, the pressure is not specified. It is preferable to set the pressure of the pressurized air to a maximum pressure of 5 MPa or less, or to form a thin mold thickness, so that the shaped sheet is less likely to remain strain. More desirably, the maximum pressure is set to 1~2MPa.

The rising portion 24 and the recess portion 23 of the mold 22 may be considered to have a crown shape or substantially have a vertical wall rise. For the surface extending locally from the sheet, the latter has an overwhelmingly large local extension, so that the point at which the hard coat crack is prevented is a highly difficult shape. Therefore, it is preferable to form a chamfer in the rising portion 24 and the concave portion 23.

Further, when focusing on the bottom surface of the rising portion 24, the curvature of the sheet formed by the conventional mold is about 2 mmR, and the sheet itself is formed to be thinly and uniformly extended when the mold of the present invention is used, so that the formability is improved and the curvature can be increased. Formed below 1 mmR. Therefore, when the mold of the present invention is used, the insertion of the stamper at the time of punching is also facilitated, and it is possible to accurately press the back surface until the bottom surface is removed, thereby eliminating the problem of unevenness in the in-mold shape.

As shown in Fig. 1, the sheet or film 32 fixed to the fixing frame 30 is softened by heating to a predetermined temperature (heating step). In this state, the movable ring 15 is advanced to the bottom surface 20S side, and the heated sheet or film 32 is pressed to form the top surface shape of the core 22 and the concave portion 23, and is stopped by abutting against the bottom surface 20S of the lower mold 20 ( See Figure 3).

The movable ring 15 is connected to the air cylinder and the hydraulic cylinder in the upper mold 10 The speed and the like are controlled by a flow meter attached to the pressure forming machine (all not shown).

Further, the motion control is controlled by a program sequence of the air compressor. The timing is performed at the time when the sheet reaches a predetermined heating time or a predetermined temperature, and then the movable ring 15 is advanced. After the movable ring 15 is given the end of the pressure, it is returned to the predetermined position of the upper mold 10 immediately or during the end of the exhausting step. When the retreat of the movable ring 15 deviates to the mold opening (release) step, the risk of occurrence of a flaw on the rising surface of the molded article is not preferable.

Further, when the movable ring 15 is operated and the sheet is pressed into the initial shape, the timing for introducing the pressure is performed within 1 second.

The sheet is heated to a temperature at which it can be shaped (above Tg). The time from the initial shaping to the second shaping is such that if the time is not within 1 second, the film is cooled (below Tg), and the secondary shape cannot be used. shape. The earlier the timing of introducing the pressurized air is, the better the formation of the secondary forming is. However, if the initial shaping is not completed, the molded article having the desired height cannot be obtained, and thus the setting can be appropriately performed.

As described above, the speed of the movable ring 15 (the hydraulic cylinder speed) is advanced by the flow meter setting, and the timing can be adjusted.

The distance between the fixed frame 30 and the core 22 is preferably a distance that is twice or more the height of the rising portion 24. More ideally 3 to 4 times. When the distance between the fixing frame 30 and the core 22 is less than twice the height of the rising portion 24, the film which is interposed therebetween is actually pushed through the movable ring 15, so that the amount of stretching of the sheet 32 is locally excessive. Even the core The low height of 22 also causes the sheet 32 to be easily broken, or the hard coat product is liable to be cracked.

The difference DL between the inner diameter of the movable ring 15 and the outer diameter of the core 22 is set to be in the range of 1 mm to 4 mm with respect to (thickness (mm) × 2 of the sheet) (see Fig. 2, the sheet is not shown). That is, in a certain direction, for example, a direction indicated by an arrow B in the second drawing (corresponding to a direction perpendicular to the plane of the paper of Fig. 1), the distance DL ₁ between the rising portion 24 of the core 22 and the movable ring 15 is A value of a distance of 0.5 mm to 2 mm is added to the thickness of the sheet. I.e., the sheet thickness is 0.5mm, the core 22 is the movable distance DL ring 15 ₁ is to be 1mm (thickness of the sheet from a gap of 0.5mm to 0.5mm ₁ subtracting the distance DL) to 2.5mm ₍₁ is subtracted from the distance DL The gap of the sheet thickness of 0.5 mm is 2 mm). Further, the range of the distance DL ₂ between the rising portion 24 of the core 22 and the movable ring 15 is also equal to the above-described distance DL ₁ , and therefore the difference DL between the inner diameter of the movable ring 15 and the outer diameter of the core 22 is DL ₁ + DL ₂ ) It is determined by the thickness of the sheet of 0.5 mm × 2, that is, 1 mm plus 1 mm to 4 mm, and 2 mm to 5 mm.

In the second embodiment in which a hole (recess) is provided on the upper surface of the core 22, the dimensional relationship between the outer diameter of the recess provided in the core 22 and the inner diameter of the movable ring is also the above numerical value.

The effect of the gap is that the sheet is shaped in a form close to two-dimensional bending, so that the rising portion 24 is not extended. Therefore, the forming can be performed once substantially uniformly.

When the gap is less than 0.5 mm on one side (DL ₁ or DL _{2 is} less than 0.5 mm), when the movable ring 15 is pressed, the sheet or the film 32 is pulled by the movable ring to form an extended form, and is partially stretched. In particular, the top surface side becomes liable to cause cracking of the hard coat layer, which improves the precision in the production of the mold and also increases the mold cost.

Further, when the one side exceeds 2 mm (the value of DL ₁ or DL _{2 is} larger than 2 mm), when the movable ring 15 is pressed, wrinkles are generated at positions corresponding to the corners of the core 22 of the core 22, since the mold is formed during the secondary forming. The distance between the cores is increased and the cooling is performed, and when the secondary forming is performed, local stretching occurs on the bottom surface side, which is not preferable.

The shape of the core 22 and the movable ring 15, the recess 23 and the movable ring 15 provided in the core 22 are preferably substantially similar shapes.

It is sufficient to set within the aforementioned size range, and the core 22 may be a rectangular or substantially elliptical shape having a circular shape even if it is a rectangular movable ring 15. Or it may have a circular shape only at the corners of the core 22, or may have an angle of 45°.

When the size range of the above gap is exceeded, there is a possibility that the above-described defect occurs.

As described above, when the sheet or film 32 heated by the movable ring is pressed from the state shown in Fig. 1, the heated sheet fixed to the fixed frame and the fixed frame 30, the upper mold 10, and the lower mold 20 are simultaneously combined. Mode (see Figure 3). As described above, the film or sheet 32 is moved to the bottom surface 20S of the lower mold 20, and the initial shaping (primary shaping step) is performed. Next, the pressurized air is introduced into the hole 12 from the upper mold 10, and the pressurized air is introduced as indicated by an arrow C (see Fig. 4). By the pressure of the pressurized air thus introduced, the secondary shaping which completely shapes the film or sheet 32 is performed at the time of molding to correspond to the shape of the core 22 and the concave portion 23 (secondary forming step). At this time, at work The moving ring 15 is also formed with an air introduction hole 13, and the pressurized air can be efficiently introduced to the surface of the sheet or film 32.

Next, a second embodiment of the mold for pressure forming will be described. As shown in Fig. 5, in the second embodiment, a hole (concave portion) for forming a hole or a recess is formed in the film 32 on the upper surface of the core 22.

Hereinafter, an example of the present invention will be described by way of examples, but the present invention is not limited by the examples.

[Examples]

A pressure forming machine (manufactured by NK Enterprise Inc.) was used as a molding machine.

Further, a hydraulic drive device (manufactured by Oil Research Co., Ltd.) linked in series is attached to the molding machine.

Aluminum is used as the material of the pressure forming mold 40 (see Fig. 1 and the like) of the present invention.

As the core 22 provided in the lower mold 20, a 50 mm angle (curvature R of four corners; 2 mmR) having a square shape from the top is used, and the center portion has 20, the core of the 5 mm recess, the top surface of the curvature of 2 mmR, the height of 12 mm of the substantially vertical rising surface 24 core. Further, as the movable ring 15 mounted on the upper mold 10, a ring having a shape similar to the shape of the outer periphery of the core 22 and the concave portion 23 is used. Further, the movable ring 15 is retracted before being formed and stored in a predetermined position of the upper mold 10.

The movable ring 15 is a chamfered shape having a front end of 0.5 mm and a thickness of 2 mm, and is used as a ring for outer shape and recess, and is attached to the upper mold and is driven by a hydraulic pressure. Connected to the hydraulic piping.

Outer ring; inner diameter of movable ring (53mm) - outer diameter of core (50mm) = (0.5mm (thickness) × 2) + 2mm = 3mm, that is, the film has a gap of 1mm on one side.

Ring for recess (not shown); inner diameter of the recess of the core (20 mm) - outer diameter of the ring for the recess of the movable ring (16 mm) = (0.5 mm (film thickness) × 2) + 3 mm = 4 mm

That is, the film has a gap of 1.5 mm on one side when it is shaped.

(Example 1)

The surface of the base material of the 140 mm-angle aromatic polycarbonate resin, the propylene resin layer of the co-extruded sheet formed of the acryl resin layer, and the sheet having the hard coat layer on the propylene resin layer (Mitsubishi Gas Chemical Co., Ltd.) MRF08U 0.5mm (hard coating elongation; 40%), anti-scratch test (based on ASTM D 2486-79, using a pig brush and 450g round load 450g), the use of the resulting scratch is 5 The PC surface (inner surface) of the scratch-resistant practical hard coat layer below the strip was designed to form a printed layer (IMB006 adhesive laminated on INQ-HF (white) manufactured by Imperial Ink Manufacturing Co., Ltd.). Further, the fixing frame 30 of the fixing sheet is a fixing frame formed with a window opening to enable formation of a sheet having an angle of 100 mm. The distance between the fixing frame 30 and the core 22 is 50 mm.

The sheet was set in the sheet fixing frame, and the sheet was conveyed to a heating zone, heated by an IR heater (set at 400 ° C), and confirmed to reach 190 ° C by an infrared radiation thermometer, and then moved toward the mold clamping area shown in Fig. 1 to be combined. mold. Immediately thereafter, the hydraulic drive unit is driven to advance the movable ring to abut against the lower mold and the bottom surface of the recess. After the completion of the advancement, the pressurized air introduced into the mold 40 at a maximum pressure of 2 MPa was introduced 0.5 seconds later.

The lower portion of the rising portion 24 and the lower portion of the concave portion on the top surface of the core 22 have an R of 0.8 mm or less.

In the shaped hard-coated sheet, no crack occurred on the hard coat layer regardless of the peripheral height of 12 mm and the height of the recess of 5 mm.

Then, the formed part is obtained by punching an unnecessary portion of the die.

(Example 2)

The molded article obtained in Example 1 was inserted into the cavity at an angle of 51 mm and a concave portion was provided on the surface. In an injection molding die having a wall thickness of 2 mm, an injection molding machine (J110AD manufactured by Nippon Steel Co., Ltd.) was used, and a PC (Mitsubishi ENGINEERING PLASTIC Co., Ltd. jupilon H3000) resin temperature of 300 ° C, a mold temperature of 80 ° C, and an injection pressure of 100 MPa. Injection molding is performed to obtain a decorative molded article in which the molded article and the injection material are integrated.

In the molded article of the first embodiment, since the edge of the bottom surface is small, the insert can be perfectly inserted in the mold, and problems such as injection molding are not caused.

In Example 2, an injection molded article decorated with a hard coat layer was obtained.

(Example 3)

Using the mold used in Example 1, the height of the core was changed to 5mm.

Further, as a sheet, a PET sheet having a hard coat layer extending at an angle of 140 mm (TUFTOPTHS 0.18 mm manufactured by Toray Industries, Inc. (hard coat elongation; 20%, scratch resistance test (by ASTM D 2486-79) was used. According to the use of a pig hair brush and a load of 450 g (200 times), the hard coat layer having a scratch of 5 or less is used to form a printed layer (Imperial ink manufacturing ( The design of the IMB006 adhesive on the INQ-HF (white) system. The relationship of the gap is as follows.

Outline ring; inner diameter of movable ring (53mm) - outer diameter of core (50mm) = (0.18mm (film thickness) × 2) + 2.64mm = 3mm, that is, the film has a gap of 1.32mm on one side.

Annular ring (not shown); inner diameter of the die recess (20 mm) - outer diameter of the ring for the recess of the movable ring (16 mm) = (0.18 mm (film thickness) × 2) + 3.64 mm = 4 mm

That is, the film has a gap of 1.82 mm on one side when it is shaped.

The sheet was set in the sheet fixing frame, and the sheet was conveyed to a heating zone, heated by an IR heater (set at 400 ° C), and confirmed to reach 190 ° C by an infrared radiation thermometer, and then moved toward the mold clamping region to perform mold clamping. Immediately thereafter, the hydraulic drive unit is driven to advance the movable ring 15 to abut against the bottom surface 20S of the lower mold 20. After the end of the advancement, the pressurized air set to the maximum pressure of 2 MPa was introduced into the mold 40 after 0.8 seconds.

In the above embodiment, the PET film which is not deformable can be formed at the time of the press forming, and the lower portion of the rising portion 24 and the lower portion of the concave portion on the top surface of the core 22 have an R of 1.2 mm or less.

In the shaped hard-coated sheet, no crack occurred on the hard coat layer regardless of the height of the outer periphery of 5 mm and the height of the recess of 5 mm.

Then, the formed part is obtained by punching an unnecessary portion of the die.

(Comparative Example 1)

With the mold used in Example 1, the movable ring 15 was not operated, and the pressure forming was carried out under the same conditions and conditions as in Example 1.

The shape of the shaped article on the bottom surface is poor, and when measuring the shape of the sheet on the bottom surface portion, it is about 2 mmR. Further, regarding the sheet of the MRF08U (see Example 1), the vicinity of the bottom surface partially extends to cause cracks in the vicinity of the bottom surface portion. As in Example 2, it was carried out until injection molding, but cracking occurred in the hard coat layer so that the appearance of the molded article was unsightly.

(Comparative Example 2)

Using the mold and the sheet used in Example 1, the movable ring 15 was operated under the same heating conditions, and after the completion of the advancement, pressurized air set to a maximum pressure of 1 MPa was introduced into the mold 40 after 1.5 seconds.

Due to the delayed timing of introduction of pressurized air, the cooling of the film is delayed and cracking of the hard coat layer occurs near the rising bottom surface.

(Comparative Example 3)

The cavitation molding was carried out in the same manner as in Example 1 except for the change in the size of the outer ring of the mold used in Example 1.

Shape ring; inner diameter of movable ring (56mm) - outer diameter of core (50mm) = (0.5 mm (film thickness) × 2) + 5 mm = 6 mm, that is, a film having a gap of 2.5 mm on one side.

Since the gap is large, the distance from the initial shaping to the secondary shaping becomes long, and only the vicinity of the bottom surface of the rising portion fixed by the ring shows a partial extension in the secondary shaping, so that the hard coating has cracks. .

(Comparative Example 4)

The cavitation molding was carried out in the same manner as in Example 1 except for the change in the size of the outer ring of the mold used in Example 1.

Outer ring; inner diameter of movable ring (51mm) - outer diameter of core (50mm) = (0.5mm (film thickness) × 2) + 1.0mm = 2mm, that is, the film has a gap of 0.5mm on one side.

Since the gap is small, the rising top side is pulled by the ring at the time of initial shaping, and it shows that there is only a local extension near the top surface of the rising portion, so that cracks occur in the hard coat layer.

[Industrial availability]

According to the present invention, cracking does not occur even if it is shaped by using a hard coat layer which is practically usable in hardness, and thus it is possible to easily provide a molded article and a mold which are excellent in design from the point of being unrestricted in design. Inner molded product.

Further, since an inexpensive PET film which is difficult to shape can be easily formed, it is also possible to provide a product which is inexpensive.

In particular, the film of the present invention and the method of forming the same can be suitably used for decoration For the manufacture of sheet-formed products or in-mold molded articles, containers, toys, etc. for exterior components of mobile phones, automotive-related components, medical machinery, electronic products, home appliances, building materials, lotions, cosmetics, etc. can be used. field of.

Claims (23)

A film characterized in that it is provided with at least 10 scratches caused by scratches in a scratch resistance test (200 mm for 450 g load using a pig hair brush based on ASTM D 2486-79) The film of the hard coat layer is formed by forming the second region (end portion) of the film on the outer side of the convex portion of the lower mold of the molding die used for molding, with respect to the above-mentioned convex portion The elongation of the first region (thick portion) of the film is 100% or less. A film formed by a molding method using a molding die, the molding die comprising: a lower die having a convex portion; and an upper die having a pressing force on the outer side of the convex portion when clamping And a fixing frame, wherein the film is fixed between the upper die and the lower die, and the film is formed into a predetermined three-dimensional shape by using the molding die, and is characterized in that: a heating step is performed to push the upper die When the pressing member is retracted, the film is fixed to the fixing frame, and then heated and softened. In the initial shaping step, when the upper mold and the lower mold are closed, the pressing member is advanced at least in the above The outer side of the convex portion presses the film to perform initial shaping; and the second forming step, by the pressure of the gas introduced from the upper mold side, at least outside the convex portion of the lower mold after the mold clamping The film is subjected to secondary shaping. A film formed by a molding method using a molding die, the molding die comprising: a lower die having a convex portion provided with a concave portion for forming a hole and/or a concave portion in a molded article; The upper mold includes a pressing member positioned outside the convex portion at the time of clamping; and a fixing frame for fixing the film between the upper mold and the lower mold, and forming the film into a predetermined three-dimensional shape using the molding die Further, the method includes a heating step of fixing the film to the fixing frame while the pressing member of the upper mold is retracted, and heating and softening the film; the initial shaping step is performed on the upper mold and In the mold clamping of the lower mold, the pressing member is advanced to press the film at least on the outer side of the convex portion to perform initial shaping; and the secondary forming step is performed by pressure of gas introduced from the upper mold side. The film is secondarily shaped at least on the outer side of the convex portion of the lower mold after the mold clamping. The film according to the second or third aspect of the invention, wherein the elongation of the second region (end portion) of the film formed on the outer side of the convex portion during molding is the same as that of the convex portion disposed on the convex portion The elongation of the first region (thick portion) of the film is 100% or less. The film of claim 2, wherein the film is a hard coat film having a hard coat layer. The film according to claim 1, wherein the film A printed hard coat film is applied to the surface opposite to the above hard coat layer. The film according to claim 5, wherein the film is coated with a hard coat film on a surface opposite to the hard coat layer. A molded article comprising: the film according to any one of items 1 to 7 of the patent application. A method for forming a film, which is a molding die, comprising: a lower mold having a convex portion; and an upper mold having a pressing member positioned outside the convex portion when the mold is closed; and a fixing frame The film is fixed between the upper mold and the lower mold, and the film is formed into a predetermined three-dimensional shape by using the molding die, and is characterized in that the heating step is performed, and the film is removed in a state where the pressing member is retracted. After being fixed to the fixing frame, heating is performed to soften it; in the initial shaping step, when the upper mold and the lower mold are closed, the pressing member is advanced to press the film at least outside the convex portion to perform The initial shaping; and the secondary shaping step, the film is secondarily shaped at least outside the convex portion of the lower mold after the mold clamping by the pressure of the gas introduced from the upper mold side. A method for forming a film, which is a molding die, comprising: a lower mold having a hole and/or a recess formed in a surface of the molded article; a convex portion of the concave portion; the upper mold includes a pressing member positioned outside the convex portion at the time of clamping; and a fixing frame for fixing the film between the upper mold and the lower mold, and using the molding die The film is formed into a predetermined three-dimensional shape, and includes a heating step of fixing the film to the fixing frame while the pressing member of the upper mold is retracted, and heating and softening the film; a step of advancing the pressing member at least on the outer side of the convex portion to perform initial shaping during the mold clamping of the upper mold and the lower mold; and a secondary forming step by The pressure of the gas introduced on the mold side is secondarily shaped on the outer side of the convex portion of the lower mold after the mold clamping. The method for forming a film according to the ninth or tenth aspect, wherein the pressing member is advanced, and pressurized air is introduced within one second after the start of the initial shaping step to start a secondary forming step. . The method for forming a film according to claim 9 or 10, wherein the gas is pressurized air. The method for forming a film according to claim 9 or 10, wherein the film is a hard coat film having a hard coat layer. The method for molding a film according to claim 13, wherein the film is formed on a surface opposite to the hard coat layer. A printed hard coat film. The method for molding a film according to the ninth or tenth aspect, wherein the fixing frame is fitted to the upper mold and the lower mold at the time of mold clamping. The method for molding a film according to claim 9 or claim 10, wherein a gas introduction hole is formed in the upper mold, and a gas is introduced into the film from the gas introduction hole in the secondary forming step. s surface. A method for forming a molded article, characterized in that the film formed by the method of claim 9 or 10 is a hard coat film which is printed on the surface opposite to the hard coat layer, and the above-mentioned forming The method includes: a processing step of processing the hard coat film corresponding to the shape of the injection molding cavity; and an embedding step of embedding the hard coat film in the cavity of the injection molding die such that the hard coat surface and the cavity The film substrate is formed by contact with the body; and the molding step is performed by injection molding to form the film substrate and the injection molding material into a molded article. A molding die, comprising: a lower mold having a convex portion; an upper mold having a pressing member positioned outside the convex portion when clamping; and a fixing frame fixing the film to the upper mold and the above Between the lower molds, The pressing member can advance and retreat in the vertical direction, and when the upper mold and the lower mold are closed, the pressing member can advance the film at least outside the convex portion. The molding die according to claim 18, wherein the lower mold is provided with a concave portion for forming a hole and/or a concave portion in the molded article. The molding die according to claim 18, wherein the pressing member has an inner surface having a shape similar to the convex portion. The molding die according to claim 18, wherein in the secondary forming step, a gas introduction hole is formed in the upper mold in order to introduce a gas into the surface of the film. The molding die according to claim 18, wherein a difference between an inner diameter of the pressing member and an outer diameter of the convex portion is (thickness (mm) of the film before molding × 2) +1 mm Up to 4mm. The molding die according to claim 18, wherein the pressing member is operated by a cylinder or a hydraulic cylinder, and a cross-sectional shape of a tip end of the pressing member that presses the film is chamfered and/or crowned. The film does not contact the top surface on the convex portion in the initial shaping step and the secondary shaping step.