US20140147630A1 - Molded article coated with a film - Google Patents

Molded article coated with a film Download PDF

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Publication number
US20140147630A1
US20140147630A1 US14/131,516 US201114131516A US2014147630A1 US 20140147630 A1 US20140147630 A1 US 20140147630A1 US 201114131516 A US201114131516 A US 201114131516A US 2014147630 A1 US2014147630 A1 US 2014147630A1
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Prior art keywords
film
substrate
molded article
adhesive layer
pressure
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English (en)
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Yasuhiro Suzuki
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Riken Technos Corp
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Riken Technos Corp
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Publication of US20140147630A1 publication Critical patent/US20140147630A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0007—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality
    • B32B37/0023—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality around holes, apertures or channels present in at least one layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/10—Forming by pressure difference, e.g. vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/12—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor of articles having inserts or reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/14—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/16—Lining or labelling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
    • B29C63/02—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
    • B29C66/022—Mechanical pre-treatments, e.g. reshaping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0007—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/006—Using vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/04—Combined thermoforming and prestretching, e.g. biaxial stretching
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/42—Heating or cooling
    • B29C51/421—Heating or cooling of preforms, specially adapted for thermoforming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/0097—Glues or adhesives, e.g. hot melts or thermofusible adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/722—Decorative or ornamental articles
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]

Definitions

  • the present invention relates to a molded article whose surface is covered with a film such as a decorative film.
  • a film such as a decorative film.
  • the present invention relates to molded article such as automobile interior and exterior parts, housings of household electrical appliances including refrigerators and housings of information-processing electronic equipments including personal computers and smartphones, whose surface is covered with a decorative film.
  • Housings of household electrical appliances were directly coated with hard coat paint of an ultraviolet curable acrylic resin, in order to provide the housings with scratch resistance, durability, stain resistance and design.
  • Patent Literatures 1 to 3 it was proposed to apply a decorative film having an adhesive layer an one side to a surface of a molded article, such as automobile parts, by vacuum forming, instead of the direct costing (see the following Patent Literatures 1 to 3).
  • Application of a decorative film solves the problems on workability, environment safety and design which occur in the direct coating, However, it is associated with such problems that air remains between a surface of a molded article, to which surface a decorative film is applied, and the decorative film to cause blisters on the surface of the molded article covered with the film (hereinafter, referred, to as a covered molded article) so as to deteriorate the appearance of the covered molded article. Even if the blisters are so small as invisible immediately after the application, the residual air expands highly upon exposure to high-temperature environment to remarkably deteriorate the appearance. This is very troublesome.
  • the film sinks in the grooves to form a concave-convex pattern on the surface of the covered molded article. Further, air is still present in the grooves after the covering. As a result, when the surface of the film is touched with a hand, the air moves to form a concave-convex pattern on the surface of the covered molded article; or when the covered molded article is exposed to high-temperature environment, the air expands to cause blisters on the surface of the covered molded article and remarkably deteriorates the appearance.
  • Patent Literature 1 Japanese Patent Publication No. Sho 56-45768/1981
  • Patent Literature 2 Japanese Patent No. 3016518
  • Patent Literature 4 Japanese Patent Application Laid-open No. 2004-237510
  • Patent Literature 5 Japanese Patent Application Laid-Open No. 2000-157346
  • An object of the present invention is to provide a moiled article which comprises a substrate whose surface is covered with a film, which article has good appearance and does not deteriorate in the appearance even in severe environment where the article is actually used, such as high-temperature environment.
  • the present inventor has found that the aforesaid problems are solved by controlling a surface roughness of the substrate whose surface is to the covered with a film, and reached the present invention.
  • the present invention is a molded article comprising a substrate whose surface is partially or wholly covered with a film, wherein the film has an adhesive layer, the adhesive layer is in contact with the substrate, and the surface of the substrate, which surface is in contact with the adhesive layer, has a surface roughness (A) of 3 to 20 ⁇ m.
  • the present invention also provides a process for producing the aforesaid molded article.
  • the present molded article covered with a film does not allow air to remain between the film and the substrate. Therefore, the molded article has excellent appearance, does not deteriorate in the appearance even in severe environment where the article is actually used, such as high-temperature environment, and has excellent durability.
  • FIG. 1 is a schematic illustration on vacuum forming.
  • FIG. 2 is a schematic illustration on vacuum and pressure forming.
  • FIG. 3 is a photograph of an example of the present molded article.
  • the present molded article comprises a substrate whose surface is partially or wholly covered with a film.
  • the film comprises a base layer and an adhesive layer, and the adhesive layer is in contact with the substrate, so that the substrate is covered with the film.
  • the present molded article requires that a surface of the substrate, which surface is in contact with the adhesive layer of the film, has a surface roughness (A) of 3 to 20 ⁇ m, preferably 6 to 15 ⁇ m.
  • This range of the surface roughness (A) of the substrate attains enough deaeration between the surface of the substrate and the film and, therefore, no air remains there, when the film is applied to the surface of the substrate. Therefore, the resulting molded article has good appearance and does not deteriorate in the appearance even exposed to high-temperature environment. If the surface roughness (A) is less than 3 ⁇ m, deaeration is not enough.
  • a profile of the surface of the substrate reflects a concave-convex pattern on the surface of the film after the application of the film to deteriorate the appearance. Further, adhesion between the film and the substrate is worse. Further, air tends to remain between the film and the substrate to cause blisters in high-temperature environment.
  • a surface which is not covered with the film may have any profile. It may be flat or of a larger surface roughness.
  • the surface roughness is a mean maximum height (Rtm) obtained by extracting any part with an evaluation length L from a roughness profile, dividing the length L into five equal lengths, measuring a maximum height from a bottom to a top in the profile in each of the five sections and averaging these five maximum heights.
  • Rtm mean maximum height
  • a Material for the substrate may be those usually used for automobile parts or housings of household electrical appliances, but not particularly limited to such.
  • a covering operation on the surface of, for instance, automobile part or housing of household electrical appliance with a decorative film is usually carried out by vacuum forming or vacuum and pressure forming. Therefore, the material for the substrate is generally durable in such forming methods.
  • use may be appropriately made of metal such as an aluminum alloy and a magnesium alloy or one or more resin materials selected from polystyrene resins, acrylic resins, acryl-styrene resins, acryl-butadiene-styrene resins, polycarbonate resins, polyester resins, polyamide resins, polypropylene resins and polyethylene resins.
  • the material may be drawn to obtain a substrate having a desired shape.
  • the material may be injection molded to obtain a substrate having a desired shape. The surfaces of the substrates thus obtained are flat and have a surface roughness of less than 3 ⁇ m.
  • the substrate having a desired shape is subjected to surface roughening so as to have the specified surface roughness (A).
  • a method for the roughening is not particularly limited. Examples of a method for directly roughening the surface of the substrate include sandblasting, sanding, etching, embossing and matte coating.
  • a surface of a mold is roughened by, for instance, sandblasting, sanding or etching and the pattern on the surface of the mold is transferred to the surface of the substrate to obtain a roughened surface on the substrate.
  • the present molded article may be obtained by applying the film to the substrate so that the adhesive layer of the film is in contact with the surface of the substrate.
  • the surface of the adhesive layer of the film preferably has a surface roughness (B) of 3 to 20 ⁇ m, more preferably 6 to 15 ⁇ m before the application. This range of the surface roughness (B) attains good deaeration when the film is applied to the substrate, while maintaining good adhesion and durability. If the surface roughness (B) is less than 3 ⁇ m, deaeration may not be enough sometimes. If the surface roughness (B) exceeds 20 ⁇ m, a profile of the surface of the adhesive layer may reflect a concave-convex pattern on the surface of the film after the application of the film to deteriorate the appearance. Further, adhesion between the film and the substrate tends to be worse. Further, air tends to remain between the film and the substrate to cause blisters in high-temperature environment.
  • the surface roughness of the adhesive layer may be obtained by roughening a releasing surface of a release film and then transferring the profile of the resulting surface to the adhesive layer.
  • the roughened releasing surface of a release film may be obtained by roughening a surface of a base film for the release film by means of, for instance, sandblasting, sanding, etching, embossing or matte coating, and then applying a releasing agent to the surface, or by applying a releasing agent to a surface of a base film for the release film, drying and curing the releasing agent, and then roughening the surface by means of embossing.
  • a surface of the adhesive layer may be directly embossed immediately before the substrate is covered with the film by, for instance, vacuum forming.
  • any adhesive material may be used for the adhesive layer as long as it has enough tacky or adhesive strength to the substrate and the base layer of the film.
  • any adhesive material may be used for the adhesive layer as long as it has enough tacky or adhesive strength to the substrate and the base layer of the film.
  • use may be made of conventional adhesives and pressure-sensitive adhesives such as those of acrylate, ethylene vinyl acetate, vinyl acetate, polyester, polyurethane, natural rubber, epoxy resin, polyisobutylene, chloroprene rubber, and styrene-butadiene-rubber types.
  • the adhesive layer is necessarily soft to be able to transform so that no air remains between the film and the substrate when the film is applied to the substrate, and is necessarily so hard as not to flow.
  • the adhesive preferably has a glass transition temperature of ⁇ 10 to 50 degrees C.
  • the pressure-sensitive adhesive preferably has a glass transition temperature of ⁇ 70 to ⁇ 10 degrees C.
  • both of the pressure-sensitive adhesive and the adhesive preferably have a viscosity of 5 to 30 Pa ⁇ s at 25 degrees C.
  • VYLON 50AS ex TOYOBO Co., Ltd.
  • S K Dyne 1309 ex Soken Chemical & Engineering Co., Ltd.
  • the film comprises a base layer besides the adhesive layer.
  • the base layer may be, for example, a film of a thermoplastic resin such as polyvinyl chloride, non-crystalline, low-crystalline or crystalline polyester, polyolefin including polypropylene and polyethylene, styrene resin including acrylonitrile-butadiene-styrene copolymer (ABS resin), styrene-ethylene-butadiene-styrene copolymer, acrylonitrile-styrene-acryl copolymer, acrylonitrile-ethylene-propylene-diene-styrene copolymer and their hydrogenated ones, polyamide, acrylic resin, polycarbonate and polyurethane, and a film of two or more of these thermoplastic resins.
  • a thermoplastic resin such as polyvinyl chloride, non-crystalline, low-crystalline or crystalline polyester, polyolefin including polypropylene and polyethylene
  • ABS resin acrylonitrile-
  • These films may be a non-drawn film, a uniaxially-drawn film and a biaxiaily-drawn film.
  • non-drawn films of polyvinyl chloride, non-crystalline polyester and acrylic resin are particularly preferred.
  • polyvinyl chloride film S12109 Fc1174, ex Riken Technos Corp.
  • non-crystalline polyester film FET101, ex Riken Technos Corp.
  • acrylic resin film TECHNOLLOY S001G, ex Sumitomo Chemical Co., Ltd., may preferably be used.
  • the present molded article may be produced by covering the surface of the substrate with the film, preferably, in a vacuum forming or vacuum and pressure forming process.
  • FIG. 1 shows an example of the vacuum forming process.
  • film ( 1 ) is first heated to soften with, for instance, an infrared heater ( 2 ), as shown in FIG. 1 ( a ).
  • the softened film ( 1 ) is removed from infrared heater ( 2 ) and promptly applied onto substrate ( 3 ) ( FIG. 1( b )).
  • space ( 4 ) between film ( 1 ) and substrate ( 3 ) is decompressed so that film ( 1 ) is tightly adhered to substrate ( 3 ) to obtain molded article ( 5 ) covered with the film ( FIG. 1( c )).
  • the pressure in space ( 4 ) is preferably 10 KPa or less, more preferably 1 KPa or less. Such decompression in space ( 4 ) makes film ( 1 ) adhered tightly to substrate ( 3 ). As a result, no air remains between the film and the substrate. If the pressure in space ( 4 ) is higher than the aforesaid range, air tends to remain between the substrate and the film. The strength of the adhesion increases as the pressure in space ( 4 ) decreases. However, considering costs for obtaining less pressure, which increase exponentially, and mechanical strengths of the substrate and the film, the practical lower limit of the pressure in space ( 4 ) is approximately 10 ⁇ 5 KPa.
  • FIG. 2 shows an example of the vacuum and pressure forming process.
  • film ( 1 ) and substrate ( 6 ) are first placed at the middle and at the bottom center of a molding room, respectively, the room is tightly closed and then upper chamber ( 7 ) and lower chamber ( 8 ) are decompressed to the same pressure ( FIG. 2( a )).
  • the pressures in upper chamber ( 7 ) and lower chamber ( 8 ) are preferably 10 KPa or less, more preferably 1 KPa or less, as in the vacuum forming process.
  • file: ( 1 ) is heated to soften with heater ( 9 ) such as an infrared heater and then the well-softened film ( 1 ) is brought into contact with substrate ( 6 ) ( FIG. 2( b )). Then, upper chamber ( 7 ) only is compressed to atmospheric pressure or higher, while keeping the decompression in lower chamber ( 8 ), so that film ( 1 ) is tightly adhered to substrate ( 6 ) ( FIG. 2( c )) to obtain molded article ( 10 ) covered with the film ( FIG. 2( d )).
  • the pressure in upper chamber ( 7 ) in FIG. 2( c ) is preferably 100 to 1000 KPa, more preferably 150 to 500 KPa.
  • Such a pressure in upper chamber ( 7 ) makes film ( 1 ) adhered tightly to substrate ( 6 ). As a result, no air remains between the film and the substrate. If the pressure in upper chamber ( 7 ) is less than the aforesaid range or if the pressure in lower chamber ( 8 ) exceeds 10 KPa in FIG. 2( c ), air tends to remain between the substrate and the film. If the pressure in upper chamber ( 7 ) exceeds the aforesaid range, the substrate or the film may be damaged during the vacuum and pressure forming. The strength of the adhesion increases as the pressure in lower chamber ( 8 ) decreases. However, considering costs for obtaining less pressure, which increase exponentially, and mechanical strengths of the substrate and the film, the practical lower limit of the pressure in lower chamber ( 8 ) is approximately 10 ⁇ 5 KPa.
  • the present molded articles and the present production process may be applied to automobile exterior resin parts such as automobile instrument panels, window pillars and bumpers, housings of televisions, and housings of information-processing electronic equipments such as personal computers and smartphones, whose surfaces are to be covered with a film in order to protecting the surfaces or providing the surfaces with design.
  • automobile exterior resin parts such as automobile instrument panels, window pillars and bumpers, housings of televisions, and housings of information-processing electronic equipments such as personal computers and smartphones, whose surfaces are to be covered with a film in order to protecting the surfaces or providing the surfaces with design.
  • ABS/PC alloy resin (EXCELLOY, trade name, ex Techno Polymer Co., Ltd.) was dried at a temperature of 100 degrees C. for 4 hours and then subjected to injection molding with a 100 ton injection molding machine, S-2000i 100A (ex Mitsubishi Heavy Industries Plastic Technology Co., Ltd.), at a cylinder temperature of 260 degrees C., a mold temperature of 70 degrees C., an injection rate of 250 mm/sec. and a holding pressure of 50 MPa to obtain a thermoplastic resin substrate having the shape as shown in FIG. 3 .
  • FIG. 3 is a photograph of the molded article of Example 1.
  • this substrate blasted was glass beads J-200 having a median diameter of 75 to 45 ⁇ m using a blasting machine, Myblast MY-30D (trade name, ex Sintokogio, Ltd.), in conditions of an air pressure of 0.3 MPa and an angle of 30 to 60 degrees.
  • the time for the blasting was adjusted appropriately in the range of 1 to 20 seconds so that the desired surface roughness of the substrate was attained.
  • the substrate was thoroughly washed with water and dried to obtain resin substrate (R) having the desired surface roughness (A).
  • An aluminum plate (A5052, trade name, thickness; 2 mm, ex Nippon Light Metal Company, Ltd.) was drawn using a pressing machine (O8S80S, trade name, ex Komatsu Industries Corp.) to obtain a metal substrate having a similar shape to that of the substrate (R). Glass beads were blasted to the surface of this substrate in the same manner as in (1) above to obtain a metal substrate (M) having the desired surface roughness (A).
  • An acrylic pressure-sensitive adhesive (acrylic acid and acrylate, SK Dyne 1309, trade name, ex Soken Chemical & Engineering Co., Ltd. ) and a curing agent (L-45, tolylene diisocyanate, ex Soken Chemical & Engineering Co., Ltd.) were mixed with toluene and ethyl acetate as solvents in a weight ratio of 1000:6:100:100, and stirred well at room temperature for two minutes.
  • This mixture was applied to a release film (Cerapeel W Z, trade name, thickness; 38 ⁇ m, ex Toray Advanced Film Co., Ltd.) and dried at 100 degrees C. for two minutes to obtain a pressure-sensitive adhesive layer having a thickness of 30 ⁇ m.
  • this pressure-sensitive adhesive layer layered was a film of cyclohexanedimethanol-copolymerized polyethylene terephthalate (PETG rein film, SET329 FZ26401, trade name, thickness: 100 ⁇ um, ex Riken Technos Corp.) as a base layer to obtain film ( ⁇ 0 ) comprising the acrylic pressure-sensitive adhesive layer.
  • the pressure-sensitive adhesive had a glass transition temperature of ⁇ 25 degrees C. and a viscosity of 10 Pa ⁇ s at 25 degrees C.
  • the release film was EMBLET S100 whose surface was processed by blasting glass beads J-200 having a median diameter of 75 to 45 ⁇ m using a blasting machine, Myblast MY-30D (trade name, ex Sintokogio, Ltd.), in conditions of an air pressure of 0.3 MPa and an angle of 30 to 60 degrees, washed with water, dried and then treated with silicone. The time for the blasting was adjusted appropriately in the range of 1 to 20 seconds so that the surface of the release film which surface was in contact with the pressure-sensitive adhesive layer had the desired surface roughness (B).
  • polyester adhesive layer was obtained as follows. Acid components consisting of terephthalic acid, isophthalic acid and adipic acid in a molar ratio of 30:30:40 were mixed with glycol components consisting of 1,4-butanediol and 1,6-hexanediol in a molar ratio of 25:75, and heated in the presence of a catalyst, tetrabutyl titanate, to prepare a thermoplastic saturated copolymeric polyester resin.
  • thermoplastic saturated copolymeric polyester resin thus obtained was dissolved in a solvent, methyl ethyl ketone, to obtain a solution having a solid content of 30% by mass.
  • a solvent methyl ethyl ketone
  • To this solution added were 2 equivalents of polyisocyanate (CORONATE HX, hexamethylene diisocyanate, solid content: 100%, ex Nippon Polyurethane Industry Co., Ltd.), and stirred well at room temperature for 2 minutes. This mixture was applied to a release film to obtain an adhesive layer having a thickness of 30 ⁇ m.
  • the release film was the same as in (2) above, except that the time for the blasting of the glass beads was adjusted so that the surface of the adhesive layer, which surface was to be in contact with the release film, had a surface roughness (B) of 13 ⁇ m.
  • the adhesive had a glass transition temperature of 23 degrees C. and a viscosity of 25 Pa ⁇ s at 25 degrees C.
  • the substrate and the film obtained as described above were subjected to the vacuum forming as shown in FIG. 1 or the vacuum and pressure forming as shown in FIG. 2 to obtain a molded article comprising the substrate whose surface was covered with the film.
  • the molded article thus obtained was allowed to stand at room temperature for 24 hours or more and then subjected to the following tests.
  • the results are as shown in Table 1, together with the hinds of the substrates and films, and the forming methods used.
  • pressure in lower chamber (8) and pressure in upper chamber (7) in Table 1 were those in FIG. 2( c ).
  • Appearance of the surface of the film of the molded article was visually rated on the following criteria.
  • B Blister or concave-convex pattern was observed which was as large as to catch a finger when touched the surface.
  • the surface of the film of the molded article was cut square in 100 ⁇ 25 mm.
  • the film was peeled off at one end of the square. This end was held by a chuck of a tensile testing machine, Tensilon RTG-1310, ex A&D Company, Ltd., and an end at the molded article was held by the other chuck of the testing machine corner sure a peeling strength at a rate of pulling of 300 mm/min.
  • the peeling strength was 30N/25 mm or more.
  • the peeling strength was 20N/25 mm to less than 30N/25 mm.
  • the molded article was kept in a Geer oven at 100 degrees C. for 168 hours and then taken out. After allowed to stand at room temperature for an hour, the appearance of the molded article was visually rated on the following criteria.
  • B Blister or concave-convex pattern was observed, which was as large as to catch a finger when touched the molded article.
  • the present molded articles were superior in appearance, adhesiveness and heat resistance.
  • the avoided articles of Comparative Examples 1, 3 and 5 had the surface roughness (A) below the present lower limit and were inferior in appearance and heat resistance.
  • the molded articles of Comparative Examples 2, 4 and 6 had the surface roughness (A) above the present upper limit and were inferior in appearance, adhesiveness and heat resistance.
  • the pressure in upper chamber ( 7 ) in the vacuum and pressure forming was as high as 1300 KPa and, therefore, the substrate of the resulting molded article was deformed.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Quality & Reliability (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Manufacturing & Machinery (AREA)
  • Laminated Bodies (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
US14/131,516 2011-07-12 2011-07-12 Molded article coated with a film Abandoned US20140147630A1 (en)

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TWI625217B (zh) * 2015-11-27 2018-06-01 遠東科技大學 射出成形方法及由該方法製造的成形品
KR101839481B1 (ko) * 2016-06-17 2018-03-16 주식회사 캐리마 3d 프린팅 및 진공흡착 공정을 이용한 인공안구 제조방법
FR3053272B1 (fr) * 2016-07-04 2019-08-09 Aplix Piece thermoformee comportant un element rapporte et procede pour la fabrication d'une telle piece
JP2019042927A (ja) * 2017-08-29 2019-03-22 共和レザー株式会社 加飾成形体及び加飾成形体の製造方法
CN110154378B (zh) * 2018-02-12 2021-09-10 何英信 3c电子装置的曲面壳体制造方法
EP3778195B1 (en) * 2018-03-30 2023-07-12 Toray Industries, Inc. Method for manufacturing molded article
JP6691624B2 (ja) * 2019-04-22 2020-04-28 株式会社浅野研究所 熱成形装置及び熱成形方法
JP2021138388A (ja) * 2020-03-03 2021-09-16 株式会社ケーピープラテック ラミネートパルプ容器の製造方法、及び、ラミネートパルプ容器の製造装置
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CN103826827A (zh) 2014-05-28
KR20140034233A (ko) 2014-03-19
WO2013008318A1 (ja) 2013-01-17
KR101802556B1 (ko) 2017-11-28
EP2732952A4 (en) 2015-04-15
US10369770B2 (en) 2019-08-06
ES2625793T3 (es) 2017-07-20
JPWO2013008318A1 (ja) 2015-02-23
EP2732952B1 (en) 2017-03-01
EP2732952A1 (en) 2014-05-21
CN103826827B (zh) 2016-04-27
JP5777714B2 (ja) 2015-09-09
US20150375443A1 (en) 2015-12-31

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