WO2010053142A1 - Molded resin and process for producing same - Google Patents

Molded resin and process for producing same Download PDF

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Publication number
WO2010053142A1
WO2010053142A1 PCT/JP2009/068952 JP2009068952W WO2010053142A1 WO 2010053142 A1 WO2010053142 A1 WO 2010053142A1 JP 2009068952 W JP2009068952 W JP 2009068952W WO 2010053142 A1 WO2010053142 A1 WO 2010053142A1
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WO
WIPO (PCT)
Prior art keywords
multilayer film
molded product
resin molded
texture
resin
Prior art date
Application number
PCT/JP2009/068952
Other languages
French (fr)
Japanese (ja)
Inventor
英郎 秋元
高広 冨永
Original Assignee
小野産業株式会社
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Application filed by 小野産業株式会社 filed Critical 小野産業株式会社
Priority to JP2010536795A priority Critical patent/JPWO2010053142A1/en
Publication of WO2010053142A1 publication Critical patent/WO2010053142A1/en

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    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/76—Measuring, controlling or regulating
    • B29C45/78—Measuring, controlling or regulating of temperature
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • B29C45/14811—Multilayered articles
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/26—Moulds
    • B29C45/37—Mould cavity walls, i.e. the inner surface forming the mould cavity, e.g. linings
    • B29C45/372—Mould cavity walls, i.e. the inner surface forming the mould cavity, e.g. linings provided with means for marking or patterning, e.g. numbering articles
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/72—Heating or cooling
    • B29C45/73—Heating or cooling of the mould

Definitions

  • the present invention relates to a resin molded product and a manufacturing method thereof.
  • resin molded products are widely used in various products such as information appliances, communication devices, household appliances, automobiles, sports equipment, and furniture.
  • the resin molded product can be molded into a relatively free shape and has various advantages such as low cost, light weight and high strength, but at least a part (especially exterior)
  • the resin gloss and the metal parts are often combined, or the resin molding is subjected to a plating treatment to obtain a metallic luster, texture, and luxury.
  • compounding with metal parts and plating treatment are performed after the molding of the resin molded product, the working time and manufacturing cost are greatly increased, and the working efficiency becomes very poor.
  • Patent Documents 1 and 2 when a multilayer plastic film including a metal thin film layer is inserted into a mold and insert-molded, the metal thin film layer having a thickness of about 200 to 800 ⁇ is formed when the multilayer plastic film is pre-molded. It is necessary to precisely set the processing conditions so that microcracks do not occur. Therefore, workability is not good. Moreover, since the transfer of the processed groove-like texture to the metal thin film layer in Patent Document 2 is performed at the time of insert molding, there is a possibility that sufficient transfer cannot be achieved. As a result, the method of Patent Document 2 has a problem that the same level of texture as a product obtained by actually grinding a metal cannot be obtained.
  • the present invention has been made in view of the above problems, and can improve the decorativeness of a lightweight and inexpensive resin molded product, for example, a resin capable of producing a metallic texture or a high-class feeling on at least a part of an exterior. It aims at providing a molded article and its manufacturing method.
  • Another object of the present invention is to provide a resin molded article capable of further improving decorativeness by satisfactorily transferring a texture containing at least one of a texture, a processed groove, or a hairline to at least a part of the exterior. And providing a manufacturing method thereof.
  • a feature of the method for producing a resin molded product of the present invention is that a multilayer film in which at least two layers of at least two kinds of polyester resins are laminated is inserted into a cavity of a mold, and the cavity is inserted into the cavity into which the multilayer film is inserted.
  • the molding material in a molten state is injected, and the molding material is solidified and integrated with the multilayer film, thereby forming a molded product in which the multilayer film is located on at least a part of the surface.
  • a texture including at least one of a texture, a processed groove, or a hairline may be formed on the entire surface or a part of the surface of the cavity that contacts the inserted multilayer film.
  • the resin molded product of the present invention is characterized by a multilayer film in which at least two layers of at least two kinds of polyester resins are laminated on at least a part of the surface, and a main body portion made of a resin integrated with the multilayer film. There is.
  • a texture including at least one of a texture, a processed groove, or a hairline may be transferred to the entire surface or a part of the multilayer film.
  • Another feature of the resin molded product of the present invention is that at least a part of the surface is formed of a polyester resin layer having a thickness of 50 ⁇ m or more, and the entire surface or a part of the polyester resin layer has a texture, a processed groove, or a hairline.
  • the texture including at least one of the above is transferred, and when the surface roughness (Ra) and the cutoff value (L) are 0.08 (mm) ⁇ L ⁇ 0.8 (mm), Ra ⁇ L / 200 It has a relationship of
  • the polyester resin layer is a laminate in which 100 or more layers of two or more kinds of polyester resins having different refractive indexes are laminated.
  • the resin molded product of the present invention comprises a polyester resin layer having a thickness of 50 ⁇ m or more at least on the surface, and at least one of a texture, a processed groove, or a hairline on the entire surface or a part of the polyester resin layer.
  • the surface roughness (Ra) of the resin molded product is 0.8 ⁇ Ram ⁇ the surface roughness (Ram) of the mold cavity for molding the resin molded product. It has a relationship of Ra ⁇ 1.2 ⁇ Ram.
  • the multilayer film located on the surface of the resin molded product can give a metallic texture, decorativeness close to that of a metal product can be obtained while maintaining strength, low cost and light weight.
  • FIG. 5 is a cross-sectional view illustrating a state in which the mold is opened and solidified and integrated to remove the multilayer film and the molding material after the state illustrated in FIG. 4. It is sectional drawing of the resin molded product which concerns on this invention.
  • FIG. 1 An outline of a method for producing a resin molded product in the present embodiment will be described with reference to the drawings.
  • a multilayer film 3 made of polyester resin is prepared, and in accordance with the shape of the inner surface of the cavity 8 of the mold made up of the movable mold 1 and the fixed mold 2 (see FIGS. 2 to 5), Pre-molded by vacuum forming or pressure forming.
  • FIG. 2 the movable mold 1 and the fixed mold 2 are opened, and the pre-shaped multilayer film 3 is inserted into the cavity 8. Then, as shown in FIGS.
  • the movable mold 1 and the fixed mold 2 are closed, and the molding material 4 that has been plasticized and melted in the cylinder of the injection molding machine 9 is put into the cavity 8 of the closed mold. Eject.
  • the molding material 4 is solidified by cooling.
  • the movable mold 1 and the fixed mold 2 are opened again, and the integrated multilayer film 3 and molding material (main body part) 4 are pushed out from the cavity 8 by ejector pins (not shown). Thereafter, the runner portion is broken to obtain the resin molded product 5 shown in FIG.
  • the resin molded product 5 is formed by using so-called insert molding, and the multilayer film 3 is disposed on the main body portion (on the outer surface) formed by injection molding of the molding material 4. It is an integrated one.
  • the multilayer film 3 located on the surface of the implementation molded product 5 is a polyester resin multilayer film in which two kinds of polyester resins having different refractive indexes are alternately laminated.
  • the multilayer film 3 is obtained by alternately laminating 100 kinds or more of two kinds of polyester resins.
  • 100 or more layers of polyethylene terephthalate having a refractive index value of 1.57 and a polyester resin having a refractive index value generally in the range of 1.50 to 1.56 are alternately laminated.
  • Such a multilayer film 3 has a high value of light reflectance on the surface in a wide wavelength region, is close to total reflection, and exhibits a metallic appearance.
  • the resin molded product 5 of the present embodiment having the multilayer film 3 on the surface has an appearance with a metallic texture.
  • the glass transition temperature of such a polyester resin multilayer film is generally measured by a DSC (Differential scanning calorimetry) method or a TMA (Thermomechanical analysis) method and is in the range of 60 ° C. to 100 ° C. .
  • the metal-like multilayer film on which 1000 or more layers of 2 or more types of resin layers currently marketed can also be used as the multilayer film 3.
  • the polyester resin contained in the multilayer film 3 includes aromatic dicarboxylic acids, alicyclic dicarboxylic acids, and alicyclics in addition to (high purity) terephthalic acid and polyethylene terephthalate, which is a condensation polymer of dimethyl terephthalate and ethylene glycol. It may contain a copolymer resin made of diol, aliphatic diol, or the like. Since the polymerization composition affects viscoelastic properties and refractive index, a polyester resin having a polymerization composition suitable for the purpose may be used.
  • the thickness of the multilayer film 3 made of the polyester resin of the present embodiment is preferably in the range of 12 to 1000 ⁇ m.
  • the multilayer film 3 has a thickness in this range, the preliminary moldability and the mold transferability are excellent.
  • a multi-layer film 3 may be provided with an anti-scratch layer, an easy adhesion layer, a printing layer, and the like.
  • a surface protective layer such as a hard coat or a colored layer for imparting design properties may be provided on the surface of the multilayer film 3.
  • a black ink is applied to the back surface side of the multilayer film 3 (opposite the design surface serving as the exterior of the resin molded product 5) to form a printed layer, the reflectance becomes higher and the metallic tone becomes more metallic. If a portion where no ink is applied is provided between the printed layers, the portion transmits light and becomes a half mirror.
  • the multilayer film 3 can be subjected to surface treatment such as primer application, corona treatment, ozone treatment, frame treatment, silicate treatment (intro treatment), etc., to increase the adhesive strength with the molding material 4. is there.
  • a fine texture (fine irregularities) 6 is provided on the surface of the cavity 8 of the movable mold 1.
  • the fine texture 7 is formed by transferring the texture 6 of the movable mold 1 onto the surface of the finished resin molded product 5. Since the surface of the resin molded product is made of the polyester resin multilayer film 3 as described above, the light beam is reflected and has a metallic texture, but the texture 7 is further processed with a matte tone or a hairline tone. It can be finished with a high-class texture that is very similar to the applied metal surface.
  • the textures 6 and 7 are shown larger than the exact scale for easy viewing.
  • a dent may be formed on the surface opposite to the texture transferred. In FIGS. The depression is not shown.
  • the movable mold 1 is provided with a heating / cooling flow path 10. And in the manufacturing method of the above-mentioned resin molded product 5, before injecting the molding material 4 into the cavity 8, at least the cavity 8 is inserted by flowing pressurized saturated steam through the heating / cooling channel 10.
  • the surface temperature in contact with the multilayer film 3 is heated to the glass transition temperature of the polyester resin constituting the multilayer film 3 or higher (for example, 100 ° C. or higher).
  • the temperature is set in the range of 80 ° C. to 130 ° C.
  • the multilayer film 3 positioned in the cavity 8 is heated to the glass transition temperature or higher and softens.
  • the softened multilayer film 3 is pressed against the surface of the cavity 8 of the movable mold 1 by the resin pressure at that time, and the shape of the texture 6 becomes the surface of the multilayer film 3. Is transcribed. Further, when the supply of steam to the heating / cooling flow path 10 is subsequently stopped and cooling water is supplied instead, the movable mold 1 is cooled, and the multilayer film 3 and the molding material 4 are also cooled and solidified. Turn into. Then, as shown in FIG. 5, the movable mold 1 and the fixed mold 2 are opened, and the resin molded product 5 can be taken out.
  • the molding material 4 can be molded in a short time, efficiently and in a good surface state.
  • the texture 6 of the movable mold 1 can be satisfactorily transferred to the surface of the multilayer film 3 by heating the movable mold 1 before the injection of the molding material 4. If such a mold is not heated, the transfer of the texture 6 becomes insufficient, and an excellent high-quality texture cannot be obtained.
  • the surface temperature of the mold cavity in contact with the multilayer film 3 is kept constant at a high temperature equal to or higher than the glass transition temperature of the multilayer film 3, a good texture 6 transfer can be realized. Deformation may occur in the product. Therefore, as described above, the movable mold 1 is cooled after the molding material 4 is filled by supplying cooling water to the heating / cooling flow path 10 and the multilayer film 3 and the molding material 4 are also cooled and solidified accordingly. It is preferable.
  • fine unevenness (texture 6) for transferring to the surface of the multilayer film 3 is formed on the entire surface or a part of the surface of the cavity 8 of the movable mold 1.
  • the texture 6 is a so-called wrinkle, a processed groove, a hairline, or the like.
  • a texture including at least one of a texture, a processing groove, or a hairline provided in a mold is formed by overlapping a plurality of irregularities having different periods. Such a texture is generally applied in a depth range of 2 to 100 ⁇ m.
  • the molding is performed by heating the surface temperature of the cavity 8 of the movable mold 1 to be equal to or higher than the glass transition temperature of the multilayer film 3, so that the cutoff value L is 0.08 to 0.8 mm.
  • Ra ⁇ 5 L / 1000 that is, Ra ⁇ L / 200.
  • the surface roughness Ra may be set to a value equal to or greater than a value obtained by multiplying a value obtained by removing the unit of the cut-off value L (mm) by 5 and adding a unit ( ⁇ m). More preferably, Ra ⁇ 7L / 1000, and further preferably Ra ⁇ L / 100.
  • the upper limit value of the surface roughness Ra is arbitrarily determined depending on the decorativeness (designability) required for the resin molded product.
  • the texture applied to the mold is faithfully transferred to the resin molded product, and the surface roughness Ra of the resin molded product is equal to the surface roughness Ram of the mold cavity (for example, a cutoff value of 0. 0).
  • the range is 0.8 times to 1.2 times of 0.1 ⁇ m to 10 ⁇ m at 08 mm. If the surface roughness Ra of the resin molded product is less than 0.8 times the surface roughness Ram of the mold cavity, a good texture cannot be obtained. Variations are likely to occur.
  • the lower limit of the surface roughness Ra of the resin molded product based on either the above-mentioned conditions Ra ⁇ L / 200 (where the cutoff value L is 0.08 to 0.8 mm) or 0.8 ⁇ Ram ⁇ Ra. A value may be determined, and an upper limit value may be determined based on a condition of Ra ⁇ 1.2 ⁇ Ram.
  • the heating temperature of the surface of the cavity 8 of the movable mold 1 is set according to the glass transition temperature and the viscoelastic property of the polyester resin constituting the multilayer film 3, it is set to at least the glass transition temperature of the polyester resin.
  • the temperature at which the loss elastic modulus of the polyester resin is 500 MPa or less is selected. That is, the storage elastic modulus of the polyester resin laminate can be obtained as temperature-dependent data using a tensile mode dynamic viscoelasticity measuring apparatus. Considering based on the data, when the ratio of the storage elastic modulus at 100 ° C. to the storage elastic modulus at 200 ° C. of the polyester resin is 10 or less, the polyester resin can be formed in a well-balanced manner at the time of pressure forming or vacuum forming.
  • the loss elastic modulus in the temperature range of 100 ° C. to 200 ° C. of the polyester resin is in the range of 500 MPa or less, the texture 6 of the movable mold 1 is easily transferred as described above. Since the transfer film 3 is composed of two or more kinds of polyester resins, the heating temperature of the movable mold 1 is set in accordance with the polyester resin having the higher temperature determined by the above-described consideration among the polyester resins. do it.
  • a heating method of the mold in addition to the method of flowing a heat medium such as steam, pressurized water, or heating oil through the heating and cooling channel 10 as described above, a method using an electric heater, a method of heating by induction heating, Further, a method of heating with a flame can be used, and a method combining these methods can also be used. Moreover, it is necessary to cool the mold after completion of injection filling until the multilayer film 3 and the molding material (main body part) 4 are cooled and solidified to such an extent that they can be taken out from the mold. As a matter of course, the lower the cooling temperature, the faster the multilayer film 3 and the molding material 4 can be taken out. As described above, the mold is generally cooled using cooling water.
  • a channel (heating / cooling channel 10) can be used. However, it is not necessarily limited to such a configuration.
  • the molding material 4 constituting a part (main body part) of the resin molded product of this embodiment, acrylic resin, polystyrene, ABS resin, polycarbonate, polyamide, polypropylene, PBT resin, polylactic acid, cyclic olefin polymer (or cyclic olefin) A copolymer) or a mixture thereof is preferably used. It is preferable that the molding material 4 has a high fluidity within a range that does not adversely affect the characteristics of the resin molded product that is the final product because the film is hardly damaged by shearing heat generation. However, other thermoplastic resins may be used. Further, these molding materials 4 include particulate or fibrous fillers, reinforcing materials such as impact resistance improving materials, coloring materials such as pigments and dyes, flame retardants, weathering stabilizers, and antioxidants. Additives such as may be added.
  • Example 1 Printed layer (colored layer) of urethane ink (TAS ink manufactured by Teikoku Mfg. Co., Ltd.) by screen printing on multilayer film 3 made of polyester resin (PICASUS188 ⁇ m manufactured by Toray Industries, Inc., glass transition temperature: 80 ° C.) (not shown) ) And a binder layer (IMB binder manufactured by Teikoku Ink Manufacturing Co., Ltd.) were formed in order.
  • the multilayer film 3 having the printing layer and the binder layer was set on an ultrahigh pressure blank molding machine manufactured by Nibling with the printing layer and the binder layer side up, and pre-shaped by pressure molding.
  • the multilayer film 3 is subjected to pressure forming under the conditions that the surface temperature of the multilayer film 3 is 120 ° C. (the heater set temperature is 200 ° C.) and the molding pressure is 10 MPa, and then the periphery of the compressed air molded product is punched. 3 was formed into a 100 mm ⁇ 50 mm rectangular shape having a concave shape with a depth of 6 mm and an arc having a radius of 5 mm at the corner.
  • the multilayer film 3 preliminarily shaped in this way was inserted into the cavity 8 of a mold (for example, the movable mold 1).
  • an ABS resin ST120 manufactured by Nippon A & L Co., Ltd., melt volume flow rate: 29 (measurement conditions: 220 ° C., 10 kg)
  • the shape of the cavity 8 is a rectangular shape of 100 mm ⁇ 50 mm having a concave shape with a depth of 6 mm and an arc with a radius of 5 mm at the corners, which matches the preshaped multilayer film 3.
  • the manufactured resin molded product 5 has the same shape and a thickness of 1.5 mm.
  • Example 2 The surface temperature of the cavity 8 is kept constant at 100 ° C., and similarly to Example 1 described above, the pre-shaped multilayer film 3 having the printing layer and the binder layer and the molding material 4 made of ABS resin are used. Insert molding was performed to obtain a resin molded product.
  • Example 3 The surface temperature of the cavity 8 is kept constant at 50 ° C., and similarly to Example 1 described above, the pre-shaped multilayer film 3 having the printing layer and the binder layer and the molding material 4 made of ABS resin are used. Insert molding was performed to obtain a resin molded product.
  • Table 1 shows the results of evaluating the resin molded products 5 produced in Examples 1 to 3 described above.
  • Example 3 when the cut-off value L is 0.08 mm, the surface roughness Ra of the molded product is 0.38 ⁇ m, and Ra ⁇ L / 200, which is undesirable shine (useless gloss). occured. Further, in Example 1, since the mold is cooled, there is an effect that deformation of the resin molded product can be prevented as compared with Example 2.

Abstract

Provided is a molded resin which can be a lightweight inexpensive molded resin that has enhanced decorative properties, for example, at least some of the exterior of the molded resin gives a metallic feeling or high-grade feeling.  Also provided is a process for producing the molded resin.  A multilayered film (3) composed of 100 or more superposed layers constituted of at least two polyester resins is inserted into the cavity (8) of a mold.  A molten molding material (4) comprising a resin is injected into the cavity (8) into which the multilayered film (3) has been inserted.  The molding material (4) is solidified to integrate the material (4) with the multilayered film (3).  Thus, a molded article (5) having the multilayered film (3) located in at least some of the surfaces is formed.  Before the molding material (4) is injected, the surface of the mold cavity (8) which comes into contact with the multilayered film (3) to be inserted is heated to a temperature not lower than the glass transition temperature of the multilayered film (3).

Description

樹脂成形品およびその製造方法Resin molded product and manufacturing method thereof
　本発明は樹脂成形品およびその製造方法に関する。 The present invention relates to a resin molded product and a manufacturing method thereof.
　現在、情報家電、通信機器、生活家電、自動車、スポーツ用品、家具等のあらゆる製品において樹脂成形品が多用されている。樹脂成形品は、比較的自由な形状に成形することが可能であり、しかも安価で軽量で強度が高いなどの様々な利点を有するが、装飾性をより高めるために、少なくとも一部（特に外装部分）に、金属に類似する光沢、表面形状、質感、高級感を付与することが望まれる場合がある。その場合、樹脂成形品と金属部品とを複合させたり樹脂成形品にメッキ処理を施したりして、金属の光沢や質感や高級感を得ることが多い。しかし、樹脂成形品の成形後に金属部品との複合やメッキ処理を行うため、作業時間や製造コストが大幅に増大し、作業効率が非常に悪くなる。 Currently, resin molded products are widely used in various products such as information appliances, communication devices, household appliances, automobiles, sports equipment, and furniture. The resin molded product can be molded into a relatively free shape and has various advantages such as low cost, light weight and high strength, but at least a part (especially exterior) In some cases, it may be desired to impart a gloss, a surface shape, a texture, and a high-class feeling similar to those of a metal to (part). In that case, the resin gloss and the metal parts are often combined, or the resin molding is subjected to a plating treatment to obtain a metallic luster, texture, and luxury. However, since compounding with metal parts and plating treatment are performed after the molding of the resin molded product, the working time and manufacturing cost are greatly increased, and the working efficiency becomes very poor.
　そこで、近年、蒸着やスパッタリングやイオンプレーティングにより形成された厚さ２００～８００オングストロームの金属薄膜層を含む多層プラスチックフィルムを、圧空成形等により予備腑形した後に、インサート成形を行う方法が提案されている（特開２００４－１４３３号公報）。これによると、樹脂成形品の表面に金属薄膜層を配置して金属調の外観を得ることができる。さらに、金属薄膜層を含む多層プラスチックフィルムを用いてインサート成形を行う際に、金型のキャビティの表面に設けられた加工溝状のテクスチャーを金属薄膜層に転写することにより、さらなる金属光沢や質感を与える方法が提案されている（特開２００６－７６１６７号公報）。 Therefore, in recent years, a method has been proposed in which insert molding is performed after preforming a multilayer plastic film including a metal thin film layer having a thickness of 200 to 800 angstroms formed by vapor deposition, sputtering, or ion plating by pressure forming or the like. (Japanese Patent Laid-Open No. 2004-1433). According to this, it is possible to obtain a metallic appearance by arranging the metal thin film layer on the surface of the resin molded product. In addition, when insert molding is performed using a multilayer plastic film containing a metal thin film layer, the texture of the groove formed on the surface of the mold cavity is transferred to the metal thin film layer, resulting in further metallic luster and texture. Has been proposed (Japanese Patent Laid-Open No. 2006-76167).
　特許文献１，２のように、金属薄膜層を含む多層プラスチックフィルムを金型に挿入してインサート成形する場合、多層プラスチックフィルムの予備腑形時に、厚さ２００～８００オングストローム程度の金属薄膜層にマイクロクラックが生じないように、加工条件を精緻に設定する必要がある。従って、作業性が良好ではない。また、特許文献２における金属薄膜層への加工溝状のテクスチャーの転写は、インサート成形時に行われるため、十分な転写が達成できない可能性がある。その結果、特許文献２の方法では、実際に金属を研削加工した製品と同じ水準の質感は得られないという問題があった。 As in Patent Documents 1 and 2, when a multilayer plastic film including a metal thin film layer is inserted into a mold and insert-molded, the metal thin film layer having a thickness of about 200 to 800 Å is formed when the multilayer plastic film is pre-molded. It is necessary to precisely set the processing conditions so that microcracks do not occur. Therefore, workability is not good. Moreover, since the transfer of the processed groove-like texture to the metal thin film layer in Patent Document 2 is performed at the time of insert molding, there is a possibility that sufficient transfer cannot be achieved. As a result, the method of Patent Document 2 has a problem that the same level of texture as a product obtained by actually grinding a metal cannot be obtained.
　本発明は、上記問題に鑑みてなされたもので、軽量で安価な樹脂成形品の装飾性を高めること、例えば外装の少なくとも一部に金属調の質感や高級感を生じさせることが可能な樹脂成形品およびその製造方法を提供することを目的とする。 The present invention has been made in view of the above problems, and can improve the decorativeness of a lightweight and inexpensive resin molded product, for example, a resin capable of producing a metallic texture or a high-class feeling on at least a part of an exterior. It aims at providing a molded article and its manufacturing method.
　また、本発明のもう１つの目的は、外装の少なくとも一部に、シボ、加工溝、またはヘアラインの少なくとも１つを含むテクスチャーを良好に転写して、装飾性をより高めることができる樹脂成形品およびその製造方法を提供することにある。 Another object of the present invention is to provide a resin molded article capable of further improving decorativeness by satisfactorily transferring a texture containing at least one of a texture, a processed groove, or a hairline to at least a part of the exterior. And providing a manufacturing method thereof.
　本発明の樹脂成形品の製造方法の特徴は、少なくとも２種類のポリエステル樹脂が１００層以上積層された多層フィルムを、金型のキャビティ内に挿入し、多層フィルムが挿入されたキャビティに、樹脂からなる溶融状態の成形材料を射出し、成形材料を固化させて多層フィルムと一体化させることにより、表面の少なくとも一部に多層フィルムが位置する成形品を形成するところにある。この場合、成形材料の射出開始前に、金型のキャビティの、挿入された多層フィルムと接触する表面の温度を、多層フィルムのガラス転移温度以上に昇温しておくことが好ましい。キャビティの、挿入された多層フィルムと接触する表面の全面または一部に、シボ、加工溝、またはヘアラインの少なくとも１つを含むテクスチャーを形成しておいてもよい。 A feature of the method for producing a resin molded product of the present invention is that a multilayer film in which at least two layers of at least two kinds of polyester resins are laminated is inserted into a cavity of a mold, and the cavity is inserted into the cavity into which the multilayer film is inserted. The molding material in a molten state is injected, and the molding material is solidified and integrated with the multilayer film, thereby forming a molded product in which the multilayer film is located on at least a part of the surface. In this case, it is preferable to raise the temperature of the surface of the mold cavity in contact with the inserted multilayer film to a temperature higher than the glass transition temperature of the multilayer film before starting the injection of the molding material. A texture including at least one of a texture, a processed groove, or a hairline may be formed on the entire surface or a part of the surface of the cavity that contacts the inserted multilayer film.
　本発明の樹脂成形品の特徴は、表面の少なくとも一部に位置する、少なくとも２種類のポリエステル樹脂が１００層以上積層された多層フィルムと、多層フィルムと一体化している樹脂からなる本体部分とからなるところにある。多層フィルムの全面または一部に、シボ、加工溝、またはヘアラインの少なくとも１つを含むテクスチャーが転写されていてもよい。 The resin molded product of the present invention is characterized by a multilayer film in which at least two layers of at least two kinds of polyester resins are laminated on at least a part of the surface, and a main body portion made of a resin integrated with the multilayer film. There is. A texture including at least one of a texture, a processed groove, or a hairline may be transferred to the entire surface or a part of the multilayer film.
　また、本発明の樹脂成形品の他の特徴は、表面の少なくとも一部が厚さ５０μｍ以上のポリエステル樹脂の層からなり、ポリエステル樹脂の層の全面または一部に、シボ、加工溝、またはヘアラインの少なくとも１つを含むテクスチャーが転写されており、表面粗さ（Ｒａ）とカットオフ値（Ｌ）が、０．０８（ｍｍ）≦Ｌ≦０．８（ｍｍ）において、Ｒａ≧Ｌ／２００の関係を有するところにある。ポリエステル樹脂の層は、屈折率が異なる２種類以上のポリエステル樹脂が１００層以上積層された積層体である。 Another feature of the resin molded product of the present invention is that at least a part of the surface is formed of a polyester resin layer having a thickness of 50 μm or more, and the entire surface or a part of the polyester resin layer has a texture, a processed groove, or a hairline. The texture including at least one of the above is transferred, and when the surface roughness (Ra) and the cutoff value (L) are 0.08 (mm) ≦ L ≦ 0.8 (mm), Ra ≧ L / 200 It has a relationship of The polyester resin layer is a laminate in which 100 or more layers of two or more kinds of polyester resins having different refractive indexes are laminated.
　また、本発明の樹脂成形品は、表面の少なくとも一部が厚さ５０μｍ以上のポリエステル樹脂の層からなり、ポリエステル樹脂の層の全面または一部に、シボ、加工溝、またはヘアラインの少なくとも１つを含むテクスチャーが転写されており、樹脂成形品の表面粗さ（Ｒａ）が、樹脂成形品を成形するための金型のキャビティの表面粗さ（Ｒａｍ）に対して、０．８×Ｒａｍ≦Ｒａ≦１．２×Ｒａｍの関係を有する。 Further, the resin molded product of the present invention comprises a polyester resin layer having a thickness of 50 μm or more at least on the surface, and at least one of a texture, a processed groove, or a hairline on the entire surface or a part of the polyester resin layer. The surface roughness (Ra) of the resin molded product is 0.8 × Ram ≦ the surface roughness (Ram) of the mold cavity for molding the resin molded product. It has a relationship of Ra ≦ 1.2 × Ram.
　本発明によると、樹脂成形品の表面に位置する多層フィルムが金属調の風合いを出すことができるため、強度や安価さや軽量さを保ちながら、金属製品に近い装飾性を得ることができる。 According to the present invention, since the multilayer film located on the surface of the resin molded product can give a metallic texture, decorativeness close to that of a metal product can be obtained while maintaining strength, low cost and light weight.
本発明に係る樹脂成形品の表面に位置する多層フィルムの断面図である。It is sectional drawing of the multilayer film located in the surface of the resin molded product which concerns on this invention. 本発明に係る樹脂成形品の製造方法において、図１に示す多層フィルムを、型開した金型のキャビティ内に挿入する状態を示す断面図である。In the manufacturing method of the resin molded product which concerns on this invention, it is sectional drawing which shows the state which inserts the multilayer film shown in FIG. 1 in the cavity of the metal mold | die which opened the mold. 図２に示す状態の後に、キャビティ内に多層フィルムが挿入された金型を閉じた状態を示す断面図である。It is sectional drawing which shows the state which closed the metal mold | die with which the multilayer film was inserted in the cavity after the state shown in FIG. 図３に示す状態の後に、多層フィルムが挿入された金型のキャビティ内に成形材料が充填された状態を示す断面図である。It is sectional drawing which shows the state with which the molding material was filled in the cavity of the metal mold | die with which the multilayer film was inserted after the state shown in FIG. 図４に示す状態の後に、金型を開いて、固化して一体化した多層フィルムおよび成形材料を取り出す状態を示す断面図である。FIG. 5 is a cross-sectional view illustrating a state in which the mold is opened and solidified and integrated to remove the multilayer film and the molding material after the state illustrated in FIG. 4. 本発明に係る樹脂成形品の断面図である。It is sectional drawing of the resin molded product which concerns on this invention.
　以下、図面を参照して本発明の好ましい実施の形態を説明する。 Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.
　本実施形態における樹脂成形品の製造方法の概略について、図面を参照して説明する。まず、図１に示すように、ポリエステル樹脂からなる多層フィルム３を用意し、可動型１と固定型２とからなる金型のキャビティ８の内面の形状（図２～５参照）に合わせて、真空成形あるいは圧空成形により予備腑形する。次に、図２に示すように、可動型１と固定型２とを開いて、予備腑形した多層フィルム３をキャビティ８内に挿入する。それから、図３～４に示すように、可動型１と固定型２を閉じ、射出成形機９のシリンダー内で可塑化溶融状態になった成形材料４を、閉じた金型のキャビティ８内に射出する。成形材料４の射出が完了したら、冷却して成形材料４を固化させる。そして、図５に示すように、可動型１と固定型２とを再び開いて、図示しないイジェクタピンによって、一体化した多層フィルム３および成形材料（本体部分）４を押し出してキャビティ８から取り出す。その後、ランナー部分を折り取ることによって、図６に示す樹脂成形品５を得る。この樹脂成形品５は、いわゆるインサート成形を用いて成形されたものであり、成形材料４の射出成形により成形された本体部分の上（外装となる表面上）に、多層フィルム３が配置されて一体化したものである。 An outline of a method for producing a resin molded product in the present embodiment will be described with reference to the drawings. First, as shown in FIG. 1, a multilayer film 3 made of polyester resin is prepared, and in accordance with the shape of the inner surface of the cavity 8 of the mold made up of the movable mold 1 and the fixed mold 2 (see FIGS. 2 to 5), Pre-molded by vacuum forming or pressure forming. Next, as shown in FIG. 2, the movable mold 1 and the fixed mold 2 are opened, and the pre-shaped multilayer film 3 is inserted into the cavity 8. Then, as shown in FIGS. 3 to 4, the movable mold 1 and the fixed mold 2 are closed, and the molding material 4 that has been plasticized and melted in the cylinder of the injection molding machine 9 is put into the cavity 8 of the closed mold. Eject. When the injection of the molding material 4 is completed, the molding material 4 is solidified by cooling. Then, as shown in FIG. 5, the movable mold 1 and the fixed mold 2 are opened again, and the integrated multilayer film 3 and molding material (main body part) 4 are pushed out from the cavity 8 by ejector pins (not shown). Thereafter, the runner portion is broken to obtain the resin molded product 5 shown in FIG. The resin molded product 5 is formed by using so-called insert molding, and the multilayer film 3 is disposed on the main body portion (on the outer surface) formed by injection molding of the molding material 4. It is an integrated one.
　実施成形品５の表面に位置する多層フィルム３は、屈折率が互いに異なる２種類のポリエステル樹脂が交互に積層されたポリエステル樹脂多層フィルムである。具体的には、この多層フィルム３は、２種類のポリエステル樹脂が合計１００層以上、交互に積層されたものである。例えば、屈折率の値が１．５７であるポリエチレンテレフタラートと、屈折率の値がおおむね１．５０～１．５６の範囲にあるポリエステル樹脂とが、交互に１００層以上積層されたものである。このような多層フィルム３は、表面の光線反射率が広い波長領域で高い値となって全反射に近くなり、金属調の外観を示す。従って、この多層フィルム３を表面に有する本実施形態の樹脂成形品５は、金属調の風合いを持つ外観を有する。このようなポリエステル樹脂多層フィルムのガラス転移温度は、一般にＤＳＣ（Differential　scanning　calorimetry：示差走査熱量測定）法やＴＭＡ（Thermomechanical　analysis：熱機械分析）法によって測定され、６０℃～１００℃の範囲にある。なお、多層フィルム３として、現在市販されている、２種類以上の樹脂層が１０００層以上積層された金属調多層フィルムを用いることもできる。 The multilayer film 3 located on the surface of the implementation molded product 5 is a polyester resin multilayer film in which two kinds of polyester resins having different refractive indexes are alternately laminated. Specifically, the multilayer film 3 is obtained by alternately laminating 100 kinds or more of two kinds of polyester resins. For example, 100 or more layers of polyethylene terephthalate having a refractive index value of 1.57 and a polyester resin having a refractive index value generally in the range of 1.50 to 1.56 are alternately laminated. . Such a multilayer film 3 has a high value of light reflectance on the surface in a wide wavelength region, is close to total reflection, and exhibits a metallic appearance. Therefore, the resin molded product 5 of the present embodiment having the multilayer film 3 on the surface has an appearance with a metallic texture. The glass transition temperature of such a polyester resin multilayer film is generally measured by a DSC (Differential scanning calorimetry) method or a TMA (Thermomechanical analysis) method and is in the range of 60 ° C. to 100 ° C. . In addition, as the multilayer film 3, the metal-like multilayer film on which 1000 or more layers of 2 or more types of resin layers currently marketed can also be used.
　多層フィルム３に含まれるポリエステル樹脂は、（高純度）テレフタル酸やテレフタル酸ジメチルとエチレングリコールの縮合重合体であるポリエチレンテレフタラートのほかに、芳香族ジカルボン酸、脂環族ジカルボン酸、脂環族ジオール、脂肪族ジオール等からなる共重合樹脂を含むものであってよい。重合組成は粘弾性特性や屈折率に影響するため、目的にかなう重合組成のポリエステル樹脂を用いるとよい。 The polyester resin contained in the multilayer film 3 includes aromatic dicarboxylic acids, alicyclic dicarboxylic acids, and alicyclics in addition to (high purity) terephthalic acid and polyethylene terephthalate, which is a condensation polymer of dimethyl terephthalate and ethylene glycol. It may contain a copolymer resin made of diol, aliphatic diol, or the like. Since the polymerization composition affects viscoelastic properties and refractive index, a polyester resin having a polymerization composition suitable for the purpose may be used.
　また、本実施形態のポリエステル樹脂からなる多層フィルム３の厚さは、１２～１０００μｍの範囲であることが好ましい。多層フィルム３がこの範囲の厚さを有していると、予備腑形性と金型転写性に優れる。 Further, the thickness of the multilayer film 3 made of the polyester resin of the present embodiment is preferably in the range of 12 to 1000 μm. When the multilayer film 3 has a thickness in this range, the preliminary moldability and the mold transferability are excellent.
　多層フィルム３に、傷つき防止層、易接着層、印刷層等を付加してもよい。例えば、多層フィルム３の表面に、ハードコート等の表面保護層や意匠性付与のための着色層を設けてもよい。多層フィルム３の裏面側（樹脂成形品５の外装となる意匠面の反対側）に黒色のインクを塗布して印刷層を形成すると、反射率がより高くなり、より金属調になる。そして、その印刷層の間に、インクを塗布しない部分を設けると、その部分は光線が透過してハーフミラーとなる。図示しないが、成形後に樹脂成形品５の表面にクリアー塗装を施して、テクスチャー６の凹凸以上の厚さのクリアー塗装膜を形成して、光の干渉作用により構造色を表現することも可能である。また、多層フィルム３に対して、プライマー塗布、コロナ処理、オゾン処理、フレーム処理、珪酸塩処理（イトロ処理）等の表面処理を行って、成形材料４との接着強度を高くすることも可能である。 A multi-layer film 3 may be provided with an anti-scratch layer, an easy adhesion layer, a printing layer, and the like. For example, a surface protective layer such as a hard coat or a colored layer for imparting design properties may be provided on the surface of the multilayer film 3. When a black ink is applied to the back surface side of the multilayer film 3 (opposite the design surface serving as the exterior of the resin molded product 5) to form a printed layer, the reflectance becomes higher and the metallic tone becomes more metallic. If a portion where no ink is applied is provided between the printed layers, the portion transmits light and becomes a half mirror. Although not shown, it is also possible to express the structural color by the interference action of light by applying a clear coating on the surface of the resin molded product 5 after molding to form a clear coating film with a thickness greater than the unevenness of the texture 6 is there. In addition, the multilayer film 3 can be subjected to surface treatment such as primer application, corona treatment, ozone treatment, frame treatment, silicate treatment (intro treatment), etc., to increase the adhesive strength with the molding material 4. is there.
　本実施形態では、図２～５に示すように、可動型１のキャビティ８の表面に微細なテクスチャー（微細な凹凸）６が設けられている。これは、完成状態の樹脂成形品５の表面に、可動型１のテクスチャー６を転写することにより微細なテクスチャー７を形成するためである。樹脂成形品の表面は、前記したようにポリエステル樹脂の多層フィルム３からなるため、光線が反射して金属調の風合いを持つが、さらに、テクスチャー７の部分ではつや消し調やヘアライン調等の加工を施した金属表面と極めて類似の、高級感ある風合いに仕上げることができる。なお、図２～６においては、見易くするために、テクスチャー６，７を正確な縮尺よりも大きく図示している。また、多層フィルム３に転写によってテクスチャー７が形成されるのに伴って、テクスチャーが転写されるのと反対側の表面に窪み（凹部）が生じることがあるが、図３～６ではそのような窪みは図示省略している。 In this embodiment, as shown in FIGS. 2 to 5, a fine texture (fine irregularities) 6 is provided on the surface of the cavity 8 of the movable mold 1. This is because the fine texture 7 is formed by transferring the texture 6 of the movable mold 1 onto the surface of the finished resin molded product 5. Since the surface of the resin molded product is made of the polyester resin multilayer film 3 as described above, the light beam is reflected and has a metallic texture, but the texture 7 is further processed with a matte tone or a hairline tone. It can be finished with a high-class texture that is very similar to the applied metal surface. In FIGS. 2 to 6, the textures 6 and 7 are shown larger than the exact scale for easy viewing. In addition, as the texture 7 is formed on the multilayer film 3 by transfer, a dent (concave portion) may be formed on the surface opposite to the texture transferred. In FIGS. The depression is not shown.
　また、本実施形態では、可動型１に加熱冷却流路１０が設けられている。そして、前記した樹脂成形品５の製造方法において、成形材料４をキャビティ８内に射出する前に、加熱冷却流路１０に加圧飽和蒸気を流すことにより、少なくとも、キャビティ８の、挿入された多層フィルム３と接触する表面の温度を、多層フィルム３を構成するポリエステル樹脂のガラス転移温度以上（例えば１００℃以上）に加熱する。一例としては、ガラス転移温度が８０℃であるポリエステル樹脂の多層フィルム３の場合、８０℃～１３０℃の範囲で設定される。それによって、キャビティ８内に位置する多層フィルム３はガラス転移温度以上に加熱されて軟化する。その後に成形材料４がキャビティ８内に充填されると、その際の樹脂圧力によって、軟化した多層フィルム３が可動型１のキャビティ８の表面に押し付けられ、テクスチャー６の形状が多層フィルム３の表面に転写される。さらに、その後に加熱冷却流路１０への蒸気の供給を止めて、代わりに冷却水を供給すると、可動型１が冷却され、それに伴って多層フィルム３および成形材料４も冷却されて固化し一体化する。そして、図５に示すように可動型１と固定型２とを開いて樹脂成形品５を取り出すことができるようになる。 In the present embodiment, the movable mold 1 is provided with a heating / cooling flow path 10. And in the manufacturing method of the above-mentioned resin molded product 5, before injecting the molding material 4 into the cavity 8, at least the cavity 8 is inserted by flowing pressurized saturated steam through the heating / cooling channel 10. The surface temperature in contact with the multilayer film 3 is heated to the glass transition temperature of the polyester resin constituting the multilayer film 3 or higher (for example, 100 ° C. or higher). For example, in the case of the polyester resin multilayer film 3 having a glass transition temperature of 80 ° C., the temperature is set in the range of 80 ° C. to 130 ° C. Thereby, the multilayer film 3 positioned in the cavity 8 is heated to the glass transition temperature or higher and softens. After that, when the molding material 4 is filled in the cavity 8, the softened multilayer film 3 is pressed against the surface of the cavity 8 of the movable mold 1 by the resin pressure at that time, and the shape of the texture 6 becomes the surface of the multilayer film 3. Is transcribed. Further, when the supply of steam to the heating / cooling flow path 10 is subsequently stopped and cooling water is supplied instead, the movable mold 1 is cooled, and the multilayer film 3 and the molding material 4 are also cooled and solidified. Turn into. Then, as shown in FIG. 5, the movable mold 1 and the fixed mold 2 are opened, and the resin molded product 5 can be taken out.
　このように、本実施形態では、金型の加熱および冷却を行うことによって、成形材料４を、短時間で効率よく、しかも表面状態が良好になるように成形することができる。その上、成形材料４の射出前に可動型１を加熱しておくことによって、可動型１のテクスチャー６を多層フィルム３の表面に良好に転写することができる。仮に、このような金型の加熱を行わないと、テクスチャー６の転写が不十分になり、優れた高級感ある風合いは得られなくなる。なお、金型のキャビティの、多層フィルム３と接触する表面の温度を、多層フィルム３のガラス転移温度以上の高温で一定に保ちつつ成形すると、良好なテクスチャー６の転写が実現できるが、樹脂成形品に変形が起こることがある。従って、前記したように、加熱冷却流路１０に冷却水を供給するなどして、成形材料４の充填後に可動型１を冷却しそれに伴って多層フィルム３および成形材料４も冷却して固化させることが好ましい。 As described above, in this embodiment, by heating and cooling the mold, the molding material 4 can be molded in a short time, efficiently and in a good surface state. In addition, the texture 6 of the movable mold 1 can be satisfactorily transferred to the surface of the multilayer film 3 by heating the movable mold 1 before the injection of the molding material 4. If such a mold is not heated, the transfer of the texture 6 becomes insufficient, and an excellent high-quality texture cannot be obtained. In addition, if the surface temperature of the mold cavity in contact with the multilayer film 3 is kept constant at a high temperature equal to or higher than the glass transition temperature of the multilayer film 3, a good texture 6 transfer can be realized. Deformation may occur in the product. Therefore, as described above, the movable mold 1 is cooled after the molding material 4 is filled by supplying cooling water to the heating / cooling flow path 10 and the multilayer film 3 and the molding material 4 are also cooled and solidified accordingly. It is preferable.
　前記したように、本実施形態では、可動型１のキャビティ８の表面の全面または一部に、多層フィルム３の表面に転写するための微細な凹凸（テクスチャー６）が形成されているが、これは、エッチング、サンドブラスト、切削加工等により形成させておくことができる。このテクスチャー６は、具体的には、いわゆるシボや加工溝やヘアライン等である。一般に、金型に設けられたシボ、加工溝、またはヘアラインの少なくとも１つを含むテクスチャーは、周期の異なる複数の凹凸の重ね合わせから成り立っている。このようなテクスチャーは深さ２～１００μｍの範囲で施されることが一般的である。通常行われているフィルムインサート成形では、金型のキャビティの表面の温度がフィルムのガラス転移温度よりも低い状態で成形が行われるため、小さい周期のテクスチャーが転写できない。すなわち、金型の加熱を行わない場合には、比較的大きい凹凸は転写されても微細な凹凸は転写されない。例えば、カットオフ値Ｌが０．８ｍｍの場合には表面粗さＲａの測定値が４μｍ程度になる（Ｒａ≧Ｌ／２００になる）が、カットオフ値Ｌが０．０８ｍｍの場合には表面粗さＲａの測定値が２μｍ程度になり（Ｒａ＜Ｌ／２００になり）、微細領域での転写が不十分になる。これに対し、本実施形態では、可動型１のキャビティ８の表面の温度を多層フィルム３のガラス転移温度以上に加熱して成形を行うので、カットオフ値Ｌが０．０８～０．８ｍｍの広い範囲でＲａ≧５Ｌ／１０００、すなわちＲａ≧Ｌ／２００となる。実用的には、表面粗さＲａを、カットオフ値Ｌ（ｍｍ）の単位を外した値を５倍して単位（μｍ）を付けた数値以上になるようにすればよい。そして、より好ましくはＲａ≧７Ｌ／１０００、さらに好ましくはＲａ≧Ｌ／１００とする。なお、表面粗さＲａの上限値は、その樹脂成形品に求められる装飾性（意匠性）によって任意に決められる。 As described above, in this embodiment, fine unevenness (texture 6) for transferring to the surface of the multilayer film 3 is formed on the entire surface or a part of the surface of the cavity 8 of the movable mold 1. Can be formed by etching, sandblasting, cutting, or the like. Specifically, the texture 6 is a so-called wrinkle, a processed groove, a hairline, or the like. In general, a texture including at least one of a texture, a processing groove, or a hairline provided in a mold is formed by overlapping a plurality of irregularities having different periods. Such a texture is generally applied in a depth range of 2 to 100 μm. In film insert molding that is usually performed, molding is performed in a state where the temperature of the surface of the mold cavity is lower than the glass transition temperature of the film, and therefore textures with a small period cannot be transferred. That is, when the mold is not heated, even if relatively large unevenness is transferred, fine unevenness is not transferred. For example, when the cut-off value L is 0.8 mm, the measured value of the surface roughness Ra is about 4 μm (Ra ≧ L / 200), but when the cut-off value L is 0.08 mm, the surface The measured value of roughness Ra becomes about 2 μm (Ra <L / 200), and transfer in a fine region becomes insufficient. On the other hand, in the present embodiment, the molding is performed by heating the surface temperature of the cavity 8 of the movable mold 1 to be equal to or higher than the glass transition temperature of the multilayer film 3, so that the cutoff value L is 0.08 to 0.8 mm. In a wide range, Ra ≧ 5 L / 1000, that is, Ra ≧ L / 200. Practically, the surface roughness Ra may be set to a value equal to or greater than a value obtained by multiplying a value obtained by removing the unit of the cut-off value L (mm) by 5 and adding a unit (μm). More preferably, Ra ≧ 7L / 1000, and further preferably Ra ≧ L / 100. The upper limit value of the surface roughness Ra is arbitrarily determined depending on the decorativeness (designability) required for the resin molded product.
　そして、本発明によれば、金型に施されたテクスチャーが樹脂成形品に忠実に転写され、樹脂成形品の表面粗さＲａは金型のキャビティの表面粗さＲａｍ（例えばカットオフ値０．０８ｍｍにおいて０．１μｍ～１０μｍ）の０．８倍～１．２倍の範囲となる。樹脂成形品の表面粗さＲａが金型のキャビティの表面粗さＲａｍの０．８倍よりも小さいと良好な質感が得られず、１．２倍よりも大きいと、光線の方向によって輝度のばらつきが出やすい。前記したＲａ≧Ｌ／２００（ただしカットオフ値Ｌが０．０８～０．８ｍｍ）という条件と０．８×Ｒａｍ≦Ｒａという条件のいずれかに基づいて樹脂成形品の表面粗さＲａの下限値を定め、Ｒａ≦１．２×Ｒａｍという条件に基づいて上限値を定めるようにしてもよい。 According to the present invention, the texture applied to the mold is faithfully transferred to the resin molded product, and the surface roughness Ra of the resin molded product is equal to the surface roughness Ram of the mold cavity (for example, a cutoff value of 0. 0). The range is 0.8 times to 1.2 times of 0.1 μm to 10 μm at 08 mm. If the surface roughness Ra of the resin molded product is less than 0.8 times the surface roughness Ram of the mold cavity, a good texture cannot be obtained. Variations are likely to occur. The lower limit of the surface roughness Ra of the resin molded product based on either the above-mentioned conditions Ra ≧ L / 200 (where the cutoff value L is 0.08 to 0.8 mm) or 0.8 × Ram ≦ Ra. A value may be determined, and an upper limit value may be determined based on a condition of Ra ≦ 1.2 × Ram.
　なお、可動型１のキャビティ８の表面の加熱温度は、多層フィルム３を構成するポリエステル樹脂のガラス転移温度や粘弾性特性に応じて設定されるが、少なくともそのポリエステル樹脂のガラス転移温度以上に設定されるべきであり、ポリエステル樹脂の損失弾性率が５００ＭＰａ以下となる温度が選択される。すなわち、ポリエステル樹脂の積層体の貯蔵弾性率は、引っ張りモードの動的粘弾性測定装置を用いて温度依存データとして得ることができる。そのデータに基づいて考察すると、ポリエステル樹脂の１００℃における貯蔵弾性率と２００℃における貯蔵弾性率の比の値が１０以下であると、圧空成形時あるいは真空成形時にバランス良く腑形できる。また、ポリエステル樹脂の１００℃から２００℃の温度範囲における損失弾性率が５００ＭＰａ以下の範囲にあると、前記したように可動型１のテクスチャー６が転写されやすい。転写フィルム３は、２種類以上のポリエステル樹脂によって構成されているので、各ポリエステル樹脂のうち、前記した考察によって求められた温度が高い方のポリエステル樹脂に合わせて、可動型１の加熱温度を設定すればよい。 In addition, although the heating temperature of the surface of the cavity 8 of the movable mold 1 is set according to the glass transition temperature and the viscoelastic property of the polyester resin constituting the multilayer film 3, it is set to at least the glass transition temperature of the polyester resin. The temperature at which the loss elastic modulus of the polyester resin is 500 MPa or less is selected. That is, the storage elastic modulus of the polyester resin laminate can be obtained as temperature-dependent data using a tensile mode dynamic viscoelasticity measuring apparatus. Considering based on the data, when the ratio of the storage elastic modulus at 100 ° C. to the storage elastic modulus at 200 ° C. of the polyester resin is 10 or less, the polyester resin can be formed in a well-balanced manner at the time of pressure forming or vacuum forming. Further, when the loss elastic modulus in the temperature range of 100 ° C. to 200 ° C. of the polyester resin is in the range of 500 MPa or less, the texture 6 of the movable mold 1 is easily transferred as described above. Since the transfer film 3 is composed of two or more kinds of polyester resins, the heating temperature of the movable mold 1 is set in accordance with the polyester resin having the higher temperature determined by the above-described consideration among the polyester resins. do it.
　金型の加熱方法としては、前記したように加熱冷却流路１０に蒸気、加圧水、または加熱オイル等の熱媒体を流す方法に加えて、電熱ヒーターを用いる方法や、誘導加熱により加熱する方法や、炎で加熱する方法を用いることもでき、さらに、それらの方法を組み合わせた方法を用いることもできる。また、射出充填終了後の金型の冷却は、多層フィルム３および成形材料（本体部分）４を金型から取り出せる程度に冷却固化させられるまで行う必要がある。当然のことながら、冷却温度が低いほど短時間で多層フィルム３および成形材料４の取り出しが可能になる。金型の冷却は、前記したように冷却水を用いて行うのが一般的である。そして、金型の加熱を蒸気や加圧水を用いて行い、かつ金型の冷却を冷却水によって行う場合には、図示されている実施形態のように、加熱媒体用かつ冷却媒体用の共通の流路（加熱冷却流路１０）を用いることができる。ただし、このような構成に限定されるわけではない。 As a heating method of the mold, in addition to the method of flowing a heat medium such as steam, pressurized water, or heating oil through the heating and cooling channel 10 as described above, a method using an electric heater, a method of heating by induction heating, Further, a method of heating with a flame can be used, and a method combining these methods can also be used. Moreover, it is necessary to cool the mold after completion of injection filling until the multilayer film 3 and the molding material (main body part) 4 are cooled and solidified to such an extent that they can be taken out from the mold. As a matter of course, the lower the cooling temperature, the faster the multilayer film 3 and the molding material 4 can be taken out. As described above, the mold is generally cooled using cooling water. When the mold is heated with steam or pressurized water and the mold is cooled with cooling water, a common flow for the heating medium and the cooling medium is used as in the illustrated embodiment. A channel (heating / cooling channel 10) can be used. However, it is not necessarily limited to such a configuration.
　本実施形態の樹脂成形品の一部（本体部分）を構成する成形材料４としては、アクリル樹脂、ポリスチレン、ＡＢＳ樹脂、ポリカーボネート、ポリアミド、ポリプロピレン、ＰＢＴ樹脂、ポリ乳酸、環状オレフィンポリマー（または環状オレフィンコポリマー）や、これらの混合物等が用いられるのが好ましい。成形材料４は、最終製品である樹脂成形品における特性に悪影響がない範囲で流動性の高いものであると、剪断発熱によるフィルムへのダメージが起こりにくいため好ましい。ただし、これら以外の熱可塑性樹脂を用いてもよい。また、これらの成形材料４に、粒子状または繊維状のフィラーや、耐衝撃性改良材などの補強材や、顔料や染料等の色材や、難燃剤や、耐候安定剤や、酸化防止剤等の添加剤が添加されていてもよい。 As the molding material 4 constituting a part (main body part) of the resin molded product of this embodiment, acrylic resin, polystyrene, ABS resin, polycarbonate, polyamide, polypropylene, PBT resin, polylactic acid, cyclic olefin polymer (or cyclic olefin) A copolymer) or a mixture thereof is preferably used. It is preferable that the molding material 4 has a high fluidity within a range that does not adversely affect the characteristics of the resin molded product that is the final product because the film is hardly damaged by shearing heat generation. However, other thermoplastic resins may be used. Further, these molding materials 4 include particulate or fibrous fillers, reinforcing materials such as impact resistance improving materials, coloring materials such as pigments and dyes, flame retardants, weathering stabilizers, and antioxidants. Additives such as may be added.
　以下、本発明のより具体的な例について説明する。 Hereinafter, more specific examples of the present invention will be described.
　［例１］
　ポリエステル樹脂からなる多層フィルム３（東レ株式会社製ＰＩＣＡＳＵＳ１８８μｍ、ガラス転移温度：８０℃）に、図示しないが、スクリーン印刷により、ウレタン系インキ（帝国インキ製造株式会社製ＴＡＳインキ）の印刷層（着色層）と、バインダー層（帝国インキ製造製ＩＭＢバインダー）を順番に形成した。この印刷層およびバインダー層を有する多層フィルム３を、印刷層およびバインダー層側を上にして、Nibling社製の超高圧空成形機にセットして圧空成形による予備賦形を行った。具体的には、多層フィルム３の表面温度が１２０℃（ヒーターの設定温度が２００℃）、成形圧力が１０ＭＰａの条件で圧空成形を行い、その後に圧空成形品の周囲を打抜いて、多層フィルム３を、深さ６ｍｍの凹状であって、角部に半径５ｍｍの円弧を有する１００ｍｍ×５０ｍｍの長方形状に形成した。 [Example 1]
Printed layer (colored layer) of urethane ink (TAS ink manufactured by Teikoku Mfg. Co., Ltd.) by screen printing on multilayer film 3 made of polyester resin (PICASUS188 μm manufactured by Toray Industries, Inc., glass transition temperature: 80 ° C.) (not shown) ) And a binder layer (IMB binder manufactured by Teikoku Ink Manufacturing Co., Ltd.) were formed in order. The multilayer film 3 having the printing layer and the binder layer was set on an ultrahigh pressure blank molding machine manufactured by Nibling with the printing layer and the binder layer side up, and pre-shaped by pressure molding. Specifically, the multilayer film 3 is subjected to pressure forming under the conditions that the surface temperature of the multilayer film 3 is 120 ° C. (the heater set temperature is 200 ° C.) and the molding pressure is 10 MPa, and then the periphery of the compressed air molded product is punched. 3 was formed into a 100 mm × 50 mm rectangular shape having a concave shape with a depth of 6 mm and an arc having a radius of 5 mm at the corner.
　このように予備賦形した多層フィルム３を、金型（例えば可動型１）のキャビティ８内にインサートした。このキャビティ８の表面には、表面粗さＲａｍ＝０．９５ｍｍ（カットオフ値Ｌ＝０．０８）のシボが形成されている。このキャビティ８の表面温度を１００℃まで昇温した状態で、成形材料４としてＡＢＳ樹脂（日本エイアンドエル株式会社製ＳＴ１２０、メルトボリュームフローレート：２９（測定条件：２２０℃、１０ｋｇ））をキャビティ８内に射出し、インサート成形を行った。成形材料４をキャビティ８内に充填させた後に、キャビティ８の表面温度を５０℃まで下げて、多層フィルム３と成形材料４が一体化した樹脂成形品５を取り出した。キャビティ８の形状は、予備賦形した多層フィルム３に一致する、深さ６ｍｍの凹状で角部に半径５ｍｍの円弧を有する１００ｍｍ×５０ｍｍの長方形状である。当然のことながら製造された樹脂成形品５は同じ形状であり、肉厚は１．５ｍｍである。 The multilayer film 3 preliminarily shaped in this way was inserted into the cavity 8 of a mold (for example, the movable mold 1). On the surface of the cavity 8, a grain having a surface roughness Ram = 0.95 mm (cut-off value L = 0.08) is formed. With the surface temperature of the cavity 8 raised to 100 ° C., an ABS resin (ST120 manufactured by Nippon A & L Co., Ltd., melt volume flow rate: 29 (measurement conditions: 220 ° C., 10 kg)) is used as the molding material 4 in the cavity 8. Were injected and subjected to insert molding. After filling the molding material 4 into the cavity 8, the surface temperature of the cavity 8 was lowered to 50 ° C., and the resin molded product 5 in which the multilayer film 3 and the molding material 4 were integrated was taken out. The shape of the cavity 8 is a rectangular shape of 100 mm × 50 mm having a concave shape with a depth of 6 mm and an arc with a radius of 5 mm at the corners, which matches the preshaped multilayer film 3. Naturally, the manufactured resin molded product 5 has the same shape and a thickness of 1.5 mm.
　［例２］
　キャビティ８の表面温度を１００℃で一定に保ち、前記した例１と同様に、印刷層およびバインダー層を有し予備賦形された多層フィルム３と、ＡＢＳ樹脂からなる成形材料４とを用いてインサート成形を行って樹脂成形品を得た。 [Example 2]
The surface temperature of the cavity 8 is kept constant at 100 ° C., and similarly to Example 1 described above, the pre-shaped multilayer film 3 having the printing layer and the binder layer and the molding material 4 made of ABS resin are used. Insert molding was performed to obtain a resin molded product.
　［例３］
　キャビティ８の表面温度を５０℃で一定に保ち、前記した例１と同様に、印刷層およびバインダー層を有し予備賦形された多層フィルム３と、ＡＢＳ樹脂からなる成形材料４とを用いてインサート成形を行って樹脂成形品を得た。 [Example 3]
The surface temperature of the cavity 8 is kept constant at 50 ° C., and similarly to Example 1 described above, the pre-shaped multilayer film 3 having the printing layer and the binder layer and the molding material 4 made of ABS resin are used. Insert molding was performed to obtain a resin molded product.
　以上説明した例１～３で製造された樹脂成形品５を評価した結果を表１に示す。 Table 1 shows the results of evaluating the resin molded products 5 produced in Examples 1 to 3 described above.
Figure JPOXMLDOC01-appb-T000001
Figure JPOXMLDOC01-appb-T000001
　この表１から明らかなように、カットオフ値Ｌが０．０８ｍｍの場合に成形品の表面粗さＲａが１．０１μｍ、０．８１μｍであり、しかも、カットオフ値Ｌが０．８ｍｍの場合に成形品の表面粗さＲａが１５．５μｍ、１４．６μｍである例１，２の構成によると、いずれもＲａ≧Ｌ／２００となり、良好なヘアライン質感が得られた。これに対して、例３では、カットオフ値Ｌが０．０８ｍｍの場合に成形品の表面粗さＲａが０．３８μｍであり、Ｒａ＜Ｌ／２００となり、好ましくないテカリ（無用な光沢）が生じた。また、例１では、金型の冷却を行っているため、例２に比べて樹脂成形品の変形を防げるという効果がある。 As apparent from Table 1, when the cut-off value L is 0.08 mm, the surface roughness Ra of the molded product is 1.01 μm and 0.81 μm, and the cut-off value L is 0.8 mm. According to the configurations of Examples 1 and 2 in which the surface roughness Ra of the molded product was 15.5 μm and 14.6 μm, Ra ≧ L / 200 for both, and a good hairline texture was obtained. On the other hand, in Example 3, when the cut-off value L is 0.08 mm, the surface roughness Ra of the molded product is 0.38 μm, and Ra <L / 200, which is undesirable shine (useless gloss). occured. Further, in Example 1, since the mold is cooled, there is an effect that deformation of the resin molded product can be prevented as compared with Example 2.

Claims (8)

  1. 　少なくとも２種類のポリエステル樹脂が１００層以上積層された多層フィルムを、金型のキャビティ内に挿入し、前記多層フィルムが挿入された前記キャビティに、樹脂からなる溶融状態の成形材料を射出し、前記成形材料を固化させて前記多層フィルムと一体化させることにより、表面の少なくとも一部に前記多層フィルムが位置する樹脂成形品を形成する、樹脂成形品の製造方法。 A multilayer film in which at least 100 layers of at least two kinds of polyester resins are laminated is inserted into a cavity of a mold, and a molten molding material made of resin is injected into the cavity into which the multilayer film is inserted, A method for producing a resin molded product, wherein a molding material is solidified and integrated with the multilayer film to form a resin molded product in which the multilayer film is located on at least a part of the surface.
  2. 　前記成形材料の射出開始前に、前記金型のキャビティの、挿入された前記多層フィルムと接触する表面の温度を、前記多層フィルムのガラス転移温度以上に昇温しておく、請求の範囲第１項に記載の樹脂成形品の製造方法。 Before starting the injection of the molding material, the temperature of the surface of the mold cavity in contact with the inserted multilayer film is raised to the glass transition temperature of the multilayer film or higher. The manufacturing method of the resin molded product of description.
  3. 　前記キャビティの、挿入された前記多層フィルムと接触する表面の全面または一部に、シボ、加工溝、またはヘアラインの少なくとも１つを含むテクスチャーを形成しておく、請求の範囲第１項または第２項に記載の樹脂成形品の製造方法。 The texture including at least one of a texture, a processing groove, and a hairline is formed on the entire surface or a part of the surface of the cavity that contacts the inserted multilayer film. The manufacturing method of the resin molded product of description.
  4. 　表面の少なくとも一部に位置する、少なくとも２種類のポリエステル樹脂が１００層以上積層された多層フィルムと、前記多層フィルムと一体化している樹脂からなる本体部分とからなる、樹脂成形品。 A resin molded product comprising a multilayer film in which at least 100 layers of at least two kinds of polyester resins are laminated on at least a part of the surface, and a main body portion made of a resin integrated with the multilayer film.
  5. 　前記多層フィルムの全面または一部に、シボ、加工溝、またはヘアラインの少なくとも１つを含むテクスチャーが転写されている、請求の範囲第４項に記載の樹脂成形品。 The resin molded product according to claim 4, wherein a texture including at least one of a texture, a processed groove, and a hairline is transferred to the entire surface or a part of the multilayer film.
  6. 　表面の少なくとも一部が厚さ５０μｍ以上のポリエステル樹脂の層からなり、前記ポリエステル樹脂の層の全面または一部に、シボ、加工溝、またはヘアラインの少なくとも１つを含むテクスチャーが転写されており、
    　表面粗さ（Ｒａ）とカットオフ値（Ｌ）が、
    　　０．０８（ｍｍ）≦Ｌ≦０．８（ｍｍ）において、Ｒａ≧Ｌ／２００
    　の関係を有する、樹脂成形品。     At least a part of the surface is composed of a polyester resin layer having a thickness of 50 μm or more, and a texture including at least one of a texture, a processed groove, or a hairline is transferred to the entire surface or a part of the polyester resin layer,
    Surface roughness (Ra) and cutoff value (L) are
    When 0.08 (mm) ≦ L ≦ 0.8 (mm), Ra ≧ L / 200
    A resin molded product having the relationship
  7. 　表面の少なくとも一部が厚さ５０μｍ以上のポリエステル樹脂の層からなり、前記ポリエステル樹脂の層の全面または一部に、シボ、加工溝、またはヘアラインの少なくとも１つを含むテクスチャーが転写されている樹脂成形品であって、
    　前記樹脂成形品の表面粗さ（Ｒａ）が、前記樹脂成形品を成形するための金型のキャビティの表面粗さ（Ｒａｍ）に対して、
    　　０．８×Ｒａｍ≦Ｒａ≦１．２×Ｒａｍ
    　の関係を有する、樹脂成形品。     Resin in which at least a part of the surface is made of a polyester resin layer having a thickness of 50 μm or more, and a texture including at least one of a texture, a processed groove, or a hairline is transferred to the entire surface or part of the polyester resin layer. A molded article,
    The surface roughness (Ra) of the resin molded product is relative to the surface roughness (Ram) of the mold cavity for molding the resin molded product.
    0.8 × Ram ≦ Ra ≦ 1.2 × Ram
    A resin molded product having the relationship
  8. 　前記ポリエステル樹脂の層は、屈折率が異なる２種類以上のポリエステル樹脂が１００層以上積層された積層体である、請求の範囲第６項または第７項に記載の樹脂成形品。 The resin molded article according to claim 6 or 7, wherein the polyester resin layer is a laminate in which two or more kinds of polyester resins having different refractive indexes are laminated.
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