WO2014083732A1 - インモールド成形方法とインモールド転写フィルムおよびその製造方法 - Google Patents
インモールド成形方法とインモールド転写フィルムおよびその製造方法 Download PDFInfo
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- WO2014083732A1 WO2014083732A1 PCT/JP2013/005522 JP2013005522W WO2014083732A1 WO 2014083732 A1 WO2014083732 A1 WO 2014083732A1 JP 2013005522 W JP2013005522 W JP 2013005522W WO 2014083732 A1 WO2014083732 A1 WO 2014083732A1
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- mold
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- coat layer
- transfer film
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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
- B29C45/14—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
- B29C45/14827—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 using a transfer foil detachable from the insert
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B11/00—Making preforms
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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
- B29C45/14—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
- B29C45/14262—Clamping or tensioning means for the insert
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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
- B29C45/72—Heating or cooling
- B29C45/7207—Heating or cooling of the moulded articles
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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
- B29C45/14—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
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- 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
- B29K2101/00—Use of unspecified macromolecular compounds as moulding material
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- 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
- B29K2703/00—Use of resin-bonded materials for preformed parts, e.g. inserts
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- 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
- B29K2715/00—Condition, form or state of preformed parts, e.g. inserts
- B29K2715/006—Glues or adhesives, e.g. hot melts or thermofusible adhesives
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- 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
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
- B29K2995/002—Coloured
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- 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
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0037—Other properties
- B29K2995/0087—Wear resistance
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- 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
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- 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
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
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- 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
- B29L2031/762—Household appliances
Definitions
- the present invention relates to an in-mold molding method and an in-mold transfer film that are used for manufacturing exterior products such as home appliances and automobile parts.
- FIG. 16 shows a general layer structure of the in-mold transfer film 33.
- This in-mold transfer film 33 includes a carrier film 30 composed of the base film 1 and the release layer 2, and a transfer section 31 composed of the hard coat layer 3 and the print layer 32.
- the print layer 32 includes an anchor layer 4, a colored layer 5, and an adhesive layer 6.
- the base film 1 is a film serving as a base constituting the in-mold transfer film 33, and each layer is formed thereon.
- the release layer 2 has a role of cleanly separating the transfer portion 31 formed thereon.
- the role of the hard coat layer 3 of the transfer unit 31 protects the molded product from scratches, dust, and the like by the outermost surface layer of the in-mold molded product.
- the anchor layer 4 serves to join the hard coat layer 3 and the colored layer 5.
- the anchor layer 4 has a function of adsorbing or fixing the ink in the colored layer 5, it is not necessary when the ink itself can be directly bonded to the hard coat layer 3.
- the colored layer 5 is a layer for decorating the design of the molded product, the pattern configuration for imparting the pattern, the layer configuration varies from single layer to multiple layers depending on the configuration of the pattern, gravure printing, screen printing, solvent-based inkjet printing Etc. are formed.
- the adhesive layer 6 has a role for bonding the colored layer 5 and the injection resin and a role for protecting the ink in the colored layer 5 from being washed away by the high temperature and high pressure injection resin.
- FIG. 17A An in-mold transfer film 33 with a design and a pattern is pulled out from a fitting (not shown) and supplied between the movable mold 101 and the fixed mold 102, and the transfer section 31. Is fed to the mold so that the side of the mold faces the injection port 41 of the fixed mold 102.
- the carrier part 30 faces the movable mold 101.
- the in-mold transfer film 33 is sucked and fixed along the molding surface of the movable mold 101, and is shaped along the mold surface shape of the movable mold 101. Thereafter, the movable mold 101 moves, the movable mold 101 is clamped with the fixed mold 102, and a cavity space 103 is formed between the transfer unit 31 and the fixed mold 102.
- high-temperature and high-pressure molding resin 104 is injected into the cavity space 103 toward the transfer side 31 and joined to the transfer unit 31.
- FIG. 17D in the step of taking out the molded product 105 cooled to the mold temperature, it is peeled off between the release layer 2 and the hard coat layer 3 at the time of mold opening and taken out from the mold. At this time, since the transfer portion 31 is transferred to the surface of the molded product 105, the hard coat layer 3 becomes the outermost surface of the molded product 105, and the molded product 105 in a form in which the transfer portion 31 and the molding resin 104 are integrated. Is obtained.
- the transfer film follows the base film 1 on this side surface extending along the shape of the molded product. 31 needs to be stretched while being in close contact with the carrier part 30, but when the hard coat layer 3 is poorly stretched, the hard coat layer 3 breaks in the middle of the elongation, and the print layer 32 is cracked.
- the release layer 2 and the hard coat layer 3 are not peeled off in the close contact state at the time of mold opening, and the carrier part 30 is separated from the molded product, and the print layer 2 has the inside. Delamination occurs at.
- the present invention solves the above-mentioned conventional problems.
- the hard coat layer does not break, and the hard coat layer does not break at the stage of mold opening.
- In-mold that can be reliably broken at the end of the side surface of the molded product and can create a stable peeled state without causing cracks in the printed layer, delamination in the printed layer, and foil burrs. It aims at providing a shaping
- the in-mold molding method of the present invention includes a preheating step of preheating an in-mold transfer film having a release layer, a hard coat layer, and a printing layer on a base film, and the in-mold transfer film is disposed in a cavity of an injection mold.
- the in-mold molding method comprising: a mold opening step for obtaining a molded product obtained by transferring the hard coat layer peeled off from the base film and the printed layer onto a transfer surface.
- the required elongation percentage of the mold transfer film is A%, and in the mold opening step, the breaking elongation of the hard coat layer on the side surface of the molded product is % + 2% or more, in the range of less than the A% + 40%, and performing the breaking of the hard coat layer.
- the in-mold transfer film of the present invention is an in-mold transfer film used when performing in-mold molding with an injection mold, and has a release layer, a hard coat layer, and a print layer on the base film,
- the required elongation percentage of the in-mold transfer film on the side surface of the molded product molded by the injection mold is A%
- the temperature of the in-mold transfer film is the mold opening of the injection mold used for in-mold molding.
- the breaking elongation of the hard coat layer is within the range of A% + 2% or more and less than A% + 40%.
- the manufacturing method of the in-mold transfer film of the present invention is a manufacturing method of an in-mold transfer film used when performing in-mold molding with an injection mold, and includes a release layer and a hard coat layer on a base film.
- the in-mold transfer film has a printing layer
- the hard coat layer is made of an ultraviolet curable resin
- the required elongation percentage of the in-mold transfer film on the side surface of the molded product molded by the injection mold is A%.
- the breaking elongation of the hard coat layer is not less than A% + 2% and less than A% + 40%.
- the integrated irradiation amount of the ultraviolet rays to the hard coat layer is adjusted so as to fall within the range.
- the in-mold transfer film maintains the adhesiveness against the elongation for following the shape of the molded product, and the transfer portion composed of the print layer and the hard coat layer is the base material. It is stretched neatly following the elongation of the carrier part consisting of the film and release layer.
- the hard coat layer of the transfer part is broken at the end of the side of the molded product at the moment the in-mold transfer film is stretched by opening the mold. Is formed at the end of the side surface of the molded product, and the hard coat layer is peeled off from the carrier portion without causing “foil burrs” over the entire periphery of the molded product based on the starting point.
- the hard coat layer is surely broken at the end of the side surface of the molded product, and the carrier part of the in-mold transfer film is separated from the molded product. Since the starting point of peeling can be the end of the side surface of the molded product, a stable peeling state can be created without causing foil burrs or transfer defects.
- the temperature rise of the breaking elongation of the hard coat layer at a temperature equal to or higher than the mold opening temperature is adjusted by adjusting the cumulative amount of ultraviolet rays according to the mold opening temperature.
- the in-mold transfer film that contributes to the realization of good in-mold molding can be made larger than the rate of increase in the breaking elongation of the hard coat layer at a temperature lower than the mold opening temperature. Can be supplied.
- it is metal mold
- Sectional drawing of mold of in-mold molded product in the embodiment of the present invention The figure which shows the definition of the breaking elongation of the hard-coat layer in embodiment of this invention Mold sectional view of an in-mold molded product that has been normally peeled off when the mold is opened according to an embodiment of the present invention Sectional drawing of a mold showing a peeled state of an in-mold transfer film immediately after mold opening in an embodiment of the present invention
- Sectional drawing of the molded article of the Example in embodiment of this invention The figure which shows the relationship between the hard-coat layer fracture
- the figure which shows the relationship between the hardening state of the hard-coat layer of an Example in embodiment of this invention, and peeling weight The figure which shows the example of the breaking elongation of the hard-coat layer of the Example in embodiment of this invention, and the state of peeling of a molded article.
- the figure which plotted the incidence rate of the transfer defect with respect to the design of the breaking elongation of the hard coat layer of the example in the embodiment of the present invention The figure which shows the behavior of the breaking elongation of the hard-coat layer of an Example in embodiment of this invention, and an in-mold transfer film temperature Diagram showing layer structure of in-mold transfer film The figure which shows the manufacturing process of the conventional in-mold molded product
- the print layer 32 includes an anchor layer 4, a colored layer 5, and an adhesive layer 6.
- the base film 1 is mainly made of polyethylene terephthalate (PET), but can also be constituted by using polycarbonate (PC, Polycarbonate) or oriented polypropylene (OPP).
- PET polyethylene terephthalate
- PC polycarbonate
- OPP oriented polypropylene
- the thickness is a layer of about 20 ⁇ m to 200 ⁇ m, but if it is thin, the base film 1 is likely to break when stretched. Conversely, if it is thick, the base film 1 is difficult to be deformed, so a film of about 30 ⁇ m to 100 ⁇ m is used. It is optimal to use.
- the release layer 2 is a layer having a thickness of about 0.5 to 5 ⁇ m formed using a melamine resin or a silicon resin.
- the hard coat layer 3 is a layer having a thickness of about 1 to 10 ⁇ m formed using a high-hardness ultraviolet curable resin or the like that becomes the outermost surface when the printing layer 32 is transferred to the molding resin.
- the anchor layer 4 is a layer having a thickness of about 1 to 10 ⁇ m, which is formed using a polyester resin or the like for enhancing the adhesion between the hard coat layer 3 and the colored layer 5 and imparting more advanced characteristics. is there.
- the colored layer 5 is a layer having a thickness of about 1 to 100 ⁇ m that is configured using a pigment ink having good weather resistance or a commonly used dye ink.
- the adhesive layer 6 is an in-mold resistant layer made of acrylic resin, urethane resin, vinyl resin, or the like and having a thickness of about 1 to 50 ⁇ m.
- each of the colored layer 5 and the adhesive layer 6 is not necessarily composed of a single layer, and may be composed of a plurality of overlapping layers.
- FIG. 17 showing the manufacturing process of a conventional in-mold molded product, (a) the in-mold transfer film 33 is supplied into the mold, and (b) the in-mold transfer film 33 is attracted to the movable mold 101 and fixed. The mold is clamped together with the mold 102. (C) The molding resin 104 is injected into the cavity space 103, and the injection resin and the in-mold transfer film are bonded.
- FIG. 1 shows a cross-sectional view of a state of a molded product in the manufacturing process of an in-mold molded product.
- the movable mold 101 and the fixed mold 102 are separated from each other, and the in-mold transfer film 33 composed of the base film 1, the release layer 2, the hard coat layer 3, and the printing layer 32 is movable.
- a state before the in-mold transfer film 33 is attracted to the movable mold 101 is shown in order to be supplied to the mold composed of 101 and the fixed mold 102 and to place the in-mold transfer film 33 in the cavity of the injection mold. .
- the in-mold transfer film 33 is vacuum-sucked from the suction port 42 provided in the cavity of the movable mold 101, and the in-mold transfer film 33 is sucked to the cavity surface of the movable mold 101.
- FIG. 1C shows a state in which resin is injected from the injection port 41 into the cavity space 103 and an in-mold molded product is made in the mold.
- the in-mold transfer film 33 is stretched by the inclination and depth of the shape of the side surface 34 of the molded product.
- the movable mold 101 and the in-mold transfer film 33 first contact each other, and the space between the fixed surface and the in-mold transfer film is depressurized so that the in-mold transfer film is stretched and adsorbed to the cavity surface of the movable mold 101. To do.
- FIG. 2 shows the elongation rate of the in-mold transfer film 33 on the side surface 34 of the molded product.
- the printing portion transfer surface 36 of the molding resin 104 extends over the upper surface 36 a and the side surface 34.
- FIG. 3 is a cross-sectional view of the molded product in the mold after resin filling.
- the movable mold 101 and the fixed mold 102 are clamped, and the molding resin 104 is filled on the printing layer 32 side of the in-mold transfer film 33 in the cavity space.
- the in-mold transfer film 33 adsorbed on the movable mold 101 is in a state where the base film 1 is adsorbed on the movable mold 101, but the state where the inclination of the side surface 34 of the molded product is large as shown in FIG.
- the in-mold transfer film 33 is attracted to the movable mold 101 in a stretched state.
- the base film 1, the release layer 2, the hard coat layer 3, and the print layer 32 that constitute the in-mold transfer film 33 need to be adsorbed in a state where they all extend uniformly.
- the print resin is in a good state in the molding resin. Since transfer cannot be performed, it is necessary to have a characteristic that each layer constituting the in-mold transfer film 33 extends to an elongation rate at which transfer to the shape of the molded product is possible.
- the elongation at break of each layer of the in-mold transfer film 33 is designed to be higher than the required elongation rate at which transfer to the side surface 34 of the molded product is possible.
- the elongation required for transfer to the side surface 34 of the molded product is referred to as “required elongation”.
- the base film 1 can be made difficult to break even if it is stretched and thinned by increasing the thickness. Moreover, it can also be set as the base film which is easy to extend by using the manufacturing method which stops extending
- the hard coat layer 3 can be easily stretched by using an after-curing type ultraviolet curable resin that does not completely cure.
- an after-curing type ultraviolet curable resin that does not completely cure.
- the in-mold transfer film 33 When the in-mold transfer film 33 is formed, it can be cured by heat drying or weak UV irradiation without causing any problems in the formation of the hard coat layer 3, and a state in which complete curing cannot be achieved can be created.
- the hardened state of the hard coat layer 3 can be evaluated by the peel weight.
- the elongation rate required for transfer to the side surface of the molded product can be set to be equal to or higher depending on the formation thickness and material selection. Elongation can be increased by increasing the proportion of urethane resin that is resistant to elongation.
- FIG. 5 shows a state in which the movable mold 101 and the fixed mold 102 are opened, and the transfer section 31 composed of the hard coat layer 3 and the printing layer 32 is a carrier section composed of the base film 1 and the release layer 2.
- the state which peeled from 30 is shown.
- the transfer part 31 transferred to the molding resin in an ideal state when the mold is opened is peeled off at the peeling layer interface of the carrier part 30. Only the portion where the hard coat layer 3 and the printing layer 32 are bonded to the molding resin 104 side from the end portion 38 on the side surface of the molded product remains, and the transfer portion 31 not bonded to the molding resin 104 remains on the carrier portion 30 as it is. It is pulled apart while remaining.
- FIG. 6 is a mold cross-sectional view showing a peeled state of the in-mold transfer film 33 immediately after the mold opening in the embodiment of the present invention.
- the movable mold 101 and the fixed mold 102 are opened, and the transfer part 31 of the in-mold transfer film 33 is peeled off from the carrier part 30 and transferred to the molding resin 104.
- FIG. 6A shows an in-mold molded product in which the transfer part 31 is peeled off in an ideal state due to the behavior of the in-mold transfer film 33 when the mold is opened after the transfer part 31 is transferred to the molding resin 104. Indicates the state.
- FIG. 6B shows a foil in which the transfer portion 31 is attached to the outside of the side end 38 of the molded product without breaking the transfer portion 31 at the side end 38 of the molded product when the mold is opened. The state where burrs have occurred is shown.
- FIG. 6C shows a state where delamination occurs between the hard coat layer 3 and the print layer 32 in the transfer portion 31 that should be separated by the hard coat layer 3 and the release layer 2 when the mold is opened. Indicates.
- the in-mold transfer film 33 is stretched more than the required elongation rate when the mold is opened.
- the hard coat layer is also stretched, and when the elongation at breakage of the hard coat layer 3 is reached when the elongation exceeds the required elongation, the hard coat layer 3 becomes the end of the side surface of the molded product.
- the rupture starts from 38.
- the printing layer 32 forming the transfer portion 31 is smaller in thickness than the hard coat layer 3, and therefore is more easily broken than the hard coat layer 3. Since the hard coat layer 3 is ruptured due to the close contact state, the print layer 32 is also ruptured at the same time, and clean peeling can be caused at the end portion 38 on the side surface of the molded product.
- the in-mold transfer film 33 is stretched more than the required elongation when the mold is opened, but the breaking elongation of the hard coat layer 3 is large. If it is too high, the transfer portion 31 will be peeled off while remaining attached to the molded product without reaching the breaking elongation of the hard coat layer 3, that is, without breaking the hard coat layer 3. For this reason, the transfer portion 31 remains to the outside of the end portion 38 on the side surface of the molded product.
- the in-mold transfer film 33 is stretched beyond the required elongation when the mold is opened, and the hard coat layer 3 and the release layer 2 are separated.
- the adhesiveness is higher than the adhesiveness between the hard coat layer 3 and the printing layer 32, the hard coat layer 3 is not broken even when the hard coat layer 3 is stretched, and the hard coat layer 3 is attached to the release layer 2 side. Therefore, in-layer destruction occurs in the printed layer 32, and transfer failure occurs as an in-mold molded product. In this case, it is impossible to return the in-mold molded product to a normal state, and it is discarded as defective.
- FIG. 7A shows a change characteristic of the breaking elongation with respect to the temperature of the hard coat layer 3 of the in-mold transfer film 33 and an end portion 38 of the in-mold transfer film 33 in which the side surface of the molded product needs to be peeled off. It shows the elongation behavior at.
- a required elongation rate of the in-mold transfer film 33 at the end portion 38 where the side surface of the molded product needs to be peeled is indicated by A.
- a solid line B indicates a breaking elongation line of the hard coat layer 3 and broken arrows C1 to C4 indicate an elongation behavior of the in-mold transfer film 33.
- the breaking elongation of the hard coat layer 3 of the in-mold transfer film 33 has a characteristic of increasing with increasing temperature. By utilizing this characteristic, when the in-mold transfer film 33 is attracted to the movable mold 101, by increasing the temperature of the in-mold transfer film 33, the breaking elongation of the hard coat layer 3 can be increased to a value higher than the required elongation A. can do.
- the elongation at break of the hard coat layer 3 is lower than the required elongation rate A. Therefore, when the in-mold transfer film 33 is adsorbed to the movable mold 101 at this temperature, the hard coat layer 3 The print layer 32 is broken due to breakage. Therefore, the in-mold transfer film 33 is preheated to raise the temperature of the hard coat layer 3 as indicated by an arrow broken line C1. Thereby, the breaking elongation of the hard coat layer 3 is higher than the required elongation A, and the printing layer 32 is not cracked when the in-mold transfer film 33 is adsorbed to the movable mold 101.
- a radiation heating method using an infrared heater As a specific method of the preheating for increasing the temperature of the in-mold transfer film 33, when the in-mold transfer film 33 is supplied to a mold including the movable mold 101 and the fixed mold 102, a radiation heating method using an infrared heater, although a heating method using hot air can be used, it is preferable to use a radiant heating method using an infrared heater in order to promote misalignment of the film supply by hot air and adhesion of foreign matters such as dust.
- the temperature of the mold during film adsorption can be increased, but if the heater of the mold is heated, it is necessary to lower the mold temperature when taking out the molded product. Become.
- the in-mold transfer film 33 is stretched along the cavity surface of the movable mold 101 by suction as indicated by the broken line C2. Further, since the high-temperature molding resin 104 flows when the resin is filled as indicated by an arrow broken line C3, the temperature of the in-mold transfer film 33 instantaneously becomes higher, so that the in-mold transfer film 33 is completely movable. Even when there is a portion that cannot be adsorbed on the cavity surface of 101, since the elongation at break of the hard coat layer 3 is further increased by increasing the temperature of the in-mold transfer film 33, the in-mold is caused by the resin flow during resin filling. In the state where the transfer film 33 is stretched, there is little possibility that the printing layer 32 will crack.
- the temperature of the in-mold transfer film 33 adhered to the molded product is almost the mold temperature as indicated by the broken line C4.
- the elongation of the in-mold transfer film 33 is equal to or less than the breaking elongation of the hard coat layer 3, but the end portion 38 that requires peeling of the side surface of the molded product when the mold is opened is locally as shown by the broken line C5. Therefore, after the transfer part 31 is normally transferred to the molded product after the injection molding, the peeling start point of the hard coat layer 3 can be easily formed at the end of the side surface of the molded product. 38 can be made.
- the term “locally extended” means that the portion C corresponding to the thickness of the hard coat layer 3 at the end portion 38 where the side surface of the molded product needs to be peeled off, as shown in FIGS. 8 (a) and 8 (b). It is done.
- the mold temperature is used at a temperature that stabilizes the resin flow of the injection molded resin, the mold temperature is set by the resin flowability in normal injection molding. However, after injection molding, the mold temperature can be intentionally lowered, but a cooling circuit is required as described above.
- the breaking elongation of the hard coat layer 3 is set to be equal to or higher than the necessary elongation A with respect to the necessary elongation A by raising the film temperature. be able to.
- the breaking elongation of the hard coat layer 3 is lowered by lowering the temperature of the in-mold transfer film 33. It can be set below the required elongation A. Thereby, the stability of peeling of the hard coat layer 3 at the end 38 on the side surface of the molded product can be increased.
- the in-mold transfer film 33 in each part of the molded product may have various elongation rates, and it is considered that there is a portion having a higher elongation rate than the end portion 38 on the side surface of the molded product.
- the hard coat layer breaking elongation line B is another region in the right side of the mold surface temperature when the mold is opened. It is advantageous to have a greater increase than in the region.
- the required elongation rate of the in-mold transfer film 33 at a certain part of the molded product is an elongation rate AA higher than the required elongation rate A at the end 38 on the side surface of the molded product.
- the degree line B has a high elongation at break even near the mold opening temperature as shown in FIG.
- the increase rate of the elongation at break of the hard coat layer 3 with respect to the temperature rise is equal to or higher than the surface temperature when the mold used for in-mold molding is opened, and higher than the temperature. Those with characteristics are effective.
- FIG. 10 shows a cross-sectional shape of the molded product 105 of the example.
- This molded product is in-mold molded by inserting and transferring the in-mold transfer film 33 into a mold.
- the configuration of the in-mold transfer film 33 used at this time is such that a release layer 2 made of a resin mainly composed of melamine having a thickness of about 1 ⁇ m is formed on the surface of the PET base film 1 having a thickness of 50 ⁇ m.
- a hard coat layer 3 of an ultraviolet curing resin of 5 ⁇ m after cure type was formed.
- An anchor layer 4 of about 1 ⁇ m is formed on the hard coat layer 3, a colored layer 5 of about 5 ⁇ m is formed by gravure printing, and an adhesive layer 6 of about 2 ⁇ m is formed. At this time, each layer is formed using a gravure coat.
- the elongation at break was changed by changing the curing conditions after the coating of the hard coat layer 3. Since the hard coat layer 3 is formed of an ultraviolet curable resin, the progress of the curing reaction of the hard coat layer 3 can be changed by irradiation power and irradiation time in ultraviolet irradiation. If the ultraviolet irradiation is increased, the hard coat layer 3 is hardened and the breaking elongation is lowered. Conversely, if the ultraviolet irradiation is weakened, the hard coat layer 3 is not hardened and the breaking elongation is increased.
- the cured state in the state of the in-mold transfer film is formed as a layer, but has the property of stretching.
- the metal halide lamp was used for ultraviolet irradiation, but in the ultraviolet irradiation, a mercury lamp or an ultraviolet light-emitting diode lamp can also be used.
- FIG. 11 shows the results of measuring the elongation at break of the hard coat layer 3 at a film temperature of 60 ° C. with respect to the integrated amount of ultraviolet irradiation.
- the integrated irradiation dose is less than 85 mJ / cm 2 , the hard coat layer 3 is not hardened, so that the elongation at break cannot be evaluated correctly. Therefore, it is not measured as data.
- the integrated irradiation amount increases, the hard coat layer 3 is cured, and is almost completely cured at about 500 mJ / cm 2 .
- irradiation is performed so that the hard coat layer 3 is in a semi-cured state at 85 mJ / cm 2 or more and less than 456 mJ / cm 2 , and the in-mold transfer film 33 is formed in a state where the breaking elongation of the hard coat layer 3 is changed. did.
- FIG. 12 is a graph obtained by measuring the correlation between the cured state of the hard coat layer 3 and the peel weight.
- the peeling weight was determined by cutting the in-mold transfer film 33 of each sample into a strip shape with a width of 19 mm, attaching the in-mold transfer film 33 on a hot plate at 100 ° C. with a double-sided tape, and then a speed of 180 mm / min. Then, while peeling at an angle of 90 degrees, the tensile strength was measured with a load cell as a load converter, and converted into a peel weight per 1 mm width and plotted.
- the peel weight increases and the hard coat layer 3
- the peel weight is reduced and the cured state of the hard coat layer 3 is increased.
- the in-mold transfer film 33 was heated once by an infrared heater installed at the upper part of the mold and heated to 280 ° C., and the surface temperature of the in-mold transfer film 33 was about 85 ° C. and supplied to the mold. . Thereafter, an ABS resin having a resin temperature of 230 ° C. was injected into the mold and molded at a mold temperature of 60 ° C.
- FIG. 13 shows a state of the molding result of the in-mold molded product with respect to the breaking elongation of the hard coat layer 3 when the required elongation rate of the in-mold transfer film 33 is 110%.
- FIG. 14 shows the inferior transfer to the breaking elongation of the hard coat layer 3 at 60 ° C. when an in-mold molded product having a required elongation rate of 110% at the end surface of the molded product is opened and molded at a temperature of 60 ° C. It is the figure which showed the incidence rate.
- the surface state of the molded product taken out after in-mold molding was visually observed to check for molding defects.
- the side face of the molded product which is prone to transfer defects, was mainly observed.
- About the crack of the fine printed layer it observed in detail by magnifying and observing several times with an optical microscope.
- the breaking elongation of the hard coat layer 3 is less than 112%, the breaking elongation is insufficient with respect to the required elongation of 110%. Therefore, when the in-mold transfer film 33 is adsorbed to the movable mold 101, the hard coat layer 3 3 breaks. Therefore, the printed layer 32 was cracked.
- the elongation at break of 112% is required for the required elongation of 110% because the elongation corresponding to the thickness of the hard coat layer 3 at the end portion 38 where the side surface of the molded product needs to be peeled off is necessary. This is thought to be necessary.
- the breaking elongation of the hard coat layer 3 is 112% or more and less than 120%, the breaking elongation is substantially the same as the required elongation A, but the temperature at the time of adsorption of the in-mold transfer film 33 is Some cracks of the printed layer 32 occurred due to variations in vacuum adsorption force. However, the defect rate within the allowable range was 5% or less.
- the breaking elongation of the hard coat layer 3 is 120% or more and less than 135%, the breaking elongation is sufficient with respect to the elongation at the time of adsorption, and the in-mold transfer film 33 is further 10% to 30% when the mold is opened. %, The hard coat layer 3 was broken, and ideal peeling could be realized starting from the end 38 on the side surface of the molded product.
- the breaking elongation of the hard coat layer 3 is 135% or more and less than 150%, the hard coat layer 3 does not break even when the in-mold transfer film 33 is further stretched by 30% or more when the mold is opened. Has started to occur, causing the appearance of the molded product to be defective due to the scattering of foil burrs and the adhesion of the movable mold 101 to the cavity surface. Further, when the adhesion between the hard coat layer 3 and the release layer 2 is higher than the adhesion between the hard coat layer 3 and the printing layer 32, the release does not break even when the hard coat layer 3 is stretched.
- the hard coat layer 3 remains in the state where the hard coat layer 3 is adhered to the side of the molded product, delamination occurs in the printed layer 32 due to the hard coat layer 3 remaining on the release layer 2 side at the end 38 on the side surface of the molded product. .
- the above-mentioned defect phenomenon partially occurred due to variations in temperature and mold opening speed during mold opening.
- the defect rate within the allowable range was 5% or less.
- the breaking elongation of the hard coat layer 3 was 150% or more, the state was further deteriorated, and the occurrence rate of transfer failure was further increased.
- the adhesiveness between the hard coat layer 3 and the release layer 2 is such that the more easily the hard coat layer 3 is stretched, the better the followability with respect to the elongation of the in-mold transfer film 33 is. In general, the higher the breaking elongation, the higher the tendency for the adhesiveness to be exhibited. If the hard coat layer 3 is peeled off from the release layer 2 on the side other than the side surface of the molded product, the end of the side surface of the molded product does not become the starting point of the peeling, so that foil burr is likely to occur.
- the breaking elongation of the hard coat layer 3 of the in-mold transfer film 33 at the temperature at which the in-mold transfer film 33 is separated from the molded product with respect to the required elongation of 110% is obtained.
- the transfer failure of the in-mold molded product could be reduced to 5% or less, which is within an allowable range. Therefore, in this example, the hard coat layer 3 is broken before the in-mold transfer film is stretched by 40% when the mold is opened with respect to the required elongation rate of the in-mold transfer film. I found that it can be suppressed.
- the transfer elongation hardly occurs by setting the breaking elongation of the hard coat layer 3 to 120% or more and less than 135%. That is, the elongation at break of the hard coat layer 3 at the mold temperature when the in-mold transfer film 33 is separated from the molded product is A% + 2% or more, A% with respect to the required elongation rate A% of the in-mold molded product. It was found that by setting it to less than + 40%, an in-mold product can be produced in a state where the occurrence rate of transfer failure is 5% or less.
- a graph showing the range of the elongation at break is shown in FIG. In FIG. 15, the same components as those in FIG. B1 is an A% + 2% hard coat layer breaking elongation line, and B2 is an A% + 40% hard coating layer breaking elongation line.
- the cumulative irradiation amount of ultraviolet rays for curing the hard coat layer 3 is set to 152 mJ / cm 2 or more and 456 mJ / it may be set to less than cm 2. Further, in order to set the breaking elongation of the hard coat layer 3 to 120% or more and less than 135%, the cumulative irradiation amount of ultraviolet rays for curing the hard coat layer 3 should be 230 mJ / cm 2 or more and less than 340 mJ / cm 2. Good.
- the optimum hard coat layer 3 can be produced in this example by setting the cumulative irradiation amount of ultraviolet rays for curing the hard coat layer 3 to 152 mJ / cm 2 or more and less than 456 mJ / cm 2 . Further, it has been found that it is more desirable to prepare the film at 230 mJ / cm 2 or more and less than 340 mJ / cm 2 .
- the adhesiveness was maintained with respect to the elongation for following the shape of the molded product, and the transfer portion 31 was stretched cleanly following the elongation of the carrier portion 30.
- the hard coat layer 3 of the transfer part is broken at the end of the side surface of the molded product at the moment when the in-mold transfer film is stretched by opening the mold.
- the starting point was formed at the end of the side surface of the molded product, and the hard coat layer 3 was peeled off from the carrier part 30 without causing foil burrs over the entire periphery of the molded product based on the starting point.
- the present invention contributes to an improvement in yield at the time of manufacturing a decorative molded product that realizes an improved appearance design such as various electrical appliances and automobile interior and exterior products.
Abstract
Description
このインモールド転写フィルム33は、基材フィルム1、剥離層2からなるキャリア部30と、ハードコート層3、印刷層32からなる転写部31で構成される。印刷層32は、アンカー層4、着色層5、接着層6で構成されている。
図17(a)では、図柄、模様が施されたインモールド転写フィルム33が、捲装体(図示せず)から引き出されて、可動型101と固定型102の間に供給され、転写部31の側が、固定型102の射出口41に向くように金型に供給される。キャリア部30は可動型101に向いている。
図17(d)では、型温まで冷却された成形品105を取り出す工程で、型開き時に剥離層2とハードコート層3の間で剥離され型内から取り出される。この時、成形品105の表面には、転写部31が転写されているためハードコート層3が成形品105の最表面となり、転写部31と成形樹脂104が一体化された形の成形品105が得られる。
なお、使用するインモールド転写フィルム33の層構成は、図16に示したものと同じであって、基材フィルム1、剥離層2からなるキャリア部30と、ハードコート層3、印刷層32からなる転写部31で構成される。印刷層32は、アンカー層4、着色層5、接着層6で構成されている。
ハードコート層3は、印刷層32が成形樹脂に転写された際には最表面となる、高硬度な紫外線硬化型樹脂などを利用して構成された厚さ1~10μm程度の層である。
接着層6は、インモールド耐性を有する、アクリル系樹脂、ウレタン系樹脂、またはビニル系樹脂などを利用して構成された厚さ1~50μm程度の層である。
従来のインモールド成形品の製造工程を示す図17のように、(a)インモールド転写フィルム33が金型内に供給され、(b)インモールド転写フィルム33が可動型101に吸着され、固定型102と合わさった状態で型締めされる。(c)キャビティ空間103に成形樹脂104が射出され、射出樹脂とインモールド転写フィルムが接着される。(d)可動型101が型開き後、成形樹脂104と接着されていない転写部31はキャリア部30に残り、接着された転写部31が成形樹脂104に転写され、キャリア部30から剥離されて、インモールド成形品が作られる。
図1(a)において、可動型101と固定型102は離れた状態にあり、基材フィルム1と剥離層2とハードコート層3と印刷層32から構成されるインモールド転写フィルム33が可動型101と固定型102からなる金型に供給され、インモールド転写フィルム33を射出成形金型のキャビティに配置するために、インモールド転写フィルム33を可動型101に吸着する前の状態を示している。
このとき、成形品の側面34の形状の傾斜と深さにより、インモールド転写フィルム33が伸ばされた状態になる。可動型101とインモールド転写フィルム33が最初に接触し、固定される面とインモールド転写フィルムの空間を、減圧することで、インモールド転写フィルムが伸ばされながら、可動型101のキャビティ面に吸着する。
必要伸び率A = L / D
で定義することができる。
図10は、実施例の成形品105の断面形状を示したものである。
成形品の側面における投影長さは30mmであり、インモールド転写フィルム33が転写される面における稜線の長さは33mmになるように設計されている。したがって、インモールド転写フィルム33を転写するために必要な成形品側面での伸び率は、33/30=110%となる。
ハードコート層3は紫外線硬化型樹脂で形成されているため、紫外線照射における照射パワーと照射時間で、ハードコート層3の硬化反応の進展を変えられる。紫外線照射を強めれば、ハードコート層3の硬化が進み、破断伸度が下がり、逆に、紫外線照射を弱めれば、ハードコート層3の硬化が進まないため、破断伸度が高くなる。
剥離重さは、各サンプルのインモールド転写フィルム33を短冊状に19mm幅でカットし、100℃のホットプレート上に、インモールド転写フィルム33を両面テープによって貼り付けた後、180mm/minの速度にて、角度90度で剥離しながら、引っ張り強度を荷重変換器としてのロードセルで測定し、1mm幅あたりの剥離重さに換算してプロットした結果となっている。
ハードコート層3と剥離層2の密着性は、ハードコート層3が伸びやすい状態ほど、インモールド転写フィルム33の伸びに対して追従性が良くなるため、剥離層2との密着性が高い状態になりやすく、剥がれにくくなるため、基本的には破断伸度が高いほど、密着性が高い傾向を示しやすい。成形品の側面以外で、ハードコート層3が剥離層2から剥がれたりすると、成形品の側面の端部が剥離の起点にならないため、箔バリが発生しやすい。
すなわち、インモールド成形品の必要伸び率A%に対して、インモールド転写フィルム33が成形品から引き離される際の金型温度におけるハードコート層3の破断伸度をA%+2%以上、A%+40%未満に設定することで、転写不良の発生率が5%以下となる状態でインモールド成形品をつくることができることがわかった。この破断伸度の範囲を示すグラフを図15に示す。図15において、図7と同じ構成要素については同じ符号を用いて説明を省略する。B1がA%+2%のハードコート層破断伸度線、B2がA%+40%のハードコート層破断伸度線である。
2 剥離層
3 ハードコート層
4 アンカー層
5 着色層
6 接着層
30 キャリア部
31 転写部
32 印刷層
33 インモールド転写フィルム
34 成形品の側面
36 印刷部転写面
37 ハードコート層のクラック
38 成形品の側面の端部
41 射出口
42 吸着口
101 可動型
102 固定型
103 キャビティ空間
104 成形樹脂
105 成形品
A インモールド転写フィルムの必要伸び率
B ハードコート層破断伸度線
C 成形品の側面の剥離が必要な端部におけるハードコート層3の厚み相当分の部分
Claims (10)
- 基材フィルム上に剥離層とハードコート層と印刷層を有するインモールド転写フィルムを予熱する予熱工程と、
前記インモールド転写フィルムを射出成形金型のキャビティに配置する配置工程と、
前記射出成形金型を型締めする型締め工程と、
前記インモールド転写フィルムが配置された前記キャビティに成形樹脂を充填する充填工程と、
前記射出成形金型を型開きすることにより、前記基材フィルムから剥離した前記ハードコート層と前記印刷層が転写面上に転写された成形品を得る型開き工程と
を有するインモールド成形方法において、
前記成形品の側面での前記インモールド転写フィルムの必要伸び率をA%とし、
前記型開き工程で、前記成形品の側面での前記ハードコート層の破断伸度を、前記A%+2%以上、前記A%+40%未満の範囲内にして、前記ハードコート層の破断を行う
インモールド成形方法。 - 前記型開き工程で、前記成形品の側面での前記ハードコート層の破断伸度を、前記A%+10%以上、前記A%+25%未満の範囲内にして、前記ハードコート層の破断を行う
請求項1に記載のインモールド成形方法。 - 前記型開き工程での前記射出成形金型の表面温度を調整することにより、前記ハードコート層の破断伸度を設定する
請求項1または2に記載のインモールド成形方法。 - 前記ハードコート層は紫外線硬化樹脂であり、前記ハードコート層への紫外線の積算照射量を調節することにより、前記ハードコート層の破断伸度を設定する
請求項1~3の何れかに記載のインモールド成形方法。 - 射出成形金型でインモールド成形を行う際に用いるインモールド転写フィルムであって、
基材フィルム上に剥離層とハードコート層と印刷層を有し、
前記射出成形金型で成形する成形品の側面での前記インモールド転写フィルムの必要伸び率をA%とし、前記インモールド転写フィルムの温度が、インモールド成形に用いる前記射出成形金型の型開き時の表面温度と同じ温度の時に、前記ハードコート層の破断伸度を、前記A%+2%以上、前記A%+40%未満の範囲内とした
インモールド転写フィルム。 - 前記インモールド転写フィルムの温度が、インモールド成形に用いる前記射出成形金型の型開き時の表面温度と同じ温度の時に、前記ハードコート層の破断伸度を、前記A%+10%以上、前記A%+25%未満の範囲内とした
請求項5に記載のインモールド転写フィルム。 - 前記ハードコート層は、紫外線硬化樹脂である
請求項5または6に記載のインモールド転写フィルム。 - 射出成形金型でインモールド成形を行う際に用いるインモールド転写フィルムの製造方法であって、
基材フィルム上に剥離層とハードコート層と印刷層を有し、
前記ハードコート層が紫外線硬化樹脂からなり、前記射出成形金型で成形する成形品の側面での前記インモールド転写フィルムの必要伸び率をA%とし、
前記インモールド転写フィルムの温度が、インモールド成形に用いる前記射出成形金型の型開き時の表面温度と同じ温度の時に、前記ハードコート層の破断伸度を、前記A%+2%以上、前記A%+40%未満の範囲内になるように、前記ハードコート層への紫外線の積算照射量を調節する
インモールド転写フィルムの製造方法。 - 前記紫外線の積算照射量は152mJ/cm2以上456mJ/cm2未満である
請求項8に記載のインモールド転写フィルムの製造方法。 - 前記型開き時に、前記成形品の側面での前記ハードコート層の破断伸度が、前記A%+10%以上、前記A%+25%未満の範囲内となるように、前記紫外線の積算照射量を、230mJ/cm2以上、340mJ/cm2未満とする
請求項8に記載のインモールド転写フィルムの製造方法。
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WO2016072450A1 (ja) * | 2014-11-05 | 2016-05-12 | 大日本印刷株式会社 | 転写シート及びこれを用いたハードコート体 |
CN106891595A (zh) * | 2017-02-23 | 2017-06-27 | 广州优瑞塑料有限公司 | 一种聚氨酯模塑模内转印膜 |
DE102016120781A1 (de) | 2016-10-31 | 2018-05-03 | Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. | Verbundfolie zur Beschichtungsstoffübertragung, deren Verwendung und ein Verfahren zur Herstellung der Verbundfolie sowie ein Verfahren zur Herstellung eines beschichteten Kunststoffbauteiles |
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JP2020082547A (ja) * | 2018-11-27 | 2020-06-04 | トヨタ自動車株式会社 | 複合部材の製造方法 |
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CN104582928B (zh) | 2017-02-22 |
US9925704B2 (en) | 2018-03-27 |
MY175748A (en) | 2020-07-08 |
JP5942309B2 (ja) | 2016-06-29 |
CN104582928A (zh) | 2015-04-29 |
US20150290852A1 (en) | 2015-10-15 |
JPWO2014083732A1 (ja) | 2017-01-05 |
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