WO2016194027A1 - インモールド成形用フィルム、インモールド成形品、およびインモールド成形品の製造方法 - Google Patents
インモールド成形用フィルム、インモールド成形品、およびインモールド成形品の製造方法 Download PDFInfo
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- WO2016194027A1 WO2016194027A1 PCT/JP2015/005903 JP2015005903W WO2016194027A1 WO 2016194027 A1 WO2016194027 A1 WO 2016194027A1 JP 2015005903 W JP2015005903 W JP 2015005903W WO 2016194027 A1 WO2016194027 A1 WO 2016194027A1
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- Prior art keywords
- mold
- film
- layer
- inorganic polymer
- molding
- Prior art date
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- BMMGVYCKOGBVEV-UHFFFAOYSA-N oxo(oxoceriooxy)cerium Chemical compound [Ce]=O.O=[Ce]=O BMMGVYCKOGBVEV-UHFFFAOYSA-N 0.000 description 1
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Images
Classifications
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- B44C1/165—Processes, not specifically provided for elsewhere, for producing decorative surface effects for applying transfer pictures or the like for decalcomanias; sheet material therefor
- B44C1/17—Dry transfer
- B44C1/1712—Decalcomanias applied under heat and pressure, e.g. provided with a heat activable adhesive
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- B44C1/165—Processes, not specifically provided for elsewhere, for producing decorative surface effects for applying transfer pictures or the like for decalcomanias; sheet material therefor
- B44C1/17—Dry transfer
- B44C1/1704—Decalcomanias provided with a particular decorative layer, e.g. specially adapted to allow the formation of a metallic or dyestuff layer on a substrate unsuitable for direct deposition
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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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
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- B29C45/14688—Coating articles provided with a decoration
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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
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- 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
- 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
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- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
- B32B3/08—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
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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
- B29C45/14688—Coating articles provided with a decoration
- B29C2045/14713—Coating articles provided with a decoration decorations in contact with injected 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
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/16—Fillers
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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
- B29K2709/00—Use of inorganic materials not provided for in groups B29K2703/00 - B29K2707/00, for preformed parts, e.g. for 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
- 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
- B29K2995/007—Hardness
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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
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B2605/00—Vehicles
- B32B2605/003—Interior finishings
Definitions
- the present invention relates to an in-mold molding film, an in-mold molded product, and a manufacturing method thereof. More specifically, the present invention relates to a high heat resistant film for in-mold molding that can withstand high temperatures during resin molding, an in-mold molded product that is realized as a result, and a method for manufacturing the same.
- FIG. 7 shows the layer structure of a conventional in-mold film.
- the film for in-mold molding described in Patent Document 1 also has the same layer structure as the conventional one.
- the in-mold molding film includes a carrier film 401 that is not transferred to the injection molding resin and a transfer film 402 that is transferred to the injection molding resin.
- the carrier film 401 is composed of a base film 403 made of PET, an acrylic film or the like that continuously supplies the transfer film 402, and a release layer 404 for peeling the transfer film 402 from the base film 403.
- the transfer film 402 includes a protective layer or hard coat layer 405, a primer layer 406, a colored layer 408, a concealing layer 410, and an adhesive layer 411.
- the protective layer or hard coat layer 405 serves to protect the transfer film 402 from scratches and dust on the outermost surface of the in-mold molded product.
- the primer layer 406 serves to connect the protective layer or hard coat layer 405 and the colored layer 408.
- the colored layer 408 contains ink that is an organic material and plays a role of imparting a design such as a color, a pattern, or a pattern to the surface of the in-mold molded product.
- the concealing layer 410 serves to conceal the color of the colored layer 408, and the adhesive layer 411 serves to adhere the transfer film 402 to the injection molding resin.
- the in-mold film is composed of a plurality of layers.
- FIG. 8 shows an outline of a conventional method for producing an in-mold molded product.
- the film pressing member 609 is used to fix the in-mold molding film 604 described with reference to FIG.
- the in-mold molding film 604 is sufficiently shaped so that the in-mold molding film 604 is sucked through the suction holes 608 and is in close contact with the mold surface of the movable mold 606.
- a cavity is formed by sandwiching the in-mold molding film 604 between the fixed mold 605 and the movable mold 606, and a molten injection molding resin 612 is injected from the gate 611 to fill the cavity.
- the injection molding resin 612 is cooled and solidified. Then, by moving the movable mold 606, the transfer film of the in-mold molding film peels from the base film, and an in-mold molded product in which the transfer film is formed on the surface of the injection molding resin 612 is obtained.
- a so-called gate mark defect occurs when in-mold molding is performed with a molding resin such as polycarbonate and a resin containing a glass filler in those resins.
- the gate mark is a phenomenon that the colored layer ink near the gate of the molded product flows toward the protective layer or the hard coat layer without being able to withstand the injection molding temperature of the resin to be injected. Due to the occurrence of such defects, the appearance quality of the in-mold molded product is significantly lowered.
- the injection molding temperature is set low in order to prevent the generation of gate marks, the injection molding resin does not reach the entire mold, resulting in a defect of insufficient filling.
- trade-off issues In other words, when the above resin is molded in-mold, it must be molded at a predetermined high temperature, and therefore the in-mold molding film is required to have high heat resistance.
- the present invention is intended to solve the conventional problems and to suppress the occurrence of defects in in-mold molded products.
- the in-mold molding film of the present invention is an in-mold molding film composed of a transfer film transferred to the surface of an injection molding resin and a carrier film that is not transferred.
- the transfer film includes an ink that is an organic material made of a thermoplastic resin and imparts a design to the in-mold molded product, and an inorganic polymer layer made of a thermosetting resin. It is in contact with the inorganic polymer layer and sandwiched between the inorganic polymer layers.
- the colored layer when the colored layer is sandwiched between the inorganic polymer layers, ink flow of the colored layer can be prevented, and the occurrence of defects in the in-mold molded product can be suppressed.
- FIG. 1 shows the layer structure of an in-mold molding film according to Embodiment 1 of the present invention.
- the in-mold film in the present embodiment is a continuous film composed of a carrier film 101 and a transfer film 102 as shown in FIG.
- the carrier film 101 is a portion of the in-mold molding film that is not transferred to the surface of the injection molding resin, and includes a base film 103 and a release layer 104.
- the base film 103 serves to supply the transfer film 102 continuously.
- the release layer 104 is used to release the transfer film 102 from the base film 103.
- the transfer film 102 is a portion of the in-mold molding film that is transferred to the surface of the injection molding resin.
- the transfer film 102 is generally configured to have a film thickness of 2 ⁇ m to 50 ⁇ m.
- the transfer film 102 includes, for example, a protective layer or a hard coat layer 105, a primer layer 106, a first inorganic polymer layer 107, a colored layer 108, a second inorganic polymer layer 109, and a concealing layer 110.
- the transfer film 102 is configured such that the thickness of the thickest layer is 10 ⁇ m, for example.
- the protective layer or hard coat layer 105 plays the role of protecting the transfer film 102 from scratches and dust on the outermost surface of the in-mold molded product.
- the primer layer 106 serves to connect the protective layer or hard coat layer 105 and the first inorganic polymer layer 107.
- the colored layer 108 contains ink, which is an organic material made of a thermoplastic resin, and plays a role of imparting a design such as a color, a pattern, or a pattern to the surface of the in-mold molded product.
- the concealing layer 110 serves to conceal the color of the colored layer 108, and the adhesive layer 111 serves to adhere the transfer film 102 to the injection molding resin.
- the adhesive layer 111, the concealing layer 110, the colored layer 108, and the primer layer 106 are each an organic material made of a thermoplastic resin. Further, there is no problem even if the release layer 104 is not provided on the base film 103 as long as the release characteristics can be obtained even if the protective layer or the hard coat layer 105 is directly formed on the base film 103.
- the transfer film 102 has a first inorganic polymer layer 107 and a second inorganic polymer layer 109, and the inorganic polymer layers 107 and 109 are colored layers.
- the layer structure is in contact with 108 and sandwiches the colored layer 108.
- the inorganic polymer layers 107 and 109 are each made of a thermosetting resin.
- the inventor diligently studied the cause of the gate mark and the countermeasures to prevent the in-mold molded product from being defective in the gate mark.
- the cause of the generation of the gate mark was that the injection molding resin was washed away from the adhesive layer to the colored layer due to the injection pressure and injection heat of the injection resin.
- the generation state of the gate mark does not change, so it was considered that the main cause of the generation of the gate mark is not the injection pressure but the injection heat.
- the ink of the colored layer is not melted by the injection heat, but each layer reaches the glass transition temperature, thereby having fluidity and shearing in the flow direction of the injection resin. It was found that the gate flow occurred and became a gate mark.
- FIG. 2 is a diagram for explaining a mechanism for generating a gate mark in a conventional in-mold molding method.
- the same components as those in FIG. 7 referred to as the background art are denoted by the same reference numerals, and the description thereof is omitted.
- Reference numeral 203 in FIG. 2 indicates injection molding resin injected from the gate. The resin heat of the injection-molded resin 203 spreads radially and propagates sequentially to each layer. As a result, the adhesive layer 411, the concealing layer 410, the colored layer 408, and the primer layer 406 made of thermoplastic resin each reach the glass transition temperature, and each layer has fluidity. Then, ink flow of the colored layer 408 occurs.
- the ink flow of the colored layer 408 gradually proceeds as the filling of the injection molding resin 203 proceeds, and reaches the hard coat layer 405 when the filling is completed. Thereby, a gate mark is generated in the in-mold molded product. In such a state, it cannot have a high-quality appearance.
- FIG. 3 is a diagram for explaining a mechanism capable of preventing a gate mark defect in the in-mold molding method according to the present embodiment.
- the same components as those in FIG. 1 are denoted by the same reference numerals, and the description thereof is omitted.
- symbol 203 of FIG. 3 shows the injection molding resin inject
- the resin heat of the injection molding resin 203 spreads radially, and the adhesive layer 111 and the concealing layer 110 near the gate reach the glass transition temperature and flow. However, propagation of resin heat is suppressed at the stage where the adhesive layer 111 and the concealing layer 110 flow.
- the inorganic polymer 109 made of a thermosetting resin has a different characteristic from the colored layer 108 formed of an organic material made of a thermoplastic resin, and does not have fluidity when heated, and is a material that accelerates the curing reaction. is there.
- the colored layer 108 made of a thermoplastic resin reaches the glass transition point due to the influence of the injection resin heat and has fluidity, but the inorganic polymer layer 109 made of thermosetting resin that does not have fluidity.
- the movement of the colored layer 108 and the concealing layer 110 made of a thermoplastic resin is stopped by being sandwiched between the layers. Therefore, gate flow can be prevented. As described above, it is possible to prevent a gate mark defect caused by ink flowing.
- the glass transition temperature of the inorganic polymer layers 107 and 109 made of the thermosetting resin is higher than the glass transition temperature of the colored layer 108 made of the thermoplastic resin, the ink with respect to the molding resin having a higher injection temperature is used. It becomes a layer structure in which a flow hardly occurs.
- FIG. 4 is an in-mold molded product manufactured through the in-mold molding method shown in FIG. 3, and shows an enlarged cross-sectional view of the in-mold molded product in the present embodiment.
- symbol 112 of FIG. 4 shows the injection molding resin of the state cooled and solidified. Of the in-mold molding film, only the transfer film 102 is transferred to the surface of the injection molding resin 112, and the carrier film is not transferred.
- the injection molding resin for example, polycarbonate or 20% polycarbonate glass filler containing glass filler is used.
- the injection temperature is, for example, 280 ° C. or higher and 320 ° C. or lower. More specifically, the above-mentioned effects are confirmed when the injection resin temperature is 300 ° C., the mold temperature is 100 ° C., and the cycle time is 45 seconds.
- the inorganic polymer layers 107 and 109 are formed by allowing a sol-gel coating material containing a thermosetting resin to permeate the primer layer 106 and the colored layer 108 and drying them.
- the thermosetting resin in the sol-gel coating penetrates into the primer layer 106 and the colored layer 108, so that the thermosetting resin in the sol-gel coating enters the primer layer 106 and the colored layer 108 together with the solvent, By stretching the roots, an anchoring action effectively works between the inorganic polymer layers 107 and 109 made of thermosetting resin between the primer layer 106 made of thermoplastic resin and the colored layer 108.
- the inorganic polymer layers 107 and 109 may be composed only of a matrix resin and may contain metal oxide fine particles. As an effect of including metal oxide fine particles, voids are formed between the matrix resin and the metal oxide by adding the metal oxide fine particles into the inorganic polymer. By including voids in the inorganic polymer layer, it becomes possible to provide heat insulation and elasticity during molding.
- a silicone resin having a siloxane bond or a resin having a molecular structure in which zirconia or titania enters the main skeleton, such as metal alkoxide, zirconium alkoxide, or titanium alkoxide, can be considered.
- metal oxide for example, one or more kinds of silicon oxide, magnesium oxide, cryolite, calcium oxide, aluminum oxide, boron oxide, zirconium oxide, titanium oxide, hafnium oxide, and cerium oxide are preferably selected. If the same effect can be obtained, there is no problem with metal oxide fine particles other than the above.
- the ratio of the oxide particles is desirably 5% by mass or more and 90% by mass or less.
- the ratio of the oxide particles is less than 5% by mass, the sufficient heat insulating action and elasticity at the time of molding do not sufficiently function in the inorganic polymer layers 107 and 109.
- the ratio is more than 90% by mass, the thermoplastic resin It becomes difficult to maintain interlayer adhesion with an organic material comprising
- in-mold molding films of 0.01 ⁇ m, 0.05 ⁇ m, 0.2 ⁇ m, 0.4 ⁇ m, and 0.5 ⁇ m were formed.
- An in-mold molded product was prepared using the film for a film, and whether or not a gate mark was generated was examined.
- the film thickness of the inorganic polymer layers 107 and 109 is 0.01 ⁇ m, the effect is small.
- the film thickness is 0.2 ⁇ m or more, cracks may occur due to thermal shrinkage during drying at the stage of producing the film.
- the effect of preventing gate mark resistance is small if the colored layer 108 is not sandwiched between the first inorganic polymer layer 107 and the second inorganic polymer layer 109. Furthermore, when the film thickness of the inorganic polymer layers 107 and 109 is 0.4 ⁇ m, the gate mark resistance is obtained, but after forming a deep-drawn molded product, the film cannot follow the elongation at the time of molding. It was found that ink cracking occurred and it was difficult to produce a high-quality appearance product. Therefore, it can be said that the film thickness of the inorganic polymer layer is 0.05 ⁇ m or more and less than 0.2 ⁇ m, which has gate mark resistance and also has elongation that can withstand deep-drawn molded products.
- the base film 103 of the carrier film 101 is made of a material such as PET or acrylic film, and the film thickness is generally selected from 20 ⁇ m to 100 ⁇ m, for example, 50 ⁇ m.
- the release layer 104 is formed on the base film 103 so that the film thickness becomes, for example, 0.1 ⁇ m to 3 ⁇ m.
- a wet method is used as a method of providing the inorganic polymer layer 107 on the primer layer 106 of the transfer film 102.
- a coating method or a printing method may be used.
- a printing method gravure printing, screen printing, and inkjet printing are used.
- the standard film thickness is 0.1 to 2 ⁇ m per layer for gravure printing, 0.5 to 3 ⁇ m per layer for screen printing, and 0.5 to 10 ⁇ m per layer for inkjet printing.
- the film thickness per layer is preferably 0.1 to 10 ⁇ m. If the film thickness is less than 0.1 ⁇ m per layer, a desired color cannot be realized, so that it is unsuitable as a decoration application.
- the layer structure according to the present invention may be a single printing method or a combination of plural printing methods.
- the average film thickness of each layer constituting the transfer film 102 is 5 ⁇ m for the protective layer or hard coat layer 105, 2 ⁇ m for the primer layer 106, 2 ⁇ m for the colored layer 108, and 0.05 ⁇ m for the inorganic polymer layer 109.
- Each layer of the transfer film 102 is formed to be less than 0.2 ⁇ m, 2 ⁇ m for the concealing layer 110, and 2 ⁇ m for the adhesive layer 111.
- a UV after-cure type is used for the protective layer or hard coat layer 105.
- the layers other than the colored layer 108 and the inorganic polymer layers 107 and 109 are not essential constituent elements, and use / nonuse determination is performed according to each use.
- FIG. 5 is an enlarged cross-sectional view of an in-mold molding film and a part of the enlarged cross-sectional view in Embodiment 2 of the present invention.
- the same elements as those in FIG. 1 are denoted by the same reference numerals, and the description thereof is omitted.
- the in-mold film in Embodiment 2 of the present invention contains a porous filler 301 in the first inorganic polymer layer 107 and the second inorganic polymer layer 109 that sandwich the colored layer 108.
- the first inorganic polymer layer 107 and the second inorganic polymer layer 109 contain the porous filler 301, the first inorganic polymer layer 107 and the second inorganic polymer The heat insulating property of the layer 109 can be improved and heat conduction to the colored layer 108 and the primer layer 106 can be suppressed. That is, in the first embodiment, the colored layer 108 that has reached the flowing temperature is sandwiched between the inorganic polymer layers 107 and 109 to stop the movement of the colored layer 108, whereas the second embodiment Then, in addition to this effect, it is possible to suppress the temperature itself at which the colored layer 108 flows.
- the injection temperature was 310 ° C. or higher and 340 ° C. or lower. Specifically, the injection resin temperature was 325 ° C., the mold temperature was 110 ° C., the cycle time was 45 seconds, the molding resin material was The effect was confirmed when the polycarbonate glass filler content was 40%.
- the average particle diameter of the porous filler 301 is preferably in the range of 0.01 ⁇ m or more and less than 0.05 ⁇ m, but is not particularly limited as long as it has a heat insulating effect.
- the kind of the porous filler 301 is not particularly limited as long as it is semitransparent and silica, talc or the like having little influence on the ink color is effective. Moreover, it is good also considering the metal oxide mentioned above as a porous filler.
- the method for producing the porous filler 301 is not particularly limited as long as the method can produce the porous filler 301 having a heat insulating effect.
- silica when silica is taken as an example, depending on the processing method, there are types of silica such as spherical silica, colloidal silica, pulverized silica, and porous silica.
- the addition amount of the porous filler 301 is not particularly limited as long as a heat insulating effect is obtained at the time of injection molding.
- a predetermined design such as a color, a pattern, or a pattern expressed by the colored layer of the transfer film is arranged at a predetermined position between the fixed mold 605 and the movable mold 606.
- An in-mold molding film 604 is fed by a foil feeding device 607.
- the carrier film of the in-mold molding film 604 is conveyed so as to face the movable mold 606 and the adhesive layer of the in-mold molding film 604 faces the fixed mold 605.
- the in-mold molding film 604 is preliminarily heated to a predetermined temperature by a preheater 615 before molding, and in the next step, the in-mold molding film 604 has a stretch property that allows the in-mold molding film 604 to be sufficiently shaped along the mold. Give it.
- the in-mold molding film 604 is sucked from the suction hole 608 opened in the cavity surface of the movable mold 606, and the in-mold molding film 604 is brought into close contact with the cavity surface of the movable mold 606. Let Thereby, the in-mold film 604 is shaped along the cavity surface. At this time, the in-mold molding film 604 is fixed by the frame-shaped film pressing member 609, and the in-mold molding film 604 is positioned.
- the movable mold 606 is moved, and the fixed mold 605 and the movable mold 606 are clamped to form a cavity.
- the film pressing member 609 is stored in a storage recess 610 (see FIGS. 6A and 6B) formed in the fixed mold 605.
- molten injection molding resin 612 is injected from the gate 611 of the fixed mold 605 toward the adhesive layer of the in-mold molding film 604, and the fixed mold 605 and the movable mold 606 are clamped.
- the molten injection molding resin 612 is injected into the cavity formed in this way. Thereby, the molten injection molding resin 612 is filled in the cavity.
- the molten injection molding resin 612 is cooled to a predetermined temperature and solidified.
- the movable mold 606 is moved to open the fixed mold 605 and the movable mold 606.
- the transfer film 603 adhered to the surface of the solidified (molded) injection molding resin 612 is peeled off from the carrier film 602.
- the obtained in-mold molded product 613 is in a state where the protective layer or hard coat layer of the transfer film 603 appears on the surface.
- the protruding pin 614 is pushed out from the fixed mold 605, and the in-mold molded product 613 is taken out.
- the step shown in FIG. 604 is conveyed and prepared for the next molding.
- the in-mold molding film 604 heated to a predetermined temperature by the pre-heater 615 has a predetermined design such as a color, a pattern, a pattern, etc. to which the colored layer is applied. It is conveyed so that it may be arranged at a predetermined position. By repeating these steps, the in-mold molded product 613 can be continuously manufactured.
- the in-mold molded product manufacturing process includes in-mold molding by sandwiching the colored layer of the in-mold molding film between the inorganic polymer layers and including, for example, a porous filler in the inorganic polymer layer. Since the film for molding follows the elongation at the time of shaping and can realize a situation in which no gate mark is generated, a molded product having a high-quality appearance can be obtained.
- Polycarbonate resins and high-temperature molding resins mixed with glass fillers are mainly used for automotive interior parts and smartphone exteriors, and heat-resistant decorative films are required to decorate these molded parts by in-mold molding. It was. By this invention, it is thought that the spread to these goods uses accelerates further.
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Abstract
Description
図1は、本発明の実施の形態1におけるインモールド成形用フィルムの層構成を示している。本実施の形態におけるインモールド成形用フィルムは、図1に示すように、キャリアフィルム101と転写フィルム102で構成された連続フィルムである。
図5は、本発明の実施の形態2におけるインモールド成形用フィルムの拡大断面図、及びその拡大断面図の一部をさらに拡大した図である。図1と同じ要素には同じ符号をつけ、その説明を省略する。本発明の実施の形態2におけるインモールド成形用フィルムは、着色層108を挟む第1無機高分子層107、第2無機高分子層109内に多孔質フィラー301を含有する。本構成のインモールド成形用フィルムにすることで、より高温の射出樹脂を使用してもゲート流れが起こり難いインモールドフィルムとなる。その他の構成については、実施の形態1と同様であるため、詳細な説明を省略する。
102‥転写フィルム
103‥ベースフィルム
104‥剥離層
105‥保護層またはハードコート層
106‥プライマー層
107‥無機高分子層
108‥着色層
109‥無機高分子層
110‥隠蔽層
111‥接着層
112‥射出成形樹脂
203‥射出成形樹脂
204‥ゲート
301‥多孔質フィラー
401‥キャリアフィルム
402‥転写フィルム
403‥ベースフィルム
404‥剥離層
405‥保護層またはハードコート層
406‥プライマー層
408‥着色層
410‥隠蔽層
411‥接着層
602‥キャリアフィルム
603‥転写フィルム
604‥インモールド成形用フィルム
605‥固定型
606‥可動型
607‥箔送り装置
608‥吸引穴
609‥フィルム押さえ部材
610‥収納凹部
611‥ゲート
612‥射出成形樹脂
613‥インモールド成形品
614‥突き出しピン
615‥予備加熱器
Claims (9)
- 射出成形樹脂の表面に転写される転写フィルムと、転写されないキャリアフィルムとで構成されるインモールド成形用フィルムであって、
前記転写フィルムは、熱可塑性樹脂から成る有機材料であるインキを含有してインモールド成形品に意匠を付与する着色層と、熱硬化性樹脂から成る無機高分子層とを含み、
前記着色層は、前記無機高分子層と接触し、かつ前記無機高分子層によって挟まれている
ことを特徴とするインモールド成形用フィルム。 - 前記無機高分子層のガラス転移温度は、前記着色層のガラス転移温度よりも高い
ことを特徴とする請求項1に記載のインモールド成形用フィルム。 - 前記無機高分子層は、ゾルゲル法によって形成される
ことを特徴とする請求項1に記載のインモールド成形用フィルム。 - 前記無機高分子層は、金属酸化物微粒子と無機マトリクス樹脂から構成され、前記金属酸化物微粒子の割合が5質量%以上90質量%以下である
ことを特徴とする請求項1に記載のインモールド成形用フィルム。 - 前記金属酸化物微粒子は、多孔質フィラーである
ことを特徴とする請求項4に記載のインモールド成形用フィルム。 - 前記無機高分子層の膜厚は、0.05μm以上0.2μm未満である
ことを特徴とする請求項1に記載のインモールド成形用フィルム。 - 前記キャリアフィルムは、
前記転写フィルムを連続的に供給するベースフィルムと、
前記ベースフィルムから前記転写フィルムを剥離させるために設けられる剥離層と、が積層して構成され、
前記転写フィルムは、
インモールド成形品を保護する保護層またはハードコート層と、
前記保護層またはハードコート層と前記無機高分子層とを繋ぐプライマー層と、
前記無機高分子層の一部である第1無機高分子層と、
前記着色層と、
前記無機高分子層の一部である第2無機高分子層と、
前記着色層の色を隠蔽する隠蔽層と、
射出成形樹脂に前記転写フィルムを接着させる接着層と、が積層して構成される
ことを特徴とする請求項1~6の何れか1項に記載のインモールド成形用フィルム。 - 請求項1に記載のインモールド成形用フィルムの転写フィルムと、
表面に前記転写フィルムが転写される射出成形樹脂と、を備える
ことを特徴とするインモールド成形品。 - 第1金型と第2金型の間に、請求項1に記載のインモールド成形用フィルムを配置し、
前記第1金型と前記第2金型を型締めして形成したキャビティに溶融した射出成形樹脂を流し込み、
前記キャビティに流し込まれた前記射出成形樹脂を冷却して固化させ、
前記第1金型と前記第2金型を型開きして、冷却された前記射出成形樹脂と、その表面に形成された前記転写フィルムとを有するインモールド成形品を取り出すことを特徴とするインモールド成形品の製造方法。
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EP15894062.7A EP3305545B1 (en) | 2015-06-04 | 2015-11-27 | Film for in-mold molding, in-mold molded article, and method for producing in-mold molded article |
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