JP3684276B2 - Hairline insert film, method for producing hairline insert molded product - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a hair run insert film integrated on a molded product at the same time as injection molding, a hair run insert molded product, and a method for producing the same. Examples of products include acoustic equipment, furniture surface materials, and architectural interior and exterior. It can be used for surface decoration such as wood materials, cabinet surface materials, kitchen door interior materials, and automobile interior parts.
[0002]
[Prior art]
Conventionally, surface decoration such as acoustic equipment is a method such as thermal transfer or simultaneous painting method for a transfer foil in which a metal vapor deposition layer or a pattern printing layer is sequentially formed on a transparent base sheet on which hairlines are formed. It was done in.
[0003]
[Problems to be solved by the invention]
However, since hairline processing is a system in which a film is continuously sent to sandpaper and the surface of the film is shaved in a hairline pattern, it cannot be patterned. Therefore, the vapor-deposited metal color part and the pattern printing part with the hairline eyes, the vapor deposition metal color part and the picture print part without the hairline eyes, and the transparent window part in which neither the vapor deposition metal color part nor the pattern print part is present are combined. Such a patterned design could not be formed on one substrate sheet.
[0004]
An object of the present invention is to solve the above-mentioned problems and provide a hairline eye insert molded product having a high design property.
[0005]
[Means for Solving the Problems]
In order to achieve the above object, the hairline insert film of the present invention has an adhesive anchor layer and metal vapor deposition on a transparent substrate sheet on which the hairline is formed as described in claim 1. A layer or a pattern printing layer is sequentially formed, and the adhesive anchor layer has a thickness smaller than the depth of the hairline recess.
[0006]
Alternatively, as described in claim 2, a hairline insert film in which a colorless transparent layer having a film thickness larger than the depth of the hairline recess is formed on a part of the anchor layer having adhesiveness.
[0007]
Or it is good also as a hairline insert film which has a window part in which the metal vapor deposition layer and the pattern printing layer are not formed on a colorless transparent layer like Claim 3.
[0008]
Or it is good also as a hairline insert film which has a window part in which the metal vapor deposition layer and the pattern printing layer are not formed on the anchor layer which has adhesiveness as described in Claim 4.
[0009]
According to a method for producing a hairline insert-molded article of the present invention, as described in claim 5, the hairline in-sert film according to claims 1 to 3 is used for injection molding so that the base sheet and the mold surface are in contact with each other. The hairline insert film is adhered to the resin molded article by placing the mold in the mold and closing the mold and then injecting the molding resin into the mold and solidifying the molding resin.
[0010]
Alternatively, as described in claim 6, the hairline insert film according to claim 4 is placed in an injection mold so that the base sheet and the mold surface are in contact with each other, and after the mold is closed, the molding resin is applied. It is injected into the mold, and the molding resin is brought into contact with the adhesive anchor layer at the window part of the hairline insert film, and the molding resin is solidified to bond the hairline insert film to the resin molded product. And
[0011]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the manufacturing method of the hairline insert film and the hairline insert molded product of the present invention will be described in detail with reference to FIGS. 1 is a hairline insert film, 2 is a substrate sheet, 3 is a hairline irregularity, 4 is an anchor layer with adhesive properties, 5 is a colorless transparent layer, 6 is a pattern printing layer, 7 is a metal vapor deposition layer, 8 is a resin molded product, 9 is a hairline insert molded product, and 10 is an adhesive layer.
[0012]
In the hairline insert film 1, an adhesive anchor layer 4, a metal deposition layer 7, or a pattern printing layer 6 is sequentially formed on a transparent base sheet 2 on which the hairline is formed. The adhesive anchor layer 4 has a film thickness smaller than the depth of the base sheet 2 (FIG. 1).
[0013]
The transparent base sheet 2 is a film or sheet made of various resins such as polyester, acrylic, polypropylene, polyvinyl chloride, and polycarbonate. The thickness of the base sheet 2 is 10 μm to 500 μm.
[0014]
The hairline may be formed by a method in which a film is continuously sent to sandpaper and the film surface is cut into a hairline shape, or a printing method using pigmented resin ink. The cross section of the hairline is uneven. The depth of the concave and convex portions is preferably half or less of the thickness of the base sheet 2, for example, 2 μm to 10 μm.
[0015]
The anchor layer 4 having adhesiveness is formed with the base sheet 2 by being in close contact with the molding resin and the function as an anchoring agent that connects the base sheet 2 with the pattern printing layer 6 or the metal vapor deposition layer 7 and the adhesive layer 10. It is a layer having a function as an adhesive layer for closely adhering resin. Further, the anchor layer 4 having adhesiveness itself has adhesiveness to the molding resin, but is an anchor layer between the metal deposition layer 7, the pattern printing layer 6, the adhesive layer 10 and the base sheet having the hairline eyes. As a main function. The adhesive anchor layer 4 is made of a thermosetting urethane-based, epoxy-based, acrylic-based, polyester-based, or melamine-based resin or an ultraviolet curable resin so as to have transparency or strength. Use to form. As a method for forming the anchor layer 4 having adhesiveness, there are general-purpose printing methods such as an offset printing method, a gravure printing method, and a flexographic printing method. The anchor layer 4 having adhesiveness has a thickness such that the hairline of the base sheet 2 is not apparently lost. For example, it is a transparent layer having a film thickness that is considerably thinner than the depth of the concave portion of the hairline and having substantially the same refractive index as that of the base film. Otherwise, when the colorless transparent layer 5 is coated, the hairline is apparently unlikely to disappear. In order to form a thin film on the inner surface of the concavo-convex portion of the hairline, the following is preferable. Use a fine plate (shallow depth) to reduce the viscosity as much as possible and print on the convex part. This is because when the viscosity is high, it is difficult to spread. In the concave portion, the inner surface of the concave portion is covered by spreading by the ink dripping from the convex portion.
[0016]
The colorless transparent layer 5 may be formed on a part of the anchor layer 4 having adhesiveness with a film thickness larger than the depth of the hairline recess. By making the colorless and transparent layer 5 have substantially the same refractive index as that of the base sheet 2, the hairline of the anchor layer 4 having adhesiveness apparently disappears in the portion where the colorless and transparent layer 5 is formed. The colorless and transparent layer 5 is formed using a thermosetting urethane-based, epoxy-based, acrylic-based, polyester-based, melamine-based resin, or an ink made of an ultraviolet curable resin. Examples of the method for forming the colorless transparent layer 5 include a general-purpose thick film printing method such as a screen printing method, and a coating method such as a roll coating method and a spray coating method. The thickness of the colorless transparent layer 5 is greater than the depth of the concave portion of the hairline, and it is necessary to completely fill the concave portion of the hairline, so that the thickness is preferably 2 μm or more.
[0017]
If the colorless and transparent layer 5 has substantially the same refractive index as that of the base sheet 2, irregular reflection does not occur at the boundary of the hairline eyes. In that case, the hairline appears to have disappeared. However, if the colorless and transparent layer 5 is thin, unevenness of the hairline remains, and the hairline is visible again by an adhesive anchor layer or the like to be coated thereafter. The adhesive anchor layer 4 is thinly coated so that the hairline is visible after the adhesive anchor layer 4 is coated.
[0018]
The pattern printing layer 6 is formed on the adhesive anchor layer 4 or the colorless transparent layer 5. When the metal vapor deposition layer 7 is formed first, the pattern printing layer 6 may be formed on the metal vapor deposition layer 7. The pattern print layer 6 formed in a portion where the colorless transparent layer 5 is not provided has a hairline pattern or pattern. In the pattern printing layer 6 formed in the portion where the colorless transparent layer 5 is present, the hairline pattern or pattern apparently disappears. Examples of the pattern of the pattern print layer 6 include a grain pattern, characters, symbols, and numbers. Examples of the pattern printing layer 6 include a pigment ink layer, a dye ink layer, a glitter ink layer, and an anchor layer (separate from the adhesive anchor layer 4). You may form the contact bonding layer 10 on a pattern printing layer or a metal vapor deposition layer. The pattern printing layer 6 is made of ink containing various pigments and dyes in a resin binder. The glitter ink layer is made of ink in which pearl powder, aluminum powder, or the like is mixed in a resin binder. The anchor layer is formed in order to improve the adhesion between the pigment ink layer, the dye ink layer, the glitter ink layer, the anchor layer, the adhesive layer, and the like. The adhesive layer 10 includes acrylic resin, urethane resin, polyester resin, polyamide resin, ethylene butyl alcohol resin, ethylene vinyl acetate copolymer, vinyl chloride / vinyl acetate copolymer, and the like.
[0019]
The metal vapor deposition layer 7 is formed on the adhesive anchor layer 4 or the colorless transparent layer 5. When the pattern printing layer 6 is formed first, the metal vapor deposition layer 7 may be formed on the pattern printing layer 6. The metal vapor deposition layer 7 formed in the portion where the colorless and transparent layer 5 is not present has a hairline. In the metal vapor-deposited layer 7 formed in the portion where the colorless transparent layer 5 is present, the hairline eyes appear to disappear. The metal vapor deposition layer 7 is formed of a metal such as aluminum, chromium, silicon dioxide, or zinc sulfide by a vacuum vapor deposition method or the like. The metal deposition layer 7 formed on the adhesive anchor layer 4 has a hairline pattern or pattern. In the metal vapor-deposited layer 7 formed on the colorless and transparent layer 5, the hairline eyes appear to disappear.
[0020]
The hairline insert film of the present invention may have a window portion A on which the metal vapor-deposited layer 7 and the pattern print layer 6 are not formed on the colorless and transparent layer 5. In the window portion A, the colorless and transparent layer 5 is exposed, and the hairline eyes apparently disappear in the state of the insert film.
[0021]
The hairline insert film of the present invention may have a window portion B on which the metal vapor-deposited layer 7 and the pattern printing layer 6 are not formed on the anchor layer 4 having adhesiveness. In the window portion B, the anchor layer 4 having adhesiveness formed on the irregularities of the hairline eyes is exposed, and the hairline eyes are present in the state of the insert film.
[0022]
In the hairline insert film of the present invention, the anchor layer 4 having adhesiveness is formed on the entire surface of the base sheet 2, the metal vapor deposition layer 7 is formed on a part of the anchor layer 4, and a part of the metal vapor deposition layer 7 is formed. A pattern printing layer 6 is formed so as to cover, and an adhesive layer 10 is formed in registration with the metal vapor deposition layer 7 and the pattern printing layer 6 (see FIG. 3). In the case of FIG. 3, the adhesive anchor layer 4 has a function as an adhesive layer for adhering the base sheet 2 to the resin molded product 8, and the picture printing layer 6 and the adhesive layer 10 are attached to the base sheet 2. The function as an anchor layer for facilitating the bonding is exhibited.
[0023]
Alternatively, in the hairline insert film of the present invention, an adhesive anchor layer 4 is formed on a part of the base sheet 2, and a metal vapor deposition layer 7 and a pattern printing layer 6 are formed only on the anchor layer 4. There is one in which an adhesive layer 10 is formed so as to cover the vapor deposition layer 7 and the pattern printing layer 6 and to cover the base sheet 2 (see FIG. 4). In the case of FIG. 4, the adhesive anchor layer 4 exhibits a function as an anchor layer for facilitating adhesion of the pattern printing layer 6 and the metal vapor deposition layer 7 to the base sheet 2.
[0024]
Alternatively, in the hairline insert film of the present invention, the anchor layer 4 having adhesiveness is formed on the entire surface of the base sheet 2, and the metal deposition layer 7 and the pattern printing layer 6 are formed on a part of the anchor layer 4, There is one in which an adhesive layer 10 is formed so as to cover the metal vapor-deposited layer 7 and the pattern printing layer 6 and to cover the anchor layer 4 having adhesiveness (see FIG. 5). In the case of FIG. 5, the adhesive anchor layer 4 exhibits a function as an anchor layer for facilitating adhesion of the pattern printing layer 6, the metal vapor deposition layer 7, and the adhesive layer 10 to the base sheet 2. .
[0025]
The method for producing a hairline insert-molded product according to the present invention comprises an adhesive anchor layer 4 having a film thickness smaller than the depth of the hairline recess, metal vapor deposition, on the transparent substrate sheet 2 on which the above-mentioned hairline is formed. The hairline insert sheet on which the layer 7 and / or the pattern printing layer 6 are sequentially formed is placed in the injection mold so that the base sheet 2 and the mold surface are in contact with each other, and after the mold is closed, the molding resin is applied. The hairline insert film 1 is adhered to the resin molded product 8 by injecting the resin into a mold and solidifying the resin.
[0026]
First, the hairline insert film 1 is placed in an injection mold comprising a movable mold and a fixed mold. The base sheet 2 side is arranged so as to be in contact with the surface of one of the movable mold and the fixed mold. Alternatively, two hairline insert films may be prepared and arranged so that the base sheet 2 side of one insert film is in contact with the movable mold and the base sheet 2 side of the other insert film is in contact with the fixed mold. After the arrangement, the hairline insert film 1 is heated and softened so as to be easily deformed, and vacuum suction is performed from a vacuum suction hole provided on the inner surface of the movable cavity so that the hairline insert film 1 is removed from the inner surface of the movable cavity. It may be adhered to.
[0027]
Next, the injection mold is closed, and the cavity is filled with molding resin from the injection port provided in the fixed mold. The pattern print layer 6 of the hairline eye insert film 1 and the molding resin come into contact with each other. Molded resins include those that are colorless and transparent, those that are colored and transparent, and those that are colored and opaque. When the molding resin is colorless and transparent or colored and transparent, if the refractive index of the molding resin is substantially the same as the refractive index of the base sheet 2 or the anchor layer 4 having adhesiveness, the hairline of the base sheet 2 is apparently visible. Can be eliminated.
[0028]
When the hairline insert film 1 having the window portion A from which the colorless and transparent layer 5 is exposed is used, the molding resin directly contacts the pattern printing layer 6 and the colorless and transparent layer 5.
[0029]
When the hairline insert film 1 having the window portion B from which the anchor layer 4 having adhesiveness is exposed is used, the molding resin is in direct contact with the pattern printing layer 6 and the anchor layer 4, and the anchor layer 4 having adhesiveness ( The hairline of the window part B) apparently disappears.
[0030]
Next, the molding resin filled in the cavity by injection is solidified to form the resin molded product 8 and, at the same time, the hairline insert film 1 is adhered to the surface. After the resin molded product 8 is cooled and solidified, and the hairline insert film 1 is adhered to the resin molded product 8, the injection mold is opened and the insert molded product to which the hairline insert film 1 is bonded is taken out.
[0031]
In the insert molded product obtained when the hairline insert film 1 in which the colorless and transparent layer 5 is exposed is used, the window portion A becomes a transparent window portion without a hairline. An insert molded product obtained when the hairline insert film 1 with the adhesive anchor layer 4 exposed is used, the window portion B is as follows. When all the layers of the base sheet 2, the adhesive anchor layer 4 and the molding resin have the same refractive index, a transparent window portion without a hairline is formed. When the base sheet 2, the adhesive anchor layer 4 and all the layers of the molding resin are not the same refractive index, a transparent window portion having hairlines is formed.
[0032]
The resulting hairline insert molded product includes a hairline insert molded product in which a metal vapor-deposited portion or a pattern printing portion with a hairline is combined with a metal vapor-deposited portion or a pattern print portion without a hairline. Alternatively, there is a hairline eye insert molded product in which a metal vapor deposition part or a pattern printing part with a hairline is combined with a transparent window part without a hairline. Alternatively, there is a hairline eye insert molded product in which a metal vapor deposition part or a pattern printing part with a hairline, a metal vapor deposition part or a pattern printing part without a hairline, and a transparent window part without a hairline are combined.
[0033]
Further, in the hairline insert molded product obtained by the manufacturing method of the present invention, the anchor layer 4 having adhesiveness is formed on the entire surface of the base sheet 2, and the metal vapor deposition layer 7 is formed on a part of the anchor layer 4, It was obtained using a hairline eye insert film in which a pattern printing layer 6 was formed so as to cover a part of the metal deposition layer 7, and an adhesive layer 10 was formed in registration with the metal deposition layer 7 and the pattern printing layer 6. There is a hairline eye insert molded product (see FIG. 3). Alternatively, the anchor layer 4 having adhesiveness is formed on a part of the base sheet 2, the metal vapor deposition layer 7 and the pattern printing layer 6 are formed only on the anchor layer 4, and the metal vapor deposition layer 7 and the pattern printing layer 6 There is a hairline insert product obtained using a hairline insert film in which the adhesive layer 10 is formed so as to cover the base sheet 2 (see FIG. 4). Alternatively, the anchor layer 4 having adhesiveness is formed on the entire surface of the base sheet 2, the metal vapor deposition layer 7 and the pattern printing layer 6 are formed on a part of the anchor layer 4, and the metal vapor deposition layer 7 and the pattern printing layer 6 are formed. There is a hairline insert product obtained using a hairline insert film in which an adhesive layer 10 is formed so as to cover the anchor layer 4 having adhesive properties (see FIG. 5).
[0034]
[Action]
Since the hairline insert film of this invention has an adhesive anchor layer with a film thickness smaller than the depth of the hairline recess, even if a pattern printing layer or a metal vapor deposition layer is formed on the hairline, The hairline is not apparently lost, and the adhesive strength between the base sheet and the pattern printing layer or the metal vapor deposition layer is strong.
[0035]
Moreover, when it is set as the hairline eye insert film in which the anchor layer having adhesiveness is exposed, the hairline in the exposed portion of the anchor layer having adhesiveness can be apparently disappeared by the molding resin to form a transparent window portion. The adhesive force between the base sheet and the molding resin can be increased by the anchor layer having adhesiveness.
[0036]
When the colorless transparent layer is partially formed on the hairline, the hairline insert film of the present invention can partially eliminate the hairline. In all layers that are sequentially formed on the colorless transparent layer, the hairline pattern is apparently lost. All the layers formed sequentially on the adhesive anchor layer without the colorless transparent layer remain with the hairline eye pattern.
[0037]
As described above, the hairlines of the insert film and the insert molded product can be freely patterned.
[0038]
【Example】
Using a polyester film having a thickness of 125 μm as a base sheet, a sand paper with a surface roughness of 10 μm was used to form a hairline with a depth of recess of 10.0 μm, and a thermosetting urethane resin was used on the unevenness of the hairline. An adhesive anchor layer having a film thickness of 0.5 μm is formed by a gravure printing method, and a colorless transparent layer having a film thickness of 12.0 μm is formed thereon by a gravure printing method using a thermosetting urethane resin. A pattern printing layer comprising 60% by weight of thermosetting acrylic resin as a resin binder and 40% by weight of heavy calcium carbonate as a pigment is formed thereon, and a film thickness of 400 mm is formed thereon by vacuum deposition using aluminum. A vacuum-deposited layer was formed, and an adhesive layer having a thickness of 2.5 μm was obtained by gravure printing using polyvinyl chloride.
[0039]
After the hairline insert film is placed in the injection mold so that the base sheet and the mold surface are in contact with each other and the mold is closed, the molding resin temperature is 220 to 250 ° C. and the mold temperature is 40 to 60 ° C. In No. 1, a transparent and transparent acrylonitrile butadiene polystyrene copolymer resin was injected into a mold as a molding resin, and the molding resin was solidified to bond the hairline insert film to the resin molded product.
[0040]
【The invention's effect】
Since the present invention has the above-described configuration and operation, the hairline eye pattern printed layer, the hairline eye metallized layer, the hairline eyed pattern printed layer, the hairline eyed metal deposited layer, and the transparent window portion are optional. Can be combined, and the patterned hairline can be freely decorated on the molded product, thereby improving the design.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing an embodiment of a hairline insert film of the present invention.
FIG. 2 is a cross-sectional view showing an example of a hairline insert molded product obtained by the method of manufacturing a hairline insert molded product of the present invention.
FIG. 3 is a cross-sectional view showing an example of a hairline insert molded product obtained by the method of manufacturing a hairline insert molded product of the present invention.
FIG. 4 is a cross-sectional view showing an example of a hairline insert molded product obtained by the method for manufacturing a hairline insert molded product of the present invention.
FIG. 5 is a cross-sectional view showing an example of a hairline insert molded product obtained by the method of manufacturing a hairline insert molded product of the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Hairline eye insert film 2 Base sheet 3 Hairline unevenness 4 Adhesive anchor layer 5 Colorless transparent layer 6 Picture printing layer 7 Metal vapor deposition layer 8 Resin molded product 9 Hairline eye insert molded product 10 Adhesive layer

Claims (6)

  An adhesive anchor layer and a metal vapor deposition layer or a pattern printing layer are sequentially formed on the hairline side of a transparent base sheet in which the hairline is formed entirely on one side, and is adhesive. A hairline insert film, wherein the anchor layer has a film thickness smaller than the depth of the recesses forming the hairline.   The hairline insert film according to claim 1, wherein a colorless transparent layer having a film thickness larger than the depth of the hairline recess is formed on a part of the anchor layer having adhesiveness.   The hairline eye insert film according to claim 2, further comprising a window portion on which the metal vapor-deposited layer and the pattern print layer are not formed on the colorless transparent layer.   The hairline insert film according to any one of claims 1 to 3, further comprising a window portion on which the metal vapor-deposited layer and the pattern print layer are not formed on the anchor layer having adhesiveness.   The hairline insert film according to any one of claims 1 to 3 is placed in an injection mold so that the base sheet side of the hairline insert film is in contact with the mold surface, and the mold resin is placed in the mold after closing the mold. A method of manufacturing a hairline eye insert molded product, comprising: injecting a hairline eye insert film to a resin molded product by injecting the resin into a resin and solidifying the molded resin.   The hairline insert film according to claim 4 is placed in an injection mold such that the base sheet side of the hairline insert film is in contact with the mold surface, and after the mold is closed, the molding resin is injected into the mold. The hairline eye insert is characterized in that the hairline eye insert film is bonded to the resin molded product by bringing the molding resin into contact with the adhesive anchor layer of the window portion of the hairline eye insert film and solidifying the molding resin. Manufacturing method of molded products.

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