JP4542667B2 - Method for producing glitter decorative sheet and glitter decorative molded product - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a glittering decorative sheet and a glittering decoration that can be used for automobile interior parts such as console panels, center clusters, and switch bases, and automobile exterior parts such as side mat guards, bumpers, foil caps, and moldings. The present invention relates to a method for manufacturing a molded product.
[0002]
The glittering decorative sheet used for automobile interior parts and exterior parts has excellent three-dimensional workability and is required to have a predetermined surface hardness and thickness. The method for producing a glittering decorative molded product is particularly suitable.
[0003]
[Prior art]
Conventionally, as a method for decorating a plastic molded article or the like, a decorative sheet having a metallic thin film layer or the like formed on a base sheet is supplied into an injection mold to produce a three-dimensional molded article. There is a method of performing decoration by adhering a decorative sheet integrally to a molded product at the same time as molding. Since the glittering decorative sheet having such a configuration has a metal thin film layer, it is possible to express a pattern having high glittering property utilizing metallic luster.
[0004]
Since the three-dimensional processability is required as the base sheet, a film made of acrylic resin, polycarbonate resin, vinyl chloride resin, polyester copolymer resin, non-crystalline or low-crystalline polypropylene resin, or the like is used. In addition, since the metal thin film layer is also required to have three-dimensional workability, an aluminum film or the like is used.
[0005]
In order to form the metal thin film layer, a vacuum forming method or the like is usually used. However, since the base sheet having three-dimensional processability is intensely thermally expanded and contracted, it is not suitable because the base sheet partially expands and contracts when the metal thin film layer is partially formed by a vacuum deposition method or the like.
[0006]
Therefore, the base sheet does not expand and contract due to the formation of the metal thin film layer, and as a glittering decorative sheet having a predetermined surface hardness and thickness for use in automobile interior parts and exterior parts, for example, hardness H or higher The base sheet is a thermoplastic sheet having a three-dimensional workability with a thickness of 200 μm or more, and a metal thin film layer is formed thereon by a transfer method. In addition, a thermoplastic sheet having a three-dimensional workability with a hardness of HB or less and a thickness of 200 μm or more is used as a base sheet, and a metal thin film layer is formed thereon by a transfer method. Are laminated on a metal thin film layer as a cover sheet.
[0007]
In order to obtain a glittering decorative molded product using such a glittering decorative sheet, the glittering decorative sheet is three-dimensionally processed by vacuum forming and pre-formed, and after punching into a desired shape, After placing in an injection mold and closing the mold, the molding resin is injected into the cavity, and the base sheet side of the glittering decorative sheet is integrally bonded to the resin molded product obtained by solidifying the molding resin. There was a method in which the decorative sheet was heated and sucked in the mold and clamped, then the molding resin was injected into the cavity, and the base sheet side of the glittering decorative sheet was integrally bonded to the resin molded product obtained by solidifying the molding resin. .
[0008]
[Problems to be solved by the invention]
However, such a glittering decorative sheet has the following problems.
[0009]
The former glittering decorative sheet with the metal thin film layer transferred onto the base sheet has a high heat softening temperature, so it takes time for preheating during vacuum forming, and the metal thin film layer moves with the heat transfer of the thermoplastic sheet. If the microcracks are generated or the preheating time is shortened, the three-dimensional shape cannot be followed and the base sheet is whitened.
[0010]
The latter glittering decorative sheet in which a metal sheet layer is transferred to a base sheet having a hardness of HB or less and then a cover sheet having a hardness of H or more is laminated on the metal film layer is obtained by laminating the cover sheet or There has been a problem that after pre-molding, residual stress such as resin shrinkage acts to cause a minute shift in a portion in contact with the metal thin film layer, resulting in delamination.
[0011]
Therefore, the present invention eliminates the above-described problems, does not cause microcracks in the metal thin film layer and does not cause whitening in the base sheet, and does not cause delamination even when a plurality of sheets are laminated. An object of the present invention is to provide a glittering decorative sheet having high hardness and excellent three-dimensional workability, and a method for producing a glittering decorative molded product using the same.
[0012]
[Means for Solving the Problems]
In order to achieve the above object, the glittering decorative sheet of the present invention is configured as follows.
[0013]
That is, the glittering decorative sheet of the present invention includes a base sheet in which a thermoplastic low-hardness sheet having three-dimensional workability and a thermoplastic high-hardness sheet having three-dimensional workability are bonded by a laminating method, and the base A glittering decorative sheet formed on the high hardness sheet side of the sheet and having a metal thin film layer having three-dimensional processability, wherein the low hardness sheet is made of acrylonitrile-butadiene-styrene copolymer resin, and the hardness (measurement method) : Japanese Industrial Standard (JIS) K5401) B or less, thickness 50 to 500 μm, high hardness sheet is made of acrylic resin, hardness (measurement method: Japanese Industrial Standard (JIS) K5401) H or more, thickness 50 to It was 200 micrometers, and it comprised so that the thickness of the whole glittering decorating sheet might be 700 micrometers or less (refer FIG. 1).
[0017]
In the above invention, the metal thin film layer may be made of aluminum, indium, chromium, tin, nickel, silver, gold, copper, platinum, or an alloy or compound thereof.
[0018]
In the above invention, the metal thin film layer may be laminated by a transfer method.
[0019]
Moreover, the manufacturing method of the glittering decorative molded product of the present invention is a method of installing the glittering decorative sheet according to claim 1 in a mold having a cavity, injecting a molten resin into the mold, The decorative sheet and the molten resin were integrated to obtain a molded product.
[0020]
In the above invention, the glittering decorative sheet may be processed into a three-dimensional shape and punched into a desired shape before the glittering decorative sheet is placed in the mold.
[0021]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described in detail with reference to the drawings.
[0022]
FIG. 1 is a cross-sectional view showing one embodiment of the glittering decorative sheet of the present invention. FIGS. 2-3 is sectional drawing which shows 1 process of the manufacturing method of the glittering decorative molded product of this invention. FIG. 4 is a cross-sectional view showing an example of a glittering decorative molded product obtained by the method for producing a glittering decorative molded product of the present invention. In the figure, 1 is a glittering decorative sheet, 2 is a low hardness sheet, 3 is a high hardness sheet, 4 is a metal thin film layer, 5 is a base sheet, 6 is a mold, 8 is a clamp member, 9 is a gate portion, 10 Is a molding resin.
[0023]
The glittering decorative sheet 1 of the present invention is a high hardness sheet 3 side of a base sheet 5 in which a thermoplastic low hardness sheet 2 having three-dimensional workability and a thermoplastic high hardness sheet 3 having three-dimensional workability are laminated. Is a glittering decorative sheet 1 in which a metal thin film layer 4 having three-dimensional workability is laminated, and the low hardness sheet 2 has a hardness (measurement method: Japanese Industrial Standard (JIS) K5401) B or less, a thickness of 50 to It is 500 μm, the high hardness sheet 3 has a hardness (measurement method: Japanese Industrial Standard (JIS) K5401) H or more and a thickness of 50 to 200 μm, and the total thickness of the glittering decorative sheet 1 is 700 μm or less. Yes (see FIG. 1).
[0024]
The low hardness sheet 2 is a thermoplastic sheet having a three-dimensional workability, and has a hardness of B or less and a thickness of 50 to 500 μm according to a measurement method defined in JIS K5401.
[0025]
Using a sheet in this range as the low hardness sheet 2 has sufficient flexibility even at a temperature lower than the softening point, so that even if the molded product has a sharp shape such as a groove, the shape follows the shape. Even if the molding shape in the preliminary molding is insufficient, the low hardness sheet 2 is not whitened when the mold 6 is put in and clamped. Here, if the hardness of the low hardness sheet 2 exceeds B, it becomes too hard when laminated with the high hardness sheet 3 and tends to whiten when clamped. On the other hand, if the thickness of the low hardness sheet 2 is less than 50 μm, uniform film formation becomes difficult in the film forming process of the low hardness sheet 2. On the other hand, if it exceeds 500 μm, when trimming unnecessary portions of the glittering decorative sheet 1, the glittering decorative sheet 1 becomes too soft and it becomes difficult to cut with a punching die.
[0026]
Specifically, as the low hardness sheet 2 having such properties, a sheet made of polycarbonate resin, acrylic rubber, polystyrene resin, vinyl chloride resin, polypropylene resin, polyethylene resin or the like can be used.
[0027]
In particular, as the low-hardness sheet 2, it is preferable to use a sheet made of acrylonitrile-butadiene-styrene copolymer resin (ABS resin). This is because it can be bonded to a molded article made of acrylic resin, which is frequently used as an automobile interior part or exterior part, by thermocompression bonding without using an adhesive layer. Further, by increasing the amount of butadiene in the ABS resin, the hardness and softening point are lowered, and molding at a lower temperature becomes possible.
[0028]
The high hardness sheet 3 is a thermoplastic sheet having three-dimensional processability, and has a hardness of H or more and a thickness of 50 to 200 μm according to a measuring method defined in JIS K5401.
[0029]
When a sheet within this range is used as the high hardness sheet 3, the glittering decorative sheet 1 has formability and the surface hardness of the metal thin film layer 4 laminated thereon can be made high. . Here, if the hardness of the high-hardness sheet 3 is less than H, depending on the type of the metal thin film layer 4 to be laminated, there is a risk that the hardness HB generally required for an automobile interior part or exterior part cannot be satisfied. There is. On the other hand, if the thickness of the high hardness sheet 3 is less than 50 μm, the film thickness is not constant at the time of film formation, and there is a possibility that sufficient surface strength is not exhibited due to the influence of the low hardness sheet 2. On the other hand, if it exceeds 200 μm, there is a risk of whitening during processing.
[0030]
As the high hardness sheet 3 having such properties, specifically, a sheet made of an acrylic resin, a fluorine resin, an AS resin, or the like can be used.
[0031]
In particular, the high hardness sheet 3 is preferably made of an acrylic resin.
It is excellent in light resistance, and when the low hardness sheet 2 is made of ABS resin, the adhesion to the low hardness sheet 2 is also excellent.
[0032]
In order to laminate the low-hardness sheet 2 and the high-hardness sheet 3, it is preferable to use a lamination method such as an extrusion lamination method, a hot melt lamination method, a heat lamination method, or a dry lamination method. If the low-hardness sheet 2 and the high-hardness sheet 3 are the same resin, both can be brought into close contact with each other without using an adhesive. Further, even if the low hardness sheet 2 and the high hardness sheet 3 are not the same resin, a sufficient adhesion strength can be obtained by selecting an appropriate laminating method. Further, according to the thermal laminating method, when the metal thin film layer 4 is formed by the transfer method, the lamination of the low hardness sheet 2 and the high hardness sheet 3 and the transfer of the metal thin film layer 4 can be integrated in one process. It is.
[0033]
The metal thin film layer 4 is a layer for expressing metallic luster, and has a three-dimensional workability.
[0034]
As the metal thin film layer 4, a metal such as aluminum, indium, chromium, tin, nickel, silver, gold, copper, platinum, iron, titanium, lead, zinc, or an alloy or compound thereof may be used. In particular, aluminum, indium, chromium, tin, nickel, silver, gold, copper, platinum, or an alloy or compound thereof is preferable. This is because it has three-dimensional workability and physical properties.
[0035]
The metal thin film layer 4 may be formed by a transfer method, a vacuum deposition method, a sputtering method, an ion plating method, a plating method, or the like.
[0036]
In particular, the metal thin film layer 4 is preferably laminated by a transfer method. When performing various decorations such as letters and patterns in combination with metallic luster, all decorations can be performed in one step.
[0037]
In order to form the metal thin film layer 4 by the transfer method, a transfer material in which a transfer layer such as the metal thin film layer 4 and an adhesive layer is formed on a base film is prepared, and the transfer material is placed on the substrate sheet 5 on the high hardness sheet 3 side. The transfer layer can be transferred to the base sheet 5 by superimposing the transfer layer side, applying hot pressure to bond the base sheet 5 and the transfer material, peeling the base film of the transfer material.
[0038]
Moreover, you may form the metal thin film layer 4 partially. As an example of partially forming the metal thin film layer 4, after forming a solvent-soluble resin layer in a portion that does not require the metal thin film layer 4, a metal thin film is formed on the entire surface, and solvent cleaning is performed. There is a method for removing unnecessary metal thin films together with a solvent-soluble resin layer. As another example, there is a method in which a metal thin film is formed on the entire surface, a resist layer is then formed on a portion where the metal thin film is to be left, and etching is performed with acid or alkali to remove the resist layer. .
[0039]
The total thickness of the glittering decorative sheet 1 thus configured is 700 μm or less. If it is within this range, even if the molded product has a sharp shape such as a groove at the time of three-dimensional processing, the glittering decorative sheet 1 follows the shape, and the preforming is insufficiently molded. In addition, the base sheet 5 is not whitened when it is put into the mold 6 and clamped.
[0040]
The glittering decorative sheet 1 of the present invention is not limited to the above configuration, and may be configured as follows.
[0041]
For example, you may make it have a design layer. The design layer is a layer that expresses decoration in addition to the expression of metallic luster by the metal thin film layer 4. Specifically, the design includes characters, symbols, etc., solid design, wood design, stone design, carbon cloth. Examples include patterns such as patterns. The design layer may be partially provided. As a material of the pattern layer, a resin such as polyvinyl resin, polyamide resin, polyester resin, acrylic resin, polyurethane resin, polyvinyl acetal resin, polyester urethane resin, cellulose ester resin, alkyd resin is used as a binder. A colored ink containing a pigment or dye of an appropriate color as a colorant may be used. The pattern layer may be formed by a normal printing method such as an offset printing method, a gravure printing method, or a screen printing method, or a coating method such as a roll coating method or a spray coating method. The thickness of the pattern layer is preferably 0.1 to 20 μm. According to the normal printing method, it is in this range.
[0042]
A hard coat layer may be formed. By forming the hard coat layer, although the three-dimensional workability of the glittering decorative sheet 1 is slightly lowered, the surface hardness can be increased to about 4H.
[0043]
In order to obtain a glittering decorative molded product using the glittering decorative sheet 1 having such a configuration, the glittering decorative sheet 1 is installed in a mold 6 having a cavity, and a molten resin is contained in the mold 6. To obtain a molded product in which the decorative sheet and the molten resin are integrated. Specifically, it may be performed as follows.
[0044]
First, the glittering decorative sheet 1 is installed in the mold 6. At this time, the fixed position of the glittering decorative sheet 1 may be aligned using a phototube sensor or the like so that the design of the glittering decorative sheet 1 and the shape of the mold 6 are aligned.
[0045]
Next, the glittering decorative sheet 1 is fixed in the mold 6 by appropriately performing heating and suction (see FIG. 2). Moreover, in order to heat the glittering decoration sheet 1 and to make it easy to follow a cavity surface, you may heat the glittering decoration sheet 1 with the heating means which consists of an infrared heater etc. Further, the glittering decorative sheet 1 may be formed by vacuum forming or pressure forming along the cavity surface.
[0046]
Next, the mold 6 is closed, the molding resin 10 is injected into the mold 6, and the glittering decorative sheet 1 and the molding resin 10 are integrated (see FIG. 3).
[0047]
As the molding resin 10, a polyethylene resin, a polypropylene resin, an acrylic resin, a polystyrene resin, a polyacrylonitrile styrene resin, a polyacrylonitrile butadiene styrene resin, a PC / ABS alloy resin containing glass fiber, or the like is used. Good.
[0048]
After the molding resin 10 is solidified, the mold is opened and the resin molded product to which the glittering decorative sheet 1 is integrated and bonded is taken out to obtain a glittering decorative molded product (see FIG. 4).
[0049]
The above-described method is an example of a forming unit and is not limited to this.
For example, when the glittering decorative sheet 1 is fed into the molding die 6, the long glittering decorative sheet 1 may be used, or the single-piece glittering decorative sheet 1 is fed one by one. But you can. Further, the glittering decorative sheet 1 may be preliminarily formed by processing into a three-dimensional shape by a vacuum forming method or the like so as to conform to the cavity shape of the mold 6 in advance. Further, the glittering decorative sheet 1 may have a periphery cut in advance according to the shape of the molded product. Moreover, you may cut and remove the extra glittering decoration sheet 1 around a glittering decorative molded product after a shaping decoration process.
[0050]
【Example】
Example 1 A chrome-colored automobile bumper was obtained as follows.
[0051]
A 25 μm thick polyethylene terephthalate film is used as a base film, an acrylic resin release layer and a urethane resin anchor layer are sequentially formed thereon, and then a 40 nm thick chromium thin film layer is formed. Then, an adhesive layer made of vinyl resin was formed to obtain a transfer material.
[0052]
Next, an ABS resin film having a hardness of 2B and a thickness of 450 μm is used as the low hardness sheet, and an acrylic resin film (N-47 manufactured by Mitsubishi Rayon Co., Ltd.) having a hardness of 2H and a thickness of 50 μm is superimposed thereon. Furthermore, after superimposing the transfer side surface of the transfer material on it and laminating the low hardness sheet, the high hardness sheet and the transfer sheet by the thermal laminating method, the base film of the transfer material is peeled off to form a glittering decorative sheet. Obtained.
[0053]
The glittering decorative sheet obtained as described above is processed into a three-dimensional shape with a vacuum molding machine, punched into a desired shape, put into an injection mold, and ABS molding resin is injected into the cavity. Thus, a glittering decorative molded product in which the glittering decorative sheet and the molten resin were integrated was obtained.
[0054]
The glittering decorative molded product, which is a chromium-colored automobile bumper thus obtained, was not whitened on the base sheet or microcracked on the metal thin film layer. Further, no delamination occurred between the low hardness sheet and the high hardness sheet. Further, the surface of the glittering decorative molded product had a hardness of H and a high hardness.
[0055]
Example 2 A smoke-colored center cluster was obtained as follows.
[0056]
A polyethylene terephthalate film having a thickness of 25 μm is used as a base film, on which a release layer made of an acrylic resin, a pattern layer of a hair-pattern made of an acrylic resin, and a smoke colored solid pattern layer made of an acrylic resin, Then, an anchor layer made of urethane resin was sequentially formed, then a metal thin film layer made of indium deposited layer having a thickness of 40 nm was formed, and then an adhesive layer made of vinyl resin was formed to obtain a transfer material.
[0057]
Next, an ABS resin film with a hardness B of 200 μm in thickness is used as a low hardness sheet, and an acrylic resin film (HT-526, manufactured by Sumitomo Chemical Co., Ltd.) with a hardness of 2 H and a thickness of 125 μm is stacked thereon as a high hardness sheet. Furthermore, after superimposing the transfer layer side surface of the transfer material on it and laminating the low-hardness sheet, high-hardness sheet and transfer sheet by the thermal laminating method, the base film of the transfer material is peeled off to give the glitter decoration A sheet was obtained.
[0058]
The glittering decorative sheet obtained as described above is placed in a mold for injection molding, sucked into the mold and closed, and ABS molding resin is injected into the cavity, and the glittering decorative sheet, molten resin, Was obtained.
[0059]
The glittering decorative molded product, which is a smoke-colored center cluster obtained in this way, does not cause whitening in the base sheet or microcracks in the metal thin film layer, and has a low hardness sheet and high hardness. No delamination occurred between the sheet and the sheet. The surface of the glittering decorative molded product had a hardness of 2H and high hardness.
[0060]
【The invention's effect】
Since this invention consists of an above-described structure, it has the following effects.
[0061]
The glittering decorative sheet of the present invention includes a base sheet in which a thermoplastic low-hardness sheet having three-dimensional workability and a thermoplastic high-hardness sheet having three-dimensional workability are bonded together by a laminating method, A glittering decorative sheet formed on a high hardness sheet side and having a metal thin film layer having three-dimensional processability, wherein the low hardness sheet is made of acrylonitrile-butadiene-styrene copolymer resin, and the hardness (measurement method: Japan) Industrial standard (JIS) K5401) B or less, thickness 50 to 500 μm, high hardness sheet is made of acrylic resin, hardness (measurement method: Japanese Industrial Standard (JIS) K5401) H or more, thickness 50 to 200 μm Yes, since the total thickness of the glittering decorative sheet is 700 μm or less, the glittering decorative molded product in which the glittering decorative sheet and the molten resin are integrated In this case, the metal thin film layer of the glittering decorative molded product is not microcracked, the substrate sheet is not whitened, and delamination occurs between the low hardness sheet and the high hardness sheet. No high hardness and excellent three-dimensional workability.
[0062]
Moreover, the manufacturing method of the glittering decorative molded product of the present invention includes the above-described glittering decorative sheet placed in a mold having a cavity, injecting a molten resin into the mold, the decorative sheet and the molten resin Therefore, there is no microcracking in the metal thin film layer or whitening in the base sheet, and delamination may occur between the low hardness sheet and the high hardness sheet. Therefore, it is possible to easily obtain a glittering decorative molded product having a high hardness surface.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing an example of a glittering decorative sheet according to the present invention.
FIG. 2 is a cross-sectional view showing one step of a method for producing a glittering decorative molded product according to the present invention.
FIG. 3 is a cross-sectional view showing one step of a method for producing a glittering decorative molded product according to the present invention.
FIG. 4 is a cross-sectional view showing an example of a glittering decorative molded product obtained by the method for producing a glittering decorative molded product of the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Glossy decorative sheet 2 Low hardness sheet 3 High hardness sheet 4 Metal thin film layer 5 Base sheet 6 Mold 8 Clamp member 9 Gate part 10 Molding resin

Claims (5)

A base sheet in which a thermoplastic low-hardness sheet having three-dimensional workability and a thermoplastic high-hardness sheet having three-dimensional workability are bonded by a laminate method;
A metal thin film layer formed on the surface side of the high hardness sheet of the base sheet and having three-dimensional workability,
A glittering decorative sheet comprising:
The low hardness sheet is made of acrylonitrile-butadiene-styrene copolymer resin, has a hardness (measurement method: Japanese Industrial Standard (JIS) K5401) B or less, and a thickness of 50 to 500 μm.
The high-hardness sheet is made of an acrylic resin, has a hardness (measurement method: Japanese Industrial Standard (JIS) K5401) H or more, and a thickness of 50 to 200 μm.
A glittering decorative sheet, wherein the thickness of the entire glittering decorative sheet is 700 μm or less. The glittering decorative sheet according to claim 1 , wherein the metal thin film layer is made of aluminum, indium, chromium, tin, nickel, silver, gold, copper, platinum, or an alloy or compound thereof. The metal thin film layer, the glitter decorative sheet according to any one of claims 1-2 in which are laminated by the transfer method. To claim the bright decorative sheet according to claim 1 to 3 is placed in a mold having a cavity, the molten resin is injected into the mold to obtain a molded article with the decorative sheet and the molten resin are integrated A method for producing a glittering decorative molded product. The method for producing a glittering decorative molded product according to claim 4 , wherein the glittering decorative sheet is processed into a three-dimensional shape and punched into a desired shape before the glittering decorative sheet is installed in the mold.

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