JP6870267B2 - Manufacturing method of decorative resin molded product with protective film, manufacturing method of decorative resin molded product, and manufacturing system - Google Patents

Description

The present invention relates to a method for manufacturing a decorative resin molded product with a protective film, a method for manufacturing a decorative resin molded product, and a manufacturing system.

Conventionally, as a method of decorating a resin molded product used for automobile interiors, etc., (A) a method of producing an undecorated resin molded product by injection molding and then decorating by painting, (B) printing, metal deposition, etc. A method of performing injection molding with a decorative sheet having a decorative layer formed by means inserted into a mold and decorating the resin molded product at the same time is widely adopted.

For example, although the method (A) above has high production efficiency and can produce a resin molded product at low cost, basically only a single color design can be obtained. On the other hand, the method (B) above enables rich design expression such as wood grain pattern and abstract pattern.

Therefore, in the method of decorating the resin molded product, the above method (A) is often adopted for low-priced products, and the above-mentioned method (B) is often adopted for high-priced products. Further, even if the members and products have the same shape and the same function, both a low-priced product by the method (A) above and a high-design product by the method (B) above are provided according to the needs of the customer. In some cases.

By the way, in the case of the above method (A), in order to improve the coating suitability and adhesion of the paint, the surface to be coated of the resin molded product before coating is set as a rough surface having a fine uneven shape, and an anchor effect is obtained. It is required to be able to exert it (see, for example, Patent Document 1). Therefore, among the injection molding dies, a method of providing an uneven shape on the surface of the die on the side to be the surface to be coated of the resin molded product is used. Further, as disclosed in Patent Document 1, when a fine uneven shape is formed to make the surface of the resin molded product matte, or to reduce static electricity on the surface of the resin molded product, the fine unevenness is formed. A shape may be formed, and even in such a case, an uneven shape is provided on the surface of the injection molding die.

Further, also in the above method (B), similarly to the above method (A), an uneven shape may be provided on the surface of the injection molding die for the purpose of matting the surface of the resin molded product. is there.

On the other hand, in the method (B) above, when a resin molded product having a smooth surface is manufactured, if there are fine uneven shapes or scratches in the mold, a decorative sheet is used when simultaneous injection molding decoration is performed. The uneven shape and scratches of the mold are formed on the surface of the mold, which impairs the original design provided on the decorative sheet. Therefore, among the surfaces of the injection molding die, the surface facing the decorative sheet is generally smoothed by means such as polishing.

As described above, the surface of the injection molding die may or may not be provided with an uneven shape. Therefore, even when manufacturing resin molded products of the same shape, it is necessary to prepare both injection molding dies that do not have an uneven shape on the surface of the injection molding die and those that have an uneven shape. Therefore, the manufacturing cost of decorative resin molded products is increasing.

Japanese Unexamined Patent Publication No. 61-219607

The present invention provides a method for manufacturing a decorative resin molded product with a protective film, which reduces the manufacturing cost by using a common injection molding die regardless of the presence or absence of an uneven shape on the surface of the injection molding die. The main purpose is to do. The present invention also provides a method for producing a decorative resin molded product from the decorative resin molded product with the protective film. Further, the present invention provides a method for manufacturing a decorative resin molded product with a film by using a common injection molding mold regardless of the presence or absence of an uneven shape on the surface of the injection molding mold, and a decorative resin molded product. It is also an object of the present invention to provide a manufacturing system having a method of manufacturing the above.

The present inventors have conducted diligent studies to solve the above problems. As a result, by adopting a method for manufacturing a decorative resin molded product with a protective film, which comprises the following steps in order, a common injection molding die can be obtained regardless of the presence or absence of an uneven shape on the surface of the injection molding die. It has been found that it can be used and the manufacturing cost can be reduced.
Step 1: A decorative sheet provided with a protective film on the surface and an injection-molded mold in which a fine uneven shape is arranged on at least one surface of a male mold and a female mold are prepared. Step 2: The fine Step 3: Insert the decorative sheet into the injection-molded mold so that the surface on which the uneven shape is arranged faces the protective film. Step 3: The injection-molded mold is molded and described. Decorative resin molding with a protective film, which comprises a step of filling an injection resin in an injection molding mold to obtain a decorative resin molded product with a protective film in which a decorative sheet and a protective film are laminated on the injection resin. How to manufacture the product.
The present invention has been completed by further studies based on such findings.

That is, the present invention provides the inventions of the following aspects.
Item 1. A method for manufacturing a decorative resin molded product with a protective film, which comprises the following steps 1 to 3 in order.
Step 1: A decorative sheet provided with a protective film on the surface and an injection-molded mold in which a fine uneven shape is arranged on at least one surface of a male mold and a female mold are prepared. Step 2: The fine Step 3: Insert the decorative sheet into the injection-molded mold so that the surface on which the uneven shape is arranged faces the protective film. Step 3: The injection-molded mold is molded and described. Decorative resin molding with a protective film, which comprises a step of filling an injection resin in an injection molding mold to obtain a decorative resin molded product with a protective film in which a decorative sheet and a protective film are laminated on the injection resin. How to manufacture the product.
Item 2. Item 2. The decorative resin molded product according to Item 1, wherein the center line average roughness (Ra) of the surface having a fine uneven shape arranged on the surface of the injection molding mold is 0.5 μm or more and 8.0 μm or less. Manufacturing method.
Item 3. The fine uneven shape on the surface of the injection molding mold enhances the adhesion of the paint applied to the surface of the molded product, reduces the gloss of the surface of the molded product, and reduces the static electricity on the surface of the molded product. , Or, which is provided on the surface of the decorative sheet according to Item 1 or 2, which is provided to give a three-dimensional effect based on the uneven shape to the surface of the molded product, Item 1 or 2. The method for manufacturing a decorative resin molded product according to the description.
Item 4. A method for producing a decorative resin molded product, comprising a step of peeling off the protective film of the decorative resin molded product with a protective film, following the method for producing the decorative resin molded product with the protective film according to any one of Items 1 to 3.
Item 5. A method A for manufacturing a decorative resin molded product with a protective film, which comprises the following steps 1A to 3A in order, and
Step 1A: A decorative sheet provided with a protective film on the surface and an injection-molded mold in which a fine uneven shape is arranged on at least one surface of a male mold and a female mold Step 2A: The fine Step 3A of inserting the decorative sheet into the injection-molded mold so that the surface on which the uneven shape is arranged and the protective film face each other: Step 3A: The injection-molded mold is molded and described. A step of filling an injection molding die with an injection resin to obtain a decorative resin molded product with a protective film in which a decorative sheet and a protective film are laminated on the injection resin. The following steps 1B to 3B are provided in order. , Manufacturing method B of a decorative resin molded product having a fine uneven shape on the surface,
Step 1B: Preparing a decorative sheet and an injection molding die in which fine uneven shapes are arranged on at least one surface of a male mold and a female mold. Step 2B: The addition inside the injection molding die. Step 3B of inserting the decorative sheet: The injection molding die is molded, the injection resin is filled in the injection molding die, the decorative sheet is laminated on the injection resin, and the surface is finely uneven. It is equipped with a process to obtain a decorative resin molded product with a shape.
A manufacturing system in which the injection molding die common to the manufacturing method A and the manufacturing method B is used.
Item 6. A method A for manufacturing a decorative resin molded product with a protective film, which comprises the following steps 1A to 3A in order, and
Step 1A: A decorative sheet provided with a protective film on the surface and an injection-molded mold in which a fine uneven shape is arranged on at least one surface of a male mold and a female mold Step 2A: The fine Step 3A of inserting the decorative sheet into the injection-molded mold so that the surface on which the uneven shape is arranged and the protective film face each other: Step 3A: The injection-molded mold is molded and described. A step of filling an injection molding die with an injection resin to obtain a decorative resin molded product with a protective film in which a decorative sheet and a protective film are laminated on the injection resin. The following steps 1C and 2C are provided in order. , Manufacturing method C of a resin molded product having a fine uneven shape on the surface,
Step 1C: Prepare an injection molding die in which a fine uneven shape is arranged on at least one surface of a male mold and a female mold. Step 2C: The injection molding die is molded and inside the injection molding die. It is equipped with a process of filling an injection resin into a resin molded product having a fine uneven shape on the surface.
A manufacturing system that uses the injection molding die that is common to the manufacturing method A and the manufacturing method C.
Item 7. Item 6. The manufacturing system according to Item 6, further comprising a step 3C of painting the surface of the resin molded product after the step 2C.

According to the present invention, a common injection molding die can be used regardless of the presence or absence of an uneven shape on the surface of the injection molding die, and the manufacturing cost is reduced. A manufacturing method can be provided. Further, according to the present invention, it is possible to provide a method for producing a decorative resin molded product from the decorative resin molded product with the protective film. Further, according to the present invention, a method for manufacturing a decorative resin molded product with a protective film using a common injection molding die regardless of the presence or absence of an uneven shape on the surface of the injection molding die, and decoration. It is also possible to provide a manufacturing system including a method for manufacturing a resin molded product.

It is a schematic diagram for demonstrating the manufacturing method of the decorative resin molded article of this invention. It is a schematic diagram for demonstrating the manufacturing method of the decorative resin molded article of this invention. It is a schematic diagram for demonstrating the manufacturing method of the decorative resin molded article of this invention. It is a schematic diagram for demonstrating the manufacturing method of the decorative resin molded article of this invention. It is a schematic sectional view of the decorative sheet with a protective film used in the manufacturing method of this invention. It is a schematic sectional view of the decorative resin molded article with a protective film obtained by the manufacturing method of this invention. It is a schematic sectional view of the decorative resin molded article obtained by the manufacturing method of this invention.

The method for producing a decorative resin molded product with a protective film of the present invention is characterized by comprising the following steps 1 to 3.
Step 1: A decorative sheet provided with a protective film on the surface and an injection-molded mold in which a fine uneven shape is arranged on at least one surface of a male mold and a female mold are prepared. Step 2: The fine Step 3: Insert the decorative sheet into the injection-molded mold so that the surface on which the uneven shape is arranged faces the protective film. Step 3: The injection-molded mold is molded and described. A process of filling an injection mold with an injection resin to obtain a decorative resin molded product with a protective film in which a decorative sheet and a protective film are laminated on the injection resin.

Since the method for manufacturing a decorative resin molded product with a protective film of the present invention has such a configuration, a common injection molding die is used regardless of the presence or absence of an uneven shape on the surface of the injection molding die. Can be used, and the manufacturing cost can be reduced. Further, according to the present invention, the decorative resin molded product can be manufactured by peeling the protective film from the decorative resin molded product with the protective film. Since the surface of the decorative resin molded product was protected by a protective film during injection molding, the uneven shape of the injection molding mold was not formed on the surface of the decorative resin molded product, and a flat surface or a desired uneven shape was obtained. can do. Hereinafter, with reference to FIGS. 1 to 7, a method for manufacturing a decorative resin molded product with a protective film of the present invention, a method for manufacturing a decorative resin molded product, and further, a decorative resin molded product with a protective film are manufactured. The manufacturing system of the present invention, in which the method and the method for manufacturing a decorative resin molded product having a fine uneven shape on the surface are performed using a common injection molding mold, will be described in detail.

The laminated structure of the decorative sheet with the protective film and specific examples of the composition of each layer used in the production of the decorative resin molded product 10 with the protective film of the present invention will be described in detail after the explanations of Steps 1 to 3. Describe. Further, in the present specification, the numerical range indicated by "~" means "greater than or equal to" and "less than or equal to", except for the parts specified as "greater than or equal to" and "less than or equal to". For example, the notation of 2 to 15 mm means 2 mm or more and 15 mm or less.

(Step 1)
In step 1 of the method for manufacturing a decorative resin molded product with a protective film of the present invention, for example, as shown in FIG. 1, a decorative sheet 2 (decorative sheet with a protective film) on which the protective film 1 is provided on the surface. And an injection molding mold in which a fine uneven shape is arranged on at least one surface M of the male mold 40 and the female mold 30 are prepared. In FIGS. 1 to 4, it is assumed that the female mold 30 side is the front surface side of the molded product and the male mold 40 side is the back surface side of the molded product, and a fine uneven shape is arranged on the inner surface M of the female mold 30. Is shown. Depending on the shape of the molded product, the male mold 40 may be on the front surface side of the molded product and the female mold 30 may be on the back surface side of the molded product, and a fine uneven shape may be arranged on the inner surface of the male mold 40. ..

The fine uneven shape of the surface M of the injection molding mold used in the present invention is, for example, to improve the adhesion of the paint applied to the surface of the molded product and to reduce the gloss of the surface of the molded product. It is provided to reduce the static electricity of the molded product or to give a three-dimensional effect based on the uneven shape to the surface of the molded product.

In the injection molding die used in the present invention, the center line average roughness (Ra) of the surface M on which the fine uneven shape is arranged is appropriately set according to the function imparted to the surface of the molded product. For example, if the fine uneven shape on the surface of the injection molding die is provided to enhance the adhesion of the paint applied to the surface of the molded product, the center line average roughness (Ra) is, for example, About 0.5 to 8.0 μm can be mentioned. The center line average roughness (Ra) is a value measured on the surface of the injection molding die (the portion where the fine uneven shape is arranged) in accordance with the provisions of JIS B 0601: 2001.

(Step 2)
In the step 2, after the step 1, a protective film is attached to the inside of the injection molding die so that the surface M on which the fine uneven shape of the injection molding die is arranged and the protective film 1 face each other. Insert the decorative sheet. As shown in FIG. 2, a decorative sheet with a protective film may be preformed in the injection molding die between the steps 2 and 3. Further, the premolding of the decorative sheet with the protective film may be performed outside the injection molding die.

The step of performing the preforming preferably includes a step of vacuum forming after heating the decorative sheet with the protective film. By such pre-molding, even when the injection molding die has a complicated shape, the shape of the decorative sheet with the protective film can be suitably molded into the shape of the injection molding die.

The heating temperature when the decorative sheet 2 is preformed, or the temperature at which the decorative sheet with the protective film is heated before the step 3, is equal to or higher than the glass transition temperature of the protective film 1 and the melting temperature (or melting point). It is preferably in the range of less than. Usually, it is more preferable to carry out at a temperature near the glass transition temperature. The vicinity of the glass transition temperature refers to a range of about ± 5 ° C. of the glass transition temperature, and is generally about 70 to 130 ° C. when a suitable polyester film is used as the protective film 1. When an injection molding die having a less complicated shape is used, the step of premolding the decorative sheet with the protective film and the step of heating the decorative sheet with the protective film before the step 3 are omitted, and the step 3 described later is omitted. In the above, the decorative sheet with a protective film may be molded into the shape of an injection molding die by the heat and pressure of the injection resin.

(Step 3)
In step 3, for example, as shown in FIGS. 3 to 4, the injection molding die is molded, the injection resin 3 is filled in the injection molding die, and the decorative sheet 2 is placed on the injection resin 3. And the protective film 1 are laminated to obtain a decorative resin molded product with a protective film. That is, in step 3, the injection resin 3 in a fluid state is injected into the injection molding die, and the decorative sheet with the protective film and the injection resin 3 are integrated. When the injection resin 3 is a thermoplastic resin, it is made into a fluid state by heating and melting, and when the injection resin 3 is a thermosetting resin, the uncured liquid composition is injected at room temperature or appropriately heated in a fluid state. Then, cool and solidify. As a result, the decorative sheet with the protective film is integrally attached to the resin molded body, and if necessary, the decorative sheet with the protective film is trimmed to remove the margin around the resin molded body, and then the decorative sheet with the protective film is attached. A decorative resin molded product can be obtained. The trimming step may be performed after the protective film 1 is peeled off as described later.

The heating temperature of the injection resin 3 depends on the type of the injection resin, but is usually about 180 to 320 ° C.

The injection resin 3 may be formed by selecting a resin according to the intended use. The injection resin 3 may be a thermoplastic resin or a thermosetting resin, but a thermoplastic resin is usually used. Further, the injection resin 3 may be transparent, translucent, or opaque.

Examples of the thermoplastic resin include polyolefin resins such as polyethylene and polypropylene, ABS resins, styrene resins, polycarbonate resins, acrylic resins, vinyl chloride resins and the like. These thermoplastic resins may be used alone or in combination of two or more.

Examples of the thermosetting resin include urethane resin and epoxy resin. These thermosetting resins may be used alone or in combination of two or more.

After step 3, the protective film 1 is removed from the decorative resin molded product with the protective film. That is, after the decorative resin molding with a protective film obtained by curing the injection resin 3 filled in step 3 by cooling or the like is taken out from the injection molding mold, the protective film 1 is applied to the surface of the decorative resin molded product ( For example, the decorative resin molded product of the present invention can be obtained through a trimming step of peeling from the surface protective layer 21) described later and, if necessary, removing a margin portion around the resin molded body of the decorative sheet 1.

The decorative resin molded product of the present invention can be used as an interior material or exterior material of a vehicle such as an automobile; a housing of a home electric appliance such as a television receiver or an air conditioner; a container or the like.

(Manufacturing system)
Further, in the present invention, the above-mentioned method A for manufacturing a decorative resin molded product with a protective film, a method B for manufacturing a decorative resin molded product having a fine uneven shape on the surface, and / or a fine uneven shape on the surface are formed. It is possible to provide the following manufacturing system including the method C for manufacturing a resin molded product. That is, in the manufacturing system of the present invention, an injection molding die in which fine uneven shapes are arranged on at least one surface of a male mold and a female mold is used as a common injection molding die, and the manufacturing method A is used. Production of the decorative resin molded product with the protective film described above, production of the decorative resin molded product having a fine uneven shape on the surface by the manufacturing method B, and / or resin molding having a fine uneven shape on the surface by the manufacturing method C. Goods can be manufactured.

(Manufacturing method A)
The manufacturing method A is a method for manufacturing a decorative resin molded product with a protective film, and includes the following steps 1A to 3A in order. Steps 1A to 3A correspond to the above-mentioned steps 1 to 3.
Step 1A: A decorative sheet provided with a protective film on the surface and an injection molding die in which fine uneven shapes are arranged on at least one surface of a male mold and a female mold Step 2A: The fine Step 3A of inserting the decorative sheet into the injection-molded mold so that the surface on which the uneven shape is arranged and the protective film face each other: Step 3A: The injection-molded mold is molded and described. A process of filling an injection mold with an injection resin to obtain a decorative resin molded product with a protective film in which a decorative sheet and a protective film are laminated on the injection resin.

(Manufacturing method B)
Further, the manufacturing method B is a method for manufacturing a decorative resin molded product having a fine uneven shape on the surface, and the following steps 1B to 3B are sequentially provided.
Step 1B: Preparing a decorative sheet and an injection molding die in which fine uneven shapes are arranged on at least one surface of a male mold and a female mold. Step 2B: The addition inside the injection molding die. Step 3B of inserting the decorative sheet: The injection molding die is molded, the injection resin is filled in the injection molding die, the decorative sheet is laminated on the injection resin, and the surface is finely uneven. Process of obtaining a decorative resin molded product having a shape

The manufacturing method B is the same as the manufacturing method A except that the decorative sheet 2 on which the protective film 1 is not provided is used instead of the decorative sheet on which the protective film is provided on the surface. In the manufacturing method B, since the decorative sheet 2 on which the protective film 1 is not provided is used, the fine uneven shape arranged on the surface of the injection molding die is formed on the surface of the decorative resin molded product. Therefore, the surface of the decorative resin molded product has a fine uneven shape.

(Manufacturing method C)
Further, the manufacturing method C is a method for manufacturing a resin molded product having a fine uneven shape on the surface, and the following steps 1C and 2C are sequentially provided.
Step 1C: Prepare an injection molding die in which a fine uneven shape is arranged on at least one surface of a male mold and a female mold. Step 2C: The injection molding die is molded and inside the injection molding die. Is filled with injection resin to obtain a resin molded product having a fine uneven shape on the surface.

The manufacturing method C is the same as the manufacturing methods A and B except that the decorative sheet is not used. In the manufacturing method C, since the decorative sheet is not used, the fine uneven shape arranged on the surface of the injection molding die is formed on the surface of the resin molded product, and the surface of the resin molded product has fine unevenness. It has a shape. However, the resin molded product obtained by the manufacturing method C is not decorated with a decorative sheet.

The manufacturing method C may further include a step 3C of painting the surface of the obtained resin molded product after the step 2C. Since the surface of the resin molded product obtained in step 2C has a fine uneven shape, the coating film formed by the coating in step 3C adheres to the surface of the resin molded product due to the anchor effect of the uneven shape. can do.

The uneven shape of the surface of the decorative resin molded product manufactured by the manufacturing method B and the resin molded product manufactured by the manufacturing method C is, for example, a molded product in order to improve the adhesion of the paint applied to the surface of the molded product. It is an uneven shape for reducing the gloss of the surface of the molded product, reducing the static electricity on the surface of the molded product, or giving the surface of the molded product a three-dimensional effect based on the uneven shape. Therefore, the surfaces of the decorative resin molded product manufactured by the manufacturing method B and the resin molded product manufactured by the manufacturing method C have, for example, the above-mentioned center line average roughness (Ra).

By adopting the manufacturing system of the present invention, an injection molding die in which fine uneven shapes are arranged can be used as a common injection molding die to manufacture a decorative resin molded product with a protective film and to have a fine surface. It is possible to manufacture a decorative resin molded product and / or a resin molded product having an uneven shape. As described above, by peeling off the protective film from the decorative resin molded product with the protective film, it is possible to manufacture the decorative resin molded product having a flat surface and a desired uneven shape. Therefore, according to the present invention. , In the same manufacturing system, both the production of a decorative resin molded product having a flat surface or a desired uneven shape and the production of a decorative resin molded product and / or a resin molded product having a fine uneven shape on the surface. It can be carried out. Therefore, it is not necessary to prepare a plurality of types of injection molding dies, and it is possible to manufacture both decorative sheets on a common production line.

[Decorative sheet with protective film]
In the present invention, specific examples of the laminated structure of the decorative sheet 2 provided with the protective film 1 on the surface and the composition of each layer used in the production of the decorative resin molded product are as follows.

Laminated structure of decorative sheet with protective film As shown in FIG. 5, the decorative sheet with protective film has a structure in which the protective film 1 and the decorative sheet 2 are laminated, and the decorative sheet 2 has a structure in which the protective film 1 and the decorative sheet 2 are laminated. For example, the design layer 23 is provided. Even if a surface protective layer 21 is provided on the surface of the decorative sheet 2 on the protective film 1 side for the purpose of improving scratch resistance and chemical resistance of the decorative resin molded product, if necessary. Good. Further, for the purpose of enhancing the adhesion of the surface protective layer 21, the primer layer 22 may be adjacent to the design layer 23 side of the surface protective layer 21 as necessary. Further, for the purpose of enhancing the adhesiveness between the decorative sheet 2 and the injection resin 3, an adhesive layer 24 is provided on the surface of the decorative sheet 2 opposite to the protective film 1 as needed. Good. The decorative sheet 2 may further include one or more other layers. Hereinafter, a typical layer provided on the protective film 1 and the decorative sheet 2 will be described.

The decorative sheet 2 used in the present invention may have a flat surface on the protective film 1 side or may have a desired uneven shape. Examples of the method of forming the uneven shape on the surface of the decorative sheet 2 include a method of forming a plurality of raised portions and a method of forming by embossing or the like. Generally, when a decorative sheet 2 having an uneven shape on the surface is used for injection molding, the uneven shape tends to be flattened by heat or pressure during injection molding, but the decorative sheet with a protective film 1 is provided. In the manufacturing method of the present invention using a sheet, the protective film 1 functions as a cushion, and an effect that it is easy to maintain the uneven shape can be expected.

[Protective film 1]
The protective film 1 is a layer that exerts a function of protecting the surface of the decorative sheet 2 from an injection-molded mold having a fine uneven shape. As the protective film 1, a resin sheet made of a thermoplastic resin is typically used. Examples of the thermoplastic resin include polyester resin; acrylic resin; polyolefin resin such as polypropylene and polyethylene; polycarbonate resin; acrylonitrile-butadiene-styrene resin (ABS resin); vinyl chloride resin and the like. Among these, it is preferable to use a polyester sheet in terms of heat resistance, dimensional stability, moldability, and versatility. The polyester resin constituting the polyester sheet represents a polymer containing an ester group obtained by polycondensation from a polyvalent carboxylic acid and a polyhydric alcohol, and is polyethylene terephthalate (PET), polybutylene terephthalate (PBT), or polyethylene naphthalate. (PEN) and the like can be preferably mentioned, and polyethylene terephthalate (PET) is particularly preferable in terms of heat resistance and dimensional stability.

When the surface of the decorative sheet 2 of the present invention on the protective film 1 side has a concavo-convex shape, the protective film 1 has the concavo-convex shape from the viewpoint of preferably protecting the concavo-convex shape due to heat pressure during injection molding. It is preferable to fill the recesses of.

The thickness of the protective film 1 is usually 10 to 150 μm, preferably 30 to 100 μm, and more preferably 50 to 80 μm. Further, as the protective film 1, a single-layer sheet of these resins or a multi-layer sheet made of the same or different resins can be used.

[Release layer]
A release layer (not shown) may be provided between the protective film 1 and the decorative sheet 2 to improve the peelability, if necessary. The release layer may be a solid release layer that covers the entire surface (the entire surface is solid), or may be provided on a part of the release layer. Usually, a solid release layer is preferable in consideration of peelability.

The release layer includes silicone-based resin, fluorine-based resin, acrylic-based resin (including, for example, acrylic-melamine-based resin), polyester-based resin, polyolefin-based resin, polystyrene-based resin, polyurethane-based resin, and cellulose-based resin. Vinyl chloride-vinyl acetate copolymer resin, thermoplastic resin such as nitrified cotton, copolymer of monomer forming the thermoplastic resin, or these resins modified with (meth) acrylic acid or urethane. It can be formed alone or by using a mixture of a plurality of resin compositions.

The thickness of the release layer is usually about 0.01 to 5 μm, preferably about 0.05 to 3 μm.

[Design layer 23]
When imparting decorativeness to a decorative resin molded product, the decorative sheet is provided with, for example, a design layer 23. The design layer 23 may be formed by using a printing ink containing a colorant, a binder resin, and a solvent or a dispersion medium, or may be formed by a metal thin film.

The colorant is not particularly limited, but is, for example, a metallic composed of a metal, alloy, or a scaly foil powder of a metal compound such as aluminum, chromium, nickel, tin, titanium, iron phosphate, copper, gold, silver, and brass. Pigments; Mica-like iron oxide, titanium dioxide-coated mica, titanium dioxide-coated bismuth oxychloride, bismuth oxychloride, titanium dioxide-coated talc, fish scale foil, colored titanium dioxide-coated mica, pearl luster consisting of foil powder such as basic lead carbonate ( Pearl) Pigment; Fluorescent pigments such as strontium aluminate, calcium aluminate, barium aluminate, zinc sulfide, calcium sulfide; white inorganic pigments such as titanium dioxide, zinc flower, antimony trioxide; carbon black, magnetite type triiron tetroxide Black pigments such as zinc flower, petal pattern, vermilion, ultramarine blue, cobalt blue, titanium yellow, yellow lead and other inorganic pigments; isoindolinone yellow, Hansa yellow A, quinacridon red, permanent red 4R, phthalocyanine blue, induslen blue Examples include organic pigments (including dyes) such as RS and aniline black. These colorants may be used alone or in combination of two or more.

The binder resin for the printing ink used for forming the design layer 23 is not particularly limited, but for example, acrylic resin, styrene resin, polyester resin, urethane resin, chlorinated polyolefin resin, vinyl chloride-. Examples thereof include vinyl acetate copolymer resin, polyvinyl butyral resin, alkyd resin, petroleum resin, ketone resin, epoxy resin, melamine resin, fluorine resin, silicone resin, fibrous derivative, rubber resin and the like. These binder resins may be used alone or in combination of two or more.

The solvent or dispersion medium of the printing ink used for forming the design layer 23 is not particularly limited, and is, for example, a petroleum-based organic solvent such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, and methylcyclohexane; Ester-based organic solvents such as ethyl acetate, butyl acetate, -2-methoxyethyl acetate and -2-ethoxyethyl acetate; alcohols such as methyl alcohol, ethyl alcohol, normal propyl alcohol, isopropyl alcohol, isobutyl alcohol, ethylene glycol and propylene glycol. Organic solvent; Ketone organic solvent such as acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone; Ether organic solvent such as diethyl ether, dioxane, tetrahydrofuran; Chlorine organic solvent such as dichloromethane, carbon tetrachloride, trichloroethylene, tetrachloroethylene; water And so on. These solvents or dispersion media may be used alone or in combination of two or more.

Further, the printing ink used for forming the design layer 23 contains, if necessary, an antioxidant, a curing catalyst, an ultraviolet absorber, an antioxidant, a leveling agent, a thickener, an antifoaming agent, a lubricant and the like. It may be included.

The design layer 23 can be formed on a layer adjacent to the design layer 23 by a known printing method such as gravure printing, flexographic printing, silk screen printing, and offset printing.

When the design layer 23 is formed of a metal thin film, examples of the metal include tin, indium, chromium, aluminum, nickel, copper, silver, gold, platinum, zinc, and alloys containing at least one of these. Be done. Further, the metal thin film can be formed by a vapor deposition method such as a vacuum vapor deposition method, a sputtering method, an ion plating method or the like using these metals. In particular, the vacuum vapor deposition method is preferable in that it is low in cost and causes less damage to the deposited material. The vaporization conditions may be appropriately set according to the melting temperature or evaporation temperature of the metal to be used. In addition to the above-mentioned forming method, a method of applying a paste containing the above-mentioned metal, a plating method using the above-mentioned metal, or the like can also be used.

Further, the design layer 23 may be a single color (so-called solid surface) or may be formed in a pattern shape. The design layer 23 may be translucent.

The thickness of the design layer 23 is not particularly limited, but in the case of printing ink, for example, 1 to 40 μm, preferably 3 to 30 μm can be mentioned, and in the case of a metal thin film, it is preferably 100 nm or less, more preferably 40 to 60 nm. The degree can be mentioned.

[Surface protection layer 21]
The surface protective layer 21 is a layer provided on the decorative sheet 2 so as to be located on the outermost surface of the decorative resin molded product in order to improve the scratch resistance, chemical resistance, etc. of the decorative resin molded product. ..

The resin forming the surface protective layer 21 is not particularly limited, and examples thereof include a thermosetting resin, a thermoplastic resin, and an ionizing radiation curable resin. Among these, an ionizing radiation curable resin is preferable from the viewpoint of enhancing the scratch resistance of the decorative sheet and imparting excellent surface characteristics, but the resin forming the surface protective layer 21 is used for the decorative sheet 2. It can be appropriately selected according to the above. The surface protective layer 21 may be formed of, for example, one layer of an ionizing radiation curable resin, or may be formed of two or more layers thereof.

The thermosetting resin is not particularly limited, and for example, epoxy resin, phenol resin, urea resin, unsaturated polyester resin, melamine resin, alkyd resin, polyimide resin, silicone resin, hydroxyl group functional acrylic resin, and carboxyl functional acrylic. Examples thereof include resins, amide functional copolymers, and urethane resins. The thermoplastic resin is not particularly limited, and acrylic resin such as polymethyl (meth) acrylate and polyethyl (meth) acrylate; polyolefin resin such as polypropylene and polyethylene; polycarbonate resin; vinyl chloride resin; polyethylene terephthalate (PET). ), Polybutylene terephthalate (PBT), polyethylene naphthalate (PEN) and other polyester resins; acrylonitrile-butadiene-styrene resin (ABS resin); acrylonitrile-styrene-acrylic acid ester resin; and the like.

The ionizing radiation curable resin used for forming the surface protective layer 21 is a resin that is crosslinked and cured by irradiation with ionizing radiation, and specifically, a polymerizable unsaturated bond or an epoxy group in the molecule. Examples thereof include those obtained by appropriately mixing at least one of a prepolymer, an oligomer, a monomer, and the like having the above. Here, ionizing radiation means electromagnetic waves or charged particle beams that have energy quanta capable of polymerizing or cross-linking molecules, and usually ultraviolet rays (UV) or electron beams (EB) are used, but in addition, X It also includes electromagnetic waves such as rays and γ-rays, and charged particle beams such as α-rays and ion rays. Among the ionizing radiation curable resins, the electron beam curable resin is suitable for forming the surface protective layer 21 because it can be made solvent-free, does not require a photopolymerization initiator, and stable curing characteristics can be obtained. Used for.

As the above-mentioned monomer used as the ionizing radiation curable resin, a (meth) acrylate monomer having a radically polymerizable unsaturated group in the molecule is preferable, and among them, a polyfunctional (meth) acrylate monomer is preferable. Further, as the above-mentioned oligomer used as an ionizing radiation curable resin, a (meth) acrylate oligomer having a radically polymerizable unsaturated group in the molecule is preferable, and among them, two or more polymerizable unsaturated bonds in the molecule. A polyfunctional (meth) acrylate oligomer having (bifunctional or higher) is preferable.

In the decorative sheet 2, the surface protective layer 21 may be cured or semi-cured, or may be uncured. When the surface protective layer 21 is uncured or semi-cured, a step of curing the surface protective layer 21 is performed after integrating the decorative sheet 2 and the injection resin 3.

The thickness of the surface protective layer 21 is not particularly limited, and examples thereof include 1 to 1000 μm, preferably 1 to 50 μm, and more preferably 1 to 30 μm. When the thickness in such a range is satisfied, sufficient physical properties as a surface protective layer such as scratch resistance and weather resistance can be obtained, and when the surface protective layer 21 is formed by using an ionizing radiation curable resin, the surface protective layer 21 is formed. Since it is possible to uniformly irradiate ionizing radiation, it is possible to cure uniformly, which is economically advantageous.

[Primer layer 22]
The primer layer 22 is a layer provided as necessary in order to enhance the adhesion between the surface protective layer 21 and the layer located below the surface protective layer 21 (on the side opposite to the protective film 1).

The resin used for forming the primer layer 22 is not particularly limited, and examples thereof include urethane resin, acrylic resin, (meth) acrylic-urethane copolymer resin, polyester resin, butyral resin, and the like. Among these resins, urethane resin, acrylic resin, and (meth) acrylic-urethane copolymer resin are preferable. These resins may be used alone or in combination of two or more.

The thickness of the primer layer 22 is not particularly limited, and examples thereof include about 0.1 to 10 μm, preferably about 1 to 10 μm.

[Adhesive layer 24]
The adhesive layer 24 is a layer provided on the back surface (opposite side of the protective film 1) of the design layer 23 as needed for the purpose of improving the adhesiveness between the decorative sheet 2 and the injection resin 3. ..

The resin forming the adhesive layer 24 is not particularly limited as long as it can improve the adhesiveness between these layers, and for example, a thermoplastic resin or a thermosetting resin is used. Examples of the thermoplastic resin include acrylic resin, acrylic modified polyolefin resin, chlorinated polyolefin resin, vinyl chloride-vinyl acetate copolymer, thermoplastic urethane resin, thermoplastic polyester resin, polyamide resin, rubber resin and the like. .. One type of thermoplastic resin may be used alone, or two or more types may be used in combination. Examples of the thermosetting resin include urethane resin and epoxy resin. One type of thermosetting resin may be used alone, or two or more types may be used in combination.

The thickness of the adhesive layer 24 is not particularly limited, and examples thereof include about 0.1 to 30 μm, preferably about 0.5 to 20 μm, and more preferably about 1 to 8 μm.

Hereinafter, the present invention will be described in detail with reference to Examples and Comparative Examples. However, the present invention is not limited to the examples.

(Example 1)
An ABS resin film (thickness 200 μm) was used as the base material layer, and a wood grain design layer (thickness 5 μm) was formed by gravure printing using an ink composition containing an acrylic resin on the base material layer. Next, a two-component curable resin composition for a primer layer containing an acrylic polyol and hexamethylene diisocyanate was applied onto the design layer and dried to form a primer layer (thickness 2 μm). Next, an ionizing radiation curable resin containing a urethane acrylate resin was applied onto the primer layer and irradiated with an electron beam to form a surface protective layer (thickness 10 μm). The surface protective layer was smooth and had a high gloss. Next, a polyethylene resin was extruded onto the surface protective layer to form a film, and a protective film (thickness 60 μm) was laminated to prepare a decorative sheet with a protective film.

The obtained decorative sheet with a protective film was supplied into the injection molding die so that the protective film side faced the female mold side, and the outer circumference of the sheet was fixed with a clamp. As the injection molding die, a die used for a method of producing an undecorated resin molded product by injection molding and then decorating by painting was used. A fine uneven shape (center line average roughness (Ra) = 2.0 μm) is arranged on the inner surface of the female mold of the injection molding die. Next, using a hot plate heated to about 350 ° C., the decorative sheet with a protective film is heated for about 8 seconds until the surface temperature reaches about 100 ° C., and vacuum is drawn from the vacuum holes provided in the injection molding die. Then, a decorative sheet with a protective film was placed along the mold shape to perform pre-molding. Next, the injection molding die was molded, and the transparent ABS resin was injected to perform injection molding. The mold was opened and the decorative resin molded product was taken out to obtain a decorative resin molded product with a protective film. Next, the protective film was peeled off from the decorative resin molded product with the protective film to obtain a decorative resin molded product. The surface of the obtained decorative resin molded product was not shaped with the fine uneven shape provided in the injection molding die, and had a flat surface and high gloss.

1 Protective film 2 Decorative sheet 3 Injection resin 10 Decorative resin molded product with protective film 11 Decorative resin molded product 21 Surface protective layer 22 Primer layer 23 Design layer 24 Adhesive layer 30 Female mold of injection molding mold 40 Injection molding gold Male mold M Fine uneven shape

Claims (6)

A method for manufacturing a decorative resin molded product with a protective film, which comprises the following steps 1 to 3 in order.
Step 1: A decorative sheet provided with a protective film on the surface and an injection-molded mold in which a fine uneven shape is arranged on at least one surface of a male mold and a female mold are prepared. Step 2: The fine Step 3: Insert the decorative sheet into the injection-molded mold so that the surface on which the uneven shape is arranged faces the protective film. Step 3: The injection-molded mold is molded and described. A step of filling an injection molding die with an injection resin to obtain a decorative resin molded product with a protective film in which a decorative sheet and a protective film are laminated on the injection resin is provided .
The fine uneven shape on the surface of the injection molding mold enhances the adhesion of the paint applied to the surface of the molded product, reduces the gloss of the surface of the molded product, and reduces the static electricity on the surface of the molded product. or Ru der provided in order to impart a three-dimensional appearance based on irregularities on the surface of the molded article, the protective film with decoration method for producing a resin molded article. The decorative resin molding according to claim 1, wherein the center line average roughness (Ra) of the surface having a fine uneven shape arranged on the surface of the injection molding mold is 0.5 μm or more and 8.0 μm or less. How to manufacture the product. A method for producing a decorative resin molded product, comprising a step of peeling off the protective film of the decorative resin molded product with a protective film, following the method for producing the decorative resin molded product with a protective film according to claim 1 or 2. A method A for manufacturing a decorative resin molded product with a protective film, which comprises the following steps 1A to 3A in order, and
Step 1A: A decorative sheet provided with a protective film on the surface and an injection-molded mold in which a fine uneven shape is arranged on at least one surface of a male mold and a female mold Step 2A: The fine Step 3A of inserting the decorative sheet into the injection-molded mold so that the surface on which the uneven shape is arranged and the protective film face each other: Step 3A: The injection-molded mold is molded and described. A step of filling an injection molding die with an injection resin to obtain a decorative resin molded product with a protective film in which a decorative sheet and a protective film are laminated on the injection resin. The following steps 1B to 3B are provided in order. , Manufacturing method B of a decorative resin molded product having a fine uneven shape on the surface,
Step 1B: Preparing a decorative sheet and an injection molding die in which fine uneven shapes are arranged on at least one surface of a male mold and a female mold. Step 2B: The addition inside the injection molding die. Step 3B of inserting the decorative sheet: The injection molding die is molded, the injection resin is filled in the injection molding die, the decorative sheet is laminated on the injection resin, and the surface is finely uneven. It is equipped with a process to obtain a decorative resin molded product with a shape.
In the method B the production process A, using a common said injection mold, the protective film with a decorative resin molded article and a method for producing a decorated resin molded article having fine irregularities on the surface. A method A for manufacturing a decorative resin molded product with a protective film, which comprises the following steps 1A to 3A in order, and
Step 1A: A decorative sheet provided with a protective film on the surface and an injection-molded mold in which a fine uneven shape is arranged on at least one surface of a male mold and a female mold Step 2A: The fine Step 3A of inserting the decorative sheet into the injection-molded mold so that the surface on which the uneven shape is arranged and the protective film face each other: Step 3A: The injection-molded mold is molded and described. A step of filling an injection molding die with an injection resin to obtain a decorative resin molded product with a protective film in which a decorative sheet and a protective film are laminated on the injection resin. The following steps 1C and 2C are provided in order. , Manufacturing method C of a resin molded product having a fine uneven shape on the surface,
Step 1C: Prepare an injection molding die in which a fine uneven shape is arranged on at least one surface of a male mold and a female mold. Step 2C: The injection molding die is molded and inside the injection molding die. It is equipped with a process of filling an injection resin into a resin molded product having a fine uneven shape on the surface.
In the manufacturing method A and manufacturing method C, using common the injection mold, the protective film with a decorative resin molded article and a method for producing a decorated resin molded article having fine irregularities on the surface. The manufacturing method according to claim 5 , further comprising a step 3C of painting the surface of the resin molded product after the step 2C.

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