JPH10180795A - Preparation of molded article of metal thin film-inserted film - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain beautiful metal luster with stable quality by a method wherein after a metal thin film-inserted film prepd. by laminating a plastic sheet on a metal thin film layer on a transparent acryl film base sheet is preformed into a required shape, it is inserted into a mold and a molding resin is injected on the plastic sheet side for integration into a body. SOLUTION: After a metal thin film-inserted film 1 prepd. by forming a metal thin film layer 3 for expressing metal luster formed by means of vacuum metallizing method, etc., on a transparent acryl film base sheet 2 made of a polymethyl methacrylate resin, etc., and furthermore, laminating a plastic sheet 5 such as an acryl film thereon is preformed into a required shape, it is inserted into a mold. An anchor layer 4 such as a thermosetting urethane resin may be provided for improving adhesiveness between the metal thin film layer 3 and a plastic sheet 5. After it is inserted into the mold, a molding resin is injected on the plastic sheet 5 side for integration into a body and as the result, a molded article with transparent luster feeling, excellent durability and beautiful metal luster in a three-dimensional shape can be obtd.

Description

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is applied to wheel caps, center ornaments, etc., which are metallic luster parts of automobiles, and plastic sinks, enamel parts, etc., which are metal parts of daily necessities. The present invention relates to a method for producing a metal thin film insert film molded product that can be manufactured. 2. Description of the Related Art Conventionally, in order to impart a metallic luster to a wheel cap, a center ornament and the like of a plastic automobile, a main body is directly plated with a metal and then a transparent gloss paint is applied. Is a common method. There is also a method in which a metal thin film layer is formed on a base sheet instead of metal plating, and an overlay film is adhered instead of painting to form a vacuum. [0004] However, metal plating and painting have high costs and are environmentally problematic. In addition, the coating has a large variation in thickness, so that it is difficult to obtain a uniform appearance, and there is a problem that the quality is not stable. Further, the method using a metal thin film layer and an overlay film has a problem that cracks occur in the case of concave drawing because the convex portions of the product are extremely elongated. That is,
When a sheet made of a base sheet, a metal thin film layer, and an overlay film is arranged in the concave portion of the vacuum forming mold and molded along the concave portion of the mold, the center of the concave portion of the molded product is greatly extended, and the metal thin film is transparent. It sometimes looked or cracked. Furthermore, in order to bond the metal thin film layer and the overlay film, a sticky anchor agent such as a dry laminating agent is required, but fine irregularities on the surface of the anchor agent appear on the surface and it is easy to notice or stick. There is a problem that when dust, foreign matter, dirt, and the like appear during the joining operation, they appear on the surface and stand out. SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to solve the above-mentioned problems and to provide a method of manufacturing a metal thin film insert film molded product capable of obtaining beautiful metallic luster with stable quality. [0007] In order to achieve the above object, a method for manufacturing a metal thin film insert film molded product according to the present invention has the following configuration. In other words, the method of manufacturing a metal thin film insert film molded product according to the present invention is a metal thin film insert comprising a transparent acrylic film as a base sheet, a metal thin film layer formed thereon, and a plastic sheet laminated thereon. After preliminarily forming the film into a desired shape, a metal thin film insert film was inserted into a mold, and a molding resin was injected into the plastic sheet side to be integrated. In the above invention, the base sheet may have a thickness of 200 μm or less. [0010] In the above invention, the metal thin film insert film may be configured so that the entire thickness is 250 to 2000 µm. Further, in the above invention, a heat absorbing protective sheet may be laminated on the base sheet side of the metal thin film insert film, preformed, and then the protective sheet may be peeled off. In the above invention, the metal thin film insert film may have a design layer between the metal thin film layer and the base sheet. [0013] In the above invention, the metal thin film insert film may have an anchor layer between the metal thin film layer and the plastic sheet. [0014] In the above invention, the preforming is performed by:
It may be configured to be a vacuum forming method or a pressure forming method. In the above invention, the base sheet may be an acrylic film, a polypropylene film, an ethylene-vinyl alcohol film, a thermoplastic elastomer film, a polycarbonate film, a polyester film, an unstretched polyester film, a fluorine film, a polybutylene terephthalate film, You may comprise so that it may be either a nylon film or a cellulose acetate film. In the above invention, the material of the metal thin film layer is aluminum, nickel, gold, platinum, chromium,
It may be configured to be any of iron, copper, tin, indium, silver, titanium, lead, zinc, germanium, zinc sulfide, silicon oxide, magnesium fluoride, tin oxide, and ITO. In the above invention, the protective sheet may be a polyethylene film, a polypropylene film,
Any of a polyvinyl chloride film, an unstretched ethylene-vinyl alcohol film, a polybutylene terephthalate film, an unstretched polypropylene film, and an unstretched polyester film may be configured to be black or smoked. Further, in the above invention, the shape of the metal thin film insert film molded product may be a deep drawing molded product having a rise of 2 mm or more around its periphery. Embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 is a perspective view showing one embodiment of an acrylic film used in the method for producing a metal thin film insert film molded product of the present invention. 2 to 4 are sectional views showing one embodiment of the method for producing a metal thin film insert film molded product of the present invention. In the drawing, 1 is a metal thin film insert film, 2 is a base sheet, 3 is a metal thin film layer, 4 is an anchor layer, 5 is a plastic sheet, 6 is a protective sheet, 7 is a vacuum forming die, 8 is a suction hole, and 9 is a heat source. Reference numeral 10 denotes a molding resin. [0021] Metal thin film insert film 1 of the present invention
The method for manufacturing a molded product is as follows: a transparent acrylic film is used as a base sheet 2, a metal thin film layer 3 is formed thereon, and a plastic thin film 5 is further laminated thereon. After molding, the metal thin film insert film 1 is inserted into a mold, and the molding resin 10 is injected into the plastic sheet 5 side to be integrated (see FIGS. 1 to 5). The metal thin film insert film 1 is made of a transparent acrylic film as a base sheet 2, a metal thin film layer 3 is formed thereon, and a plastic sheet 5 is further formed thereon.
(See FIG. 1). As the base sheet 2, a transparent acrylic film is used. As acrylic film, polymethyl methacrylate resin, polybutyl acrylate resin,
It is preferable to use an ethylene-acryl copolymer resin, an ethylene vinyl acetate-acryl copolymer resin, or the like. Acrylic films are excellent in transparency, resistant to heat and light, and rarely fade or change in gloss even when used outdoors. In addition, it has the property that it is excellent in stain resistance even without using a plasticizer, and has excellent moldability and can be deep drawn. The thickness of the acrylic film is desirably 50 μm or more that can maintain weather resistance as an overlay film and 200 μm or less that allows printing. As a more preferable range, 80 to 150 μ
m. The metal thin film layer 3 is for expressing metallic luster, and is formed by a vacuum deposition method, a sputtering method, an ion plating method, a plating method, or the like. Aluminum, nickel, gold,
Use metals such as platinum, chromium, iron, copper, tin, indium, silver, titanium, lead, zinc, and germanium, and alloys or compounds of these such as zinc sulfide, silicon oxide, magnesium fluoride, tin oxide, and ITO. . The metal thin film layer 3 is formed entirely on the base sheet 2. Further, the metal thin film layer 3 may be formed partially. As an example of the case where the metal thin film layer 3 is partially formed, after forming a solvent-soluble resin layer in a portion where the metal thin film layer 3 is not required, a metal thin film is entirely formed thereon, and the solvent cleaning is performed. There is a method of removing the unnecessary metal thin film together with the solvent-soluble resin layer. The solvent often used in this case is water or an aqueous solution. As another example, there is a method in which a metal thin film is formed on the entire surface, a resist layer is formed on a portion where the metal thin film is to be left, and the resist layer is removed by etching with an acid or alkali. . An anchor layer 4 may be provided to improve the adhesion between the metal thin film layer 3 and the plastic sheet 5. Examples of the material of the anchor layer 4 include a two-component cured urethane resin, a thermosetting urethane resin, a melamine resin, a cellulose ester resin, a chlorine-containing rubber resin, a chlorine-containing vinyl resin, an acrylic resin, an epoxy resin, and vinyl. It is preferable to use a system copolymer resin resin or the like. Examples of a method for forming the anchor layer 4 include a coating method such as a gravure coating method, a roll coating method, and a comma coating method, and a printing method such as a gravure printing method and a screen printing method. As the plastic sheet 5, an acrylic film, a polypropylene film, a thermoplastic elastomer film, a polycarbonate film, a nylon film, an acrylonitrile-butadiene-styrene film, an acrylonitrile-styrene film, a polystyrene film, a polyurethane film and the like can be used. In particular, it may be appropriately selected according to the material of the molding resin 10. Generally, if the film is of the same type as the molding resin 10, the film is fused to the molding resin 10. For example, if the molding resin 10 is polypropylene, a polypropylene film may be used as the plastic sheet 5. However, if the film is difficult to supply or expensive,
The plastic sheet 5 and the molding resin 10 may be joined by forming an adhesive layer. For example, instead of using a polypropylene film as the plastic sheet 5, a thermoplastic elastomer may be used, and an ink made of a polypropylene-based resin may be applied as an adhesive layer. As a laminating method, there are a dry laminating method, a hot melt laminating method, a heat laminating method and the like. In the case of the dry lamination method and the hot melt lamination method, the lamination is performed via an ink layer such as a polyurethane resin or an ethylene-vinyl acetate copolymer resin. When the thickness of the base sheet 2 is 200 μm or more,
There is a problem in printing mass productivity that winding is difficult.
When the thickness of the entire metal thin film insert film 1 is smaller than 250 μm, there is no stiffness, it is difficult to perform vacuum forming or pressure forming, and wrinkles are easily generated. If the total thickness is more than 2000 μm, it takes a long time for vacuum forming or pressure forming to reduce the production capacity. Since the metal thin film insert film 1 is formed by laminating the metal thin film layer 3 and the plastic sheet 5 on the base sheet 2, the elongation of the convex portion of the product is reduced.
Cracks are reduced. An anchor layer 4 for bonding the metal thin film layer 3 and the five plastic sheets is provided.
Since it is incorporated inside the metal thin film layer 3 when viewed from the surface of the final product, fine irregularities on the surface of the anchor layer 4 and biting of dust during bonding work are less noticeable. The protective sheet 6 may be laminated on the base sheet 2 of the metal thin film insert film 1. Since the metal thin film insert film 1 is heated and softened from the side of the base sheet 2 by the heat source 9, heat is reflected by the metallic glossy surface, so that it may be difficult to form a vacuum or a compressed air. Therefore, it is preferable that the black or smoke-colored protective sheets 6 having good heat absorption are laminated and vacuum-formed or pressure-formed together. The smoke color refers to a relatively dark, transparent or translucent color such as black, brown, blue, or indigo. Examples of the material of the protective sheet 6 include a polyethylene film, a polypropylene film, a polyvinyl chloride film, an unstretched ethylene-vinyl alcohol film, a polybutylene terephthalate film, an unstretched polypropylene film, and an unstretched polyester film.
The heat absorption protection sheet 6 enhances the heat absorption efficiency and makes the base sheet 2 easier to heat and soften. Therefore, 2m
Vacuum forming or pressure forming can be performed by convex drawing up to the metal thin film insert film 1 having a thickness of about m. Further, if necessary, a symbol layer may be formed. The design layer is usually formed as a printing layer on the acrylic film. As a material of the printing layer, a resin such as a polyvinyl resin, a polyamide resin, a polyester resin, an acrylic resin, a polyurethane resin, a polyvinyl acetal resin, a polyester urethane resin, a cellulose ester resin, and an alkyd resin is used as a binder. It is preferable to use a coloring ink containing a pigment or dye of an appropriate color as a coloring agent. As a method for forming the printing layer, a normal printing method such as an offset printing method, a gravure printing method, or a screen printing method may be used. In particular, an offset printing method or a gravure printing method is suitable for performing multicolor printing and gradation expression. In the case of a single color, a coating method such as a gravure coating method, a roll coating method, and a comma coating method can be adopted. The printing layer may be provided entirely or partially depending on the design to be expressed. [0033] If necessary, an adhesive layer may be formed. The adhesive layer is a layer that adheres the above layers to a molded product. As the adhesive layer, a heat-sensitive or pressure-sensitive resin suitable for the molding resin 10 is appropriately used. For example, when the molding resin 10 is an acrylic resin, an acrylic resin may be used. When the molding resin 10 is a polyphenylene oxide / polystyrene resin, a polycarbonate resin, a styrene copolymer resin, or a polystyrene blend resin, an acrylic resin, a polystyrene resin, or a polyamide resin having an affinity for these resins. Etc. should be used. Further, when the molding resin 10 is a polypropylene resin, a chlorinated polyolefin resin, a chlorinated ethylene-vinyl acetate copolymer resin, a cyclized rubber, and a coumarone indene resin can be used. Examples of a method for forming the adhesive layer include a coating method such as a gravure coating method, a roll coating method, and a comma coating method, and a printing method such as a gravure printing method and a screen printing method. The dry thickness of the adhesive layer is generally 0.5 to 10 μm. Next, the metal thin film insert film 1 is
After preforming into a desired shape, the metal thin film insert film 1 is inserted into a mold, and the molding resin 10 is injected to be integrated. In the preforming, the metal thin film insert film 1 is placed in a vacuum forming die for preforming into a desired shape, and its periphery is fixed by means such as a clamp.
The metal thin film insert film 1 is heated and softened, and is vacuum-sucked to adhere to the mold (see FIG. 2).
After the molding, air is sent from the suction holes 8 to facilitate release of the metal thin film insert film 1. Thereafter, the metal thin film insert film 1 is taken out of the mold (see FIG. 3). Next, unnecessary portions around the metal thin film insert film 1 are cut and removed.
Is peeled off and removed (see FIG. 4). Next, the metal thin film insert film 1 is inserted into a mold, and the molding resin 10 is injected to be integrated. The preformed metal thin film insert film 1 is arranged and fixed one by one between a core mold having an injection hole and a cavity mold having a concave portion by a feed mechanism or manually. Next, the cavity mold and the core mold are clamped to form a sealed space between the metal thin film insert film 1 and the core mold. By injecting the molten molding resin 10 into this space and opening the cavity mold and the core mold, an insert molded product in which the metal thin film insert film 1 and the molding resin 10 are integrated can be obtained (see FIG. 5). ). EXAMPLE A metal thin film layer of chromium having a thickness of 400 mm was formed by a vacuum evaporation method using a polymethyl methacrylate film having a thickness of 125 μm as a base sheet with the following composition. Next, an anchor layer was formed by a gravure printing method using an anchor layer ink having the following composition. Anchor layer ink Binder Polyvinyl chloride resin / polypropylene resin = 3/1 20% by weight Solvent Methyl ethyl ketone / Toluene = 1/80% by weight Next, an unstretched polypropylene film having a thickness of 400 μm is used as a plastic sheet. And a dry lamination method using a dry laminating agent having the following composition. Dry laminating agent Binder Polyurethane resin 40% by weight Solvent Methyl ethyl ketone / toluene = 1/160% by weight The thin metal insert film thus obtained is placed in a vacuum forming mold for preforming. Then, the metal thin-film insert film was softened by heating to 120 ° C., and preformed by vacuum suction at a pressure of 10 atm. Next, the preformed metal thin film insert film is placed in an injection molding die, and a molding resin temperature of 220 to 250 ° C and a mold temperature of 40 to 60 ° C.
Under the conditions described above, insert molding was performed using a polypropylene resin as a molding resin. The metal thin film insert film molded product obtained in this way is a deep drawn molded product having a rise of 2 mm or more around the periphery, and has a rising portion which is difficult to form in a single step by ordinary electrolytic plating. Met. Since the present invention has the above-described structure, the following effects can be obtained. In the method for producing a molded product of a metal thin film insert according to the present invention, a metal thin film layer is formed on a transparent base sheet, and a plastic thin film is laminated thereon to preform the metal thin film insert film into a desired shape. rear,
Since the metal thin film insert film is inserted into the mold and the molding resin is injected into the plastic sheet side and integrated,
Since the metal thin film layer is in direct contact with the base sheet, it exhibits a transparent glossiness, and since the metal thin film layer is sandwiched between the base sheet and the plastic film, it has excellent durability and has a beautiful metallic luster even in a three-dimensional shape. And a metal thin film insert film molded product having the following.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view showing one embodiment of an acrylic film used in the method for producing a metal thin film insert film molded product of the present invention. FIG. 2 is a cross-sectional view showing a method for manufacturing a metal thin film insert film molded product of the present invention. FIG. 3 is a cross-sectional view showing a method of manufacturing a metal thin film insert film molded product of the present invention. FIG. 4 is a cross-sectional view illustrating a method for manufacturing a metal thin film insert film molded product according to the present invention. [Description of Signs] 1 Metal thin film insert film 2 Base sheet 3 Metal thin film layer 4 Anchor layer 5 Plastic sheet 6 Protective sheet 7 Vacuum forming die 8 Suction hole 9 Heat source 10 Molding resin

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[Procedure amendment] [Submission date] March 3, 1997 [Procedure amendment 1] [Document name to be amended] Description [Item name to be amended] Figure 5 [Correction method] Addition [Content of amendment] [Figure 5] It is sectional drawing which shows one Example of the molded product obtained by the manufacturing method of the metal thin film insert film molded product of this invention.

Claims (1)

Claims: 1. A metal thin film insert film, in which a transparent acrylic film is used as a base sheet, a metal thin film layer is formed thereon, and a plastic sheet is further laminated thereon, is preliminarily formed into a desired shape. A method of manufacturing a molded product of a metal thin film insert film, comprising: after molding, inserting a metal thin film insert film into a mold, and injecting a molding resin into a plastic sheet side to integrate them. 2. The method according to claim 1, wherein the thickness of the base sheet is 200 μm or less. 3. The method according to claim 1, wherein the total thickness of the metal thin film insert film is 250 to 2000 μm. 4. The method according to claim 1, wherein a heat absorbing protective sheet is laminated on the base sheet side of the metal thin film insert film, preliminarily formed, and then the protective sheet is peeled off. 5. The method according to claim 1, wherein the metal thin film insert film has a design layer between the metal thin film layer and the base sheet. 6. The method according to claim 1, wherein the metal thin film insert film has an anchor layer between the metal thin film layer and the plastic sheet. 7. The method according to claim 1, wherein the preliminary forming is a vacuum forming method or a pressure forming method. 8. The material of the metal thin film layer is made of aluminum, nickel, gold, platinum, chromium, iron, copper, tin, indium, silver, titanium, lead, zinc, germanium, zinc sulfide, silicon oxide, magnesium fluoride, Tin oxide, IT
The method for producing a metal thin film insert film molded product according to claim 1, which is any one of O. 9. The plastic sheet is any one of an acrylic film, a polypropylene film, a thermoplastic elastomer film, a polycarbonate film, a nylon film, an acrylonitrile-butadiene-styrene film, an acrylonitrile-styrene film, a polystyrene film, and a polyurethane film. 2. The method for producing a metal thin film insert film molded product according to 1. 10. The protective sheet is any one of a polyethylene film, a polypropylene film, a polyvinyl chloride film, an unstretched ethylene-vinyl alcohol film, a polybutylene terephthalate film, an unstretched polypropylene film, and an unstretched polyester film, and The method for producing a metal thin-film insert film molded product according to claim 1, which is a smoke color. 12. The method for producing a metal thin film insert film molded product according to claim 1, wherein the shape of the metal thin film insert film molded product is a deep drawing molded product having a rise of 2 mm or more around its periphery.