WO2011013659A1 - Method for producing decorative sheet - Google Patents

Method for producing decorative sheet Download PDF

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Publication number
WO2011013659A1
WO2011013659A1 PCT/JP2010/062611 JP2010062611W WO2011013659A1 WO 2011013659 A1 WO2011013659 A1 WO 2011013659A1 JP 2010062611 W JP2010062611 W JP 2010062611W WO 2011013659 A1 WO2011013659 A1 WO 2011013659A1
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WO
WIPO (PCT)
Prior art keywords
sheet
curable ink
ink layer
mold
resin
Prior art date
Application number
PCT/JP2010/062611
Other languages
French (fr)
Japanese (ja)
Inventor
圭司 岸
智恒 矢部
Original Assignee
日本写真印刷株式会社
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Filing date
Publication date
Application filed by 日本写真印刷株式会社 filed Critical 日本写真印刷株式会社
Publication of WO2011013659A1 publication Critical patent/WO2011013659A1/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/026—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing of layered or coated substantially flat surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • B29C45/14811—Multilayered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/04—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts
    • B29C59/046—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts for layered or coated substantially flat surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0827—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using UV radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • B29C2045/14237—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure the inserts being deformed or preformed outside the mould or mould cavity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/0025—Applying surface layers, e.g. coatings, decorative layers, printed layers, to articles during shaping, e.g. in-mould printing
    • B29C37/0028—In-mould coating, e.g. by introducing the coating material into the mould after forming the article
    • B29C37/0032—In-mould coating, e.g. by introducing the coating material into the mould after forming the article the coating being applied upon the mould surface before introducing the moulding compound, e.g. applying a gelcoat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/002—Coloured

Definitions

  • the present invention relates to a method for manufacturing a decorative sheet used for vehicle interior materials and the like, and more particularly, to a method for manufacturing a decorative sheet having a three-dimensional pattern in which a texture or the like is raised.
  • a shaping member on which positive unevenness of a target three-dimensional pattern is formed is pressed while being heated on one side of a sheet material made of a transparent thermoplastic resin.
  • a heating shaping process for forming an irregularity that forms a negative shape of the irregularities of the shaping member on one side (hereinafter, the process of forming the negative irregularities of the irregularities of the shaping member is referred to as embossing)
  • embossing A cooling process for cooling the embossed sheet material, a coating process for applying an ink or paint containing a glittering material on one side, and forming a coating film in close contact with the uneven surface, and a coating film
  • Patent Document 1 discloses a method for producing a decorative sheet through a drying step of drying the cake.
  • the method of forming irregularities on a sheet material by embossing has an advantage that complex and relatively large irregularities can be easily formed as compared with a method of forming irregularities by cutting.
  • the present invention aims to provide a method for producing a decorative sheet that can faithfully reproduce the aesthetics of a target three-dimensional pattern even when a decorative sheet having a three-dimensional pattern is used in an insert molding method. To do.
  • the present invention has the following features.
  • the method for producing a decorative sheet according to the present invention forms an uneven surface by embossing on one surface of a base sheet, A UV curable ink layer is formed on the uneven surface, The UV curable ink layer is irradiated with UV light to cure the UV curable ink layer, A pattern layer is formed on the cured UV curable ink layer.
  • the UV curable ink layer is cured by performing UV irradiation from the concave and convex surface side of the base sheet.
  • the decorative sheet formed by the method for producing a decorative sheet of the above invention is arranged in a mold so that the surface of the base sheet faces the mold cavity. Thereafter, the mold is closed, a molding resin is poured into the mold, and the mold is cooled and solidified to form a decorative molded product in which the surface of the molding resin is decorated.
  • an uneven surface is formed on one surface of a base sheet, a UV curable ink layer is formed on the uneven surface, and the UV curable ink layer 12 is formed by UV irradiation. Therefore, even if the base sheet is heated during insert molding, the uneven shape is maintained as it is, and the decorative sheet to be manufactured can faithfully reproduce the aesthetic appearance of the target three-dimensional pattern.
  • the UV curable ink layer can be reliably cured.
  • the decorated sheet can reproduce the beauty of the target three-dimensional pattern more faithfully.
  • FIG. It is sectional drawing which shows the three-dimensional pattern formation apparatus provided with the pinching roller which can be used for the manufacturing method of the decorating sheet of this invention. It is explanatory drawing which shows the other structure of a three-dimensional pattern formation apparatus.
  • a to C are cross-sectional views showing a method for producing a decorative molded product of the present invention. It is a longitudinal cross-sectional view which shows the decorative molded product formed by the manufacturing method of the decorative molded product of this invention.
  • the uneven shape is formed.
  • a UV (ultraviolet) curable ink layer 12 is formed on the surface 11 so as to fill the concave portion, and then the UV curable ink layer 12 is cured by performing UV irradiation (see FIG. 1B), and then the UV.
  • a pattern layer 13 and an adhesive layer 14 are formed on the curable ink layer 12 (see FIG. 1C).
  • acrylic resin polycarbonate resin (PC resin), acrylonitrile-butadiene-styrene copolymer resin (ABS resin), polystyrene resin, polyurethane resin, nylon resin, ethylene vinyl alcohol resin, etc. may be used. it can.
  • the thickness of the base sheet 10 is preferably in the range of 20 to 500 ⁇ m. If the thickness is less than 20 ⁇ m, the function of protecting the UV curable ink layer 12 and the pattern layer 13 may be deteriorated. On the other hand, if it exceeds 500 ⁇ m, a large amount of heat is required for drawing during insert molding, which will be described later, and the material cost increases.
  • a decorative sheet manufacturing apparatus 40 including a pinching roller 30 can be used (see FIG. 2).
  • the decorative sheet manufacturing apparatus 40 includes, in order from the upstream side, a sandwiching roller 30, a cooling section 33, and a UV curable ink coating machine 34 in the sheet traveling path between the sheet feeding roll 31 and the sheet take-up roll 32. And a UV irradiation device 35 are arranged.
  • the sandwiching roller 30 includes a pressing roller 30a and a shaping roller 30b having a positive embossed pattern (three-dimensional pattern) formed on the peripheral surface. Then, the sandwiching roller 30 is rotated while being heated, and the base sheet 10 fed from the sheet feeding roll 31 is passed through the sandwiching roller 30.
  • the negative uneven surface 11 is formed on the base sheet 10 corresponding to the positive unevenness formed on the peripheral surface of the shaping roller 30b. It is formed on the back surface (one surface).
  • the embossed substrate sheet 10 is then naturally cooled by passing through a cooling section 33, and further UV curable ink is applied to the surface of the concavo-convex surface 11 formed on the back surface of the substrate sheet 10 by a UV curable ink coating machine 34. Is applied to form the UV curable ink layer 12.
  • the base sheet 10 is passed through the UV irradiation device 35 and the UV curable ink layer 12 is irradiated with UV light to cure the UV curable ink layer 12.
  • the decorative sheet 1 thus obtained is taken up on a sheet take-up roll 32. Since the decorative sheet 1 manufactured in this way has the UV curable ink layer 12 cured, even if the base sheet 10 is heated during the insert molding, the uneven shape is maintained as it is, and the target embossing is performed. The pattern can be faithfully reproduced.
  • the UV curable ink layer 12 can be reliably cured. Thereby, the aesthetics of the embossed pattern targeted in the decorative sheet 1 to be manufactured can be faithfully reproduced.
  • the method of continuously forming the UV curable ink layer 12 and the UV irradiation on the sheet traveling path has been described.
  • the base sheet 10 is set to a required length at the downstream end of the cooling section 33. After cutting, the UV curable ink layer 12 may be formed and UV-irradiated.
  • corrugated shaped surface 11 was formed in the back surface of the base sheet 10 using the pinching roller 30, the uneven
  • the heat press machine 50 includes a pair of lower and upper mold holders 51a and 51b for switching and flowing steam and cooling water and heating and cooling the interior of the lower mold holder 51a.
  • a shaping die 52 made of a silicon material having a positive embossed pattern with a target embossed pattern is placed via a surface plate 53, and both the base sheet 10 are set on the shaping die 52.
  • the upper mold holder 51b is lowered, and the base sheet 10 is placed between the surface plate 54 attached to the lower surface of the mold holder 51b and the shaping mold 52.
  • both mold holders 51a and 51b Cool the substrate with water for 3 to 5 minutes. After the sheet 10 is cooled, the upper die holder 51b is raised and the base sheet 10 is taken out.
  • the shaping mold 52 may be made of an epoxy resin, an etched iron plate, or an electroformed plate made of a metal such as Ni, Cu, or Fe.
  • the temperature of the heating steam is made slightly lower than the above value.
  • the mold holders 51a and 51b can be heated by electric heating.
  • the hot press machine 50 when using the hot press machine 50, it is necessary to set the base sheet 10 cut in advance to a required length one by one in the hot press machine 50 and remove it after the hot press.
  • the uneven surface 11 can be continuously formed on the long base sheet 10 fed from the sheet feed roll 31, and productivity can be improved.
  • the shaping die 52 can be produced in a shorter period of time and at a lower cost than the shaping roller 30.
  • the use of the hot press machine 50 is advantageous in that the manufacturing efficiency is good and the cooling process can be simultaneously performed using the hot press machine 50, so that a large space is not required.
  • the shaping die 52 is formed with positive unevenness on the flat plate, it is easy to clearly form the negative uneven surface 11 on the base sheet 10, and thus the quality of the decorative sheet 1 is improved. .
  • the resin used as the UV curable ink layer 12 contains a prepolymer having a reactive double bond or a reactive epoxy group and a reactive diluent.
  • prepolymers having reactive double bonds include unsaturated polyesters, alkyd acrylates, polyester acrylates, urethane acrylates, silicon acrylates, diene acrylates, melamine acrylates, and low molecular weight vinyl copolymer functional groups. There are those in which an acryloyl group is introduced by use, or those in which these prepolymers are modified with an isocyanate compound.
  • Examples of the prepolymer having a reactive epoxy group include a reactive epoxy acrylate, a composition obtained by ring-opening polymerization of a reactive epoxy compound using a compound that decomposes by light to generate a Lewis acid as a photopolymerization initiator, and the like. is there.
  • reactive diluents include monofunctional monomers such as 2-ethylhexyl acrylate, 2-hydroxyethyl acrylate, and tetrafurfryl acrylate, 1-3 butadiol diacrylate, diethylene glycol diacrylate, trimethylolpropane triacrylate, and pentaerythritol.
  • monofunctional monomers such as 2-ethylhexyl acrylate, 2-hydroxyethyl acrylate, and tetrafurfryl acrylate, 1-3 butadiol diacrylate, diethylene glycol diacrylate, trimethylolpropane triacrylate, and pentaerythritol.
  • multifunctional monomers such as triacrylate.
  • the reactive diluent is used for the purpose of, for example, adjusting the viscosity of the UV curing ink, crosslinking with the prepolymer, and improving the adhesion with the picture layer 13 to be laminated next.
  • a photopolymerization initiator is added to the prepolymer and the reactive diluent.
  • the photopolymerization initiator is used for initiating a polymerization reaction with ultraviolet rays.
  • photopolymerization initiators include carbonyl compounds such as acetophenone and benzophenone, sulfur compounds such as etramethyl-thiuram monosulfite and thioxanthone, and azo compounds such as allylazonium salts.
  • a colorant is added to the UV curable ink layer 12 in order to enhance the visibility when the uneven surface 11 is viewed from the surface.
  • a pigment or dye of an appropriate color may be added, but a bright material may be added.
  • the glittering material pearl pigments such as mica and metallic pigments such as aluminum pieces can be used.
  • the coloring agent or the glittering material is used in this way, when the decorative sheet 1 is viewed with the formation surface of the uneven surface 11 as the back surface, the light incident from the surface of the decorative sheet 1 is incident on the surface of the uneven surface 11.
  • the irregular surface 11 is clearly floated on the surface of the decorative sheet 1 as a result of irregular reflection by the glittering material contained in the UV curable ink layer 12 on the adhesion side surface of the closely contacting UV curable ink layer 12.
  • the embossed pattern is reproduced faithfully.
  • the pattern layer 13 is a layer having a function of expressing a pattern for decorating a molded product.
  • 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, or an alkyd resin is used as a binder.
  • a color ink containing an appropriate color pigment or dye as a colorant may be used.
  • a normal printing method such as a gravure printing method, a screen printing method, or an offset printing method can be used.
  • the thickness of the pattern layer 13 is preferably 1 to 30 ⁇ m.
  • the pattern layer 13 is not limited to colored ink, and a metal vapor deposition layer or the like can be formed to express a metallic gloss pattern.
  • the metal vapor deposition layer may be formed by using a vacuum vapor deposition method, a sputtering method, an ion plating method, or the like.
  • the material of the adhesive layer 14 formed as necessary includes urethane resin, vinyl chloride vinyl acetate copolymer resin, acrylic-ketone resin, acrylic-vinyl resin, acrylic resin, and the like.
  • urethane resin vinyl chloride vinyl acetate copolymer resin
  • acrylic-ketone resin acrylic-ketone resin
  • acrylic-vinyl resin acrylic resin
  • the decorative sheet 1 formed by the method for manufacturing a decorative sheet described above is bonded to the surface of the resin molded product 2 by an insert molding method, the decorative molded product 3 with an embossed pattern can be formed.
  • Examples of the resin molded product 2 constituting the decorative molded product 3 include polyolefin resins such as polyethylene and polypropylene, polystyrene resins, polyvinyl chloride resins, poly (meth) acrylate resins, acrylic resins, polyacetal resins, Known thermoplastic resins such as polyester resins such as polyethylene terephthalate and polybutylene terephthalate, polyamide resins, polycarbonate resins, polyphenylene sulfide resins, and polyimide resins can be used. These resins can be used alone or in admixture of two or more.
  • the decorative sheet 1 may be fed into the mold 21 one by one as a sheet, or a portion of the continuous long sheet necessary for decoration may be intermittently fed.
  • the sheet When the sheet is fed as a single sheet, it may be preformed in advance so as to follow the three-dimensional shape of the mold cavity surface.
  • the sheet may be fixed by the movable mold and the fixed mold after the position of the sheet is detected by a sensor.
  • the former method is a method of feeding the long sheet under timer control while keeping in mind that the molded part of the long sheet does not enter the mold cavity.
  • an abstract pattern is formed on the entire surface of the molded product. It can be used when accurate alignment is not particularly required, as in the case of performing.
  • the latter method is a method in which the vertical and horizontal positions of the long sheet are captured by a sensor and the pattern on the sheet is accurately aligned with the mold cavity.
  • the window frame pattern is adjusted to the window frame shape of the molded product. It can be used when accurate alignment is required.
  • the decorative sheet 1 is placed in the mold 21 and then closed (see FIG. 4A).
  • a molten molding resin is poured into the mold, and the resin molding 2 is formed by cooling and solidifying (see FIG. 4B).
  • FIG. 5 is an enlarged view of the decorative molded product 3 manufactured by the above method.
  • the decorative sheet 1 is laminated on the surface of the resin molded product 2 and the base sheet 10 remains as a protective layer on the surface.
  • the back surface of the UV curable ink layer 11 formed so as to fill the uneven surface 11 is formed as a smooth surface, the pattern layer 13 can be securely bonded and the deformation of the pattern is prevented. There is also an advantage that it can be done.
  • the present invention can be used when manufacturing a decorative sheet for forming an interior material of a vehicle by insert molding.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)

Abstract

A method for producing a decorative sheet (1) capable of accurately reproducing a targeted steric pattern, characterized in that a concavo-convex shaped surface (11) is formed on one surface of a base sheet (10) by embossing, an UV curable ink layer (12) is formed on the concavo-convex shaped surface (11), UV light is irradiated onto the UV curable ink layer (12) to cure the UV curable ink layer (12), and a picture layer (13) is formed on the cured UV curable ink layer (12).

Description

加飾シートの製造方法Decorative sheet manufacturing method
　本発明は、車両の内装材等に使用する加飾シートの製造方法に関し、より詳しくは、布目等が浮き出したような立体的模様を持つ加飾シートの製造方法に関する。 The present invention relates to a method for manufacturing a decorative sheet used for vehicle interior materials and the like, and more particularly, to a method for manufacturing a decorative sheet having a three-dimensional pattern in which a texture or the like is raised.
　従来、この種の加飾シートの製造方法として、目標とする立体的模様のポジ形状の凹凸が形成されている付形部材を、透明の熱可塑性樹脂製のシート材の片面に加熱しつつ押し付け、その片面に対し、付形部材の凹凸のネガ形状となる凹凸を形成する加熱付形工程（以下、このように付形部材の凹凸のネガ形状の凹凸を形成する加工をエンボス加工と呼ぶ）と、エンボス加工されたシート材を冷却する冷却工程と、前記片面に光輝材を含有するインキまたは塗料を塗布して、凹凸の表面に密着した状態で塗膜を形成する塗装工程と、塗膜を乾燥する乾燥工程とを経て加飾シートを製造する方法が特許文献１に開示されている。 Conventionally, as a method for manufacturing this type of decorative sheet, a shaping member on which positive unevenness of a target three-dimensional pattern is formed is pressed while being heated on one side of a sheet material made of a transparent thermoplastic resin. , A heating shaping process for forming an irregularity that forms a negative shape of the irregularities of the shaping member on one side (hereinafter, the process of forming the negative irregularities of the irregularities of the shaping member is referred to as embossing) A cooling process for cooling the embossed sheet material, a coating process for applying an ink or paint containing a glittering material on one side, and forming a coating film in close contact with the uneven surface, and a coating film Patent Document 1 discloses a method for producing a decorative sheet through a drying step of drying the cake.
　エンボス加工によってシート材に凹凸を形成する方法は、切削によって凹凸を形成する方法と比べ、複雑かつ比較的大きな凹凸を容易に形成できるという利点がある。 The method of forming irregularities on a sheet material by embossing has an advantage that complex and relatively large irregularities can be easily formed as compared with a method of forming irregularities by cutting.
特許４１６５６２３号公報Japanese Patent No. 4165623
　しかしながら、エンボス加工によってシート材に凹凸を形成した従来の加飾シートを用い、さらに、インサート成形法によって樹脂成形品と一体化された加飾成形品を形成しようとすると、シート材に形成された凹凸形状が、充填された溶融樹脂の熱により元の平面に戻ろうとすることによって目標とする立体的模様の美観を忠実に再現できないという問題がある。 However, when using a conventional decorative sheet in which unevenness was formed on the sheet material by embossing, and further trying to form a decorative molded product integrated with a resin molded product by an insert molding method, it was formed on the sheet material There is a problem that the irregular shape cannot faithfully reproduce the aesthetic appearance of the target three-dimensional pattern by trying to return to the original plane by the heat of the filled molten resin.
　本発明は、立体的模様を持つ加飾シートをインサート成形法に使用する場合においても、目標とする立体的模様の美観を忠実に再現し得る加飾シートの製造方法を提供することを目的とする。 The present invention aims to provide a method for producing a decorative sheet that can faithfully reproduce the aesthetics of a target three-dimensional pattern even when a decorative sheet having a three-dimensional pattern is used in an insert molding method. To do.
　本発明は前記目的を達成するため、以下のような特徴を備える。 In order to achieve the above object, the present invention has the following features.
　本発明の加飾シートの製造方法は、基体シートの一方面にエンボス加工により凹凸形状面を形成し、
　上記凹凸形状面上にＵＶ硬化性インキ層を形成し、
　上記ＵＶ硬化性インキ層にＵＶ光を照射して上記ＵＶ硬化性インキ層を硬化させ、
　硬化した上記ＵＶ硬化性インキ層上に絵柄層を形成することを特徴とする。 The method for producing a decorative sheet according to the present invention forms an uneven surface by embossing on one surface of a base sheet,
A UV curable ink layer is formed on the uneven surface,
The UV curable ink layer is irradiated with UV light to cure the UV curable ink layer,
A pattern layer is formed on the cured UV curable ink layer.
　また、本発明において、上記基体シートの凹凸形状面側からＵＶ照射を行うことにより上記ＵＶ硬化性インキ層を硬化させることが好ましい。 In the present invention, it is preferable that the UV curable ink layer is cured by performing UV irradiation from the concave and convex surface side of the base sheet.
　本発明の加飾成形品の製造方法は、上記の発明の加飾シートの製造方法で形成された加飾シートを、基体シートの表面が金型キャビティに面するように金型内に配置した後、型閉じして金型内に成形樹脂を流し込み、冷却固化することにより、成形樹脂の表面に加飾が施された加飾成形品を形成することを特徴とする。 In the method for producing a decorative molded product of the present invention, the decorative sheet formed by the method for producing a decorative sheet of the above invention is arranged in a mold so that the surface of the base sheet faces the mold cavity. Thereafter, the mold is closed, a molding resin is poured into the mold, and the mold is cooled and solidified to form a decorative molded product in which the surface of the molding resin is decorated.
　本発明の加飾シートの製造方法によれば、基体シートの一方面に凹凸形状面を形成し、凹凸形状面上にＵＶ硬化性インキ層を形成し、ＵＶ照射によりそのＵＶ硬化性インキ層１２を硬化させるため、インサート成形の際に基体シートが加熱されても凹凸形状はそのまま保持され、製造される加飾シートは、目標とする立体的模様の美観を忠実に再現することができる。 According to the method for producing a decorative sheet of the present invention, an uneven surface is formed on one surface of a base sheet, a UV curable ink layer is formed on the uneven surface, and the UV curable ink layer 12 is formed by UV irradiation. Therefore, even if the base sheet is heated during insert molding, the uneven shape is maintained as it is, and the decorative sheet to be manufactured can faithfully reproduce the aesthetic appearance of the target three-dimensional pattern.
　また、基体シートにおける凹凸形状面側からＵＶ照射を行うことによってＵＶ硬化性インキ層を硬化させる加飾シートの製造方法によれば、ＵＶ硬化性インキ層を確実に硬化させることができるため、製造される加飾シートは、目標とする立体的模様の美観をより忠実に再現することができる。 Further, according to the method for producing a decorative sheet in which the UV curable ink layer is cured by irradiating UV from the uneven surface side of the base sheet, the UV curable ink layer can be reliably cured. The decorated sheet can reproduce the beauty of the target three-dimensional pattern more faithfully.
ＡからＣは本発明の加飾シートの製造方法を示す断面図。Sectional drawing which shows the manufacturing method of the decorating sheet | seat of this invention from A to C. FIG. 本発明の加飾シートの製造方法に使用できる、挟みローラを備えた立体的模様形成装置を示す断面図である。It is sectional drawing which shows the three-dimensional pattern formation apparatus provided with the pinching roller which can be used for the manufacturing method of the decorating sheet of this invention. 立体的模様形成装置の他の構成を示す説明図である。It is explanatory drawing which shows the other structure of a three-dimensional pattern formation apparatus. ＡからＣは本発明の加飾成形品の製造方法を示す断面図である。A to C are cross-sectional views showing a method for producing a decorative molded product of the present invention. 本発明の加飾成形品の製造方法により形成された加飾成形品を示す縦断面図である。It is a longitudinal cross-sectional view which shows the decorative molded product formed by the manufacturing method of the decorative molded product of this invention.
　以下、図面を参照しながらこの発明の実施の形態について詳しく説明する。 Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
　本発明の加飾シート１の製造方法は、透明または半透明の基体シート１０の背面にエンボス加工により目標とする模様のネガ形状の凹凸形状面１１を形成した後（図１Ａ参照）、凹凸形状面１１上にその凹部を埋めるようにしてＵＶ（紫外線）硬化性インキ層１２を形成し、次いでＵＶ照射を行うことによりＵＶ硬化性インキ層１２を硬化させた後（図１Ｂ参照）、そのＵＶ硬化性インキ層１２上に絵柄層１３、接着層１４を形成する（図１Ｃ参照）。 In the method for producing the decorative sheet 1 of the present invention, after forming the negative uneven surface 11 having a target pattern on the back surface of the transparent or translucent substrate sheet 10 (see FIG. 1A), the uneven shape is formed. A UV (ultraviolet) curable ink layer 12 is formed on the surface 11 so as to fill the concave portion, and then the UV curable ink layer 12 is cured by performing UV irradiation (see FIG. 1B), and then the UV. A pattern layer 13 and an adhesive layer 14 are formed on the curable ink layer 12 (see FIG. 1C).
　基体シート１０の材質としては、アクリル樹脂、ポリカーボネート樹脂（ＰＣ樹脂）、アクリロニトリル－ブタジエン－スチレン共重合樹脂（ＡＢＳ樹脂）、ポリスチレン樹脂、ポリウレタン樹脂、ナイロン樹脂、エチレンビニルアルコール樹脂などを使用することができる。 As the material of the base sheet 10, acrylic resin, polycarbonate resin (PC resin), acrylonitrile-butadiene-styrene copolymer resin (ABS resin), polystyrene resin, polyurethane resin, nylon resin, ethylene vinyl alcohol resin, etc. may be used. it can.
　基体シート１０の厚みは２０～５００μｍの範囲とするのが好ましい。厚さが２０μｍ未満であると、ＵＶ硬化性インキ層１２や絵柄層１３を保護する機能が低下する虞がある。一方、５００μｍを超えると、後述するインサート成形時において絞り加工するのに大きな熱量が必要になり、また材料費も高くなるという不具合がある。 The thickness of the base sheet 10 is preferably in the range of 20 to 500 μm. If the thickness is less than 20 μm, the function of protecting the UV curable ink layer 12 and the pattern layer 13 may be deteriorated. On the other hand, if it exceeds 500 μm, a large amount of heat is required for drawing during insert molding, which will be described later, and the material cost increases.
　基体シート１０の背面にエンボス加工によって凹凸形状面１１を形成するためには、挟みローラ３０を備えた加飾シート製造装置４０を使用できる（図２参照）。 In order to form the concavo-convex shape surface 11 on the back surface of the base sheet 10 by embossing, a decorative sheet manufacturing apparatus 40 including a pinching roller 30 can be used (see FIG. 2).
　この加飾シート製造装置４０は、シート送り出しロール３１とシート巻き取りロール３２との間のシート走行路に、上流側から順に、挟みローラ３０と、冷却区間３３と、ＵＶ硬化性インキ塗装機３４と、ＵＶ照射装置３５とが配置して構成されている。 The decorative sheet manufacturing apparatus 40 includes, in order from the upstream side, a sandwiching roller 30, a cooling section 33, and a UV curable ink coating machine 34 in the sheet traveling path between the sheet feeding roll 31 and the sheet take-up roll 32. And a UV irradiation device 35 are arranged.
　挟みローラ３０は、押圧ローラ３０ａと、周面に目標となるエンボス模様（立体的模様）のポジ形状の凹凸が形成されている付形ローラ３０ｂとから構成されている。そして、挟みローラ３０を加熱しつつ回転させて、シート送り出しロール３１から繰り出される基体シート１０を挟みローラ３０に通過させる。 The sandwiching roller 30 includes a pressing roller 30a and a shaping roller 30b having a positive embossed pattern (three-dimensional pattern) formed on the peripheral surface. Then, the sandwiching roller 30 is rotated while being heated, and the base sheet 10 fed from the sheet feeding roll 31 is passed through the sandwiching roller 30.
　この方法によれば、付形部材としての付形ローラ３０ｂの押し付けにより、付形ローラ３０ｂの周面に形成されているポジ形状の凹凸に対応してネガ形状の凹凸形状面１１が基体シート１０の背面（一方面）に形成される。 According to this method, by pressing the shaping roller 30b as a shaping member, the negative uneven surface 11 is formed on the base sheet 10 corresponding to the positive unevenness formed on the peripheral surface of the shaping roller 30b. It is formed on the back surface (one surface).
　エンボス加工された基体シート１０は、次に冷却区間３３を通過することで自然冷却され、さらに、ＵＶ硬化性インキ塗装機３４により基体シート１０裏面の凹凸形状面１１の形成面にＵＶ硬化性インキが塗布されＵＶ硬化性インキ層１２が形成される。 The embossed substrate sheet 10 is then naturally cooled by passing through a cooling section 33, and further UV curable ink is applied to the surface of the concavo-convex surface 11 formed on the back surface of the substrate sheet 10 by a UV curable ink coating machine 34. Is applied to form the UV curable ink layer 12.
　次いで、ＵＶ照射装置３５に基体シート１０を通過させてＵＶ硬化性インキ層１２にＵＶ光を照射しＵＶ硬化性インキ層１２を硬化させる。 Next, the base sheet 10 is passed through the UV irradiation device 35 and the UV curable ink layer 12 is irradiated with UV light to cure the UV curable ink layer 12.
　かくて得られた加飾シート１をシート巻き取りロール３２に巻き取る。このようにして製造される加飾シート１は、ＵＶ硬化性インキ層１２が硬化しているため、インサート成形の際に基体シート１０が加熱されても凹凸形状はそのまま保持され、目標とするエンボス模様を忠実に再現することができる。 The decorative sheet 1 thus obtained is taken up on a sheet take-up roll 32. Since the decorative sheet 1 manufactured in this way has the UV curable ink layer 12 cured, even if the base sheet 10 is heated during the insert molding, the uneven shape is maintained as it is, and the target embossing is performed. The pattern can be faithfully reproduced.
　上記ＵＶ照射を基体シート１０の背面側から行うようにしているため、ＵＶ硬化性インキ層１２を確実に硬化させることができる。それにより、製造される加飾シート１において目標とするエンボス模様の美観を忠実に再現できる。 Since the UV irradiation is performed from the back side of the base sheet 10, the UV curable ink layer 12 can be reliably cured. Thereby, the aesthetics of the embossed pattern targeted in the decorative sheet 1 to be manufactured can be faithfully reproduced.
　なお、上記実施形態では、ＵＶ硬化性インキ層１２の形成とＵＶ照射を、シート走行路上で連続的に行なう方法について説明したが、冷却区間３３の下流端で基体シート１０を所要の長さに切断してからＵＶ硬化性インキ層１２の形成とＵＶ照射とを行うようにしても良い。 In the above embodiment, the method of continuously forming the UV curable ink layer 12 and the UV irradiation on the sheet traveling path has been described. However, the base sheet 10 is set to a required length at the downstream end of the cooling section 33. After cutting, the UV curable ink layer 12 may be formed and UV-irradiated.
　また、上記実施形態では、基体シート１０の背面に挟みローラ３０を用いて凹凸形状面１１を形成したが、図３に示す熱プレス機５０を用いて凹凸形状面１１を形成することもできる。 Moreover, in the said embodiment, although the uneven | corrugated shaped surface 11 was formed in the back surface of the base sheet 10 using the pinching roller 30, the uneven | corrugated shaped surface 11 can also be formed using the hot press machine 50 shown in FIG.
　詳しくは、熱プレス機５０は、内部に蒸気および冷却水を切り換えて流し、加熱と冷却を行う下側と上側の１対の型ホルダ５１ａ，５１ｂを備えており、下側の型ホルダ５１ａの上面に、目標とするエンボス模様のポジ形状の凹凸を形成したシリコン材から成る付形型５２を定盤５３を介して載置し、付形型５２上に基体シート１０をセットした状態で両型ホルダ５１ａ，５１ｂを約１８０～１９０℃の蒸気で加熱しつつ上側の型ホルダ５１ｂを下降させ、この型ホルダ５１ｂの下面に取付けた定盤５４と付形型５２との間に基体シート１０を２～２０ｋｇ／ｃｍ２の圧力で３～５分挟圧して、基体シート１０の下面に付形型５２の凹凸に対応するネガ形状の凹凸を形成し、次に、両型ホルダ５１ａ，５１ｂに冷却水を３～５分流して基体シート１０を冷却した後、上側の型ホルダ５１ｂを上昇させて基体シート１０を取出す。 Specifically, the heat press machine 50 includes a pair of lower and upper mold holders 51a and 51b for switching and flowing steam and cooling water and heating and cooling the interior of the lower mold holder 51a. On a top surface, a shaping die 52 made of a silicon material having a positive embossed pattern with a target embossed pattern is placed via a surface plate 53, and both the base sheet 10 are set on the shaping die 52. While heating the mold holders 51a and 51b with steam of about 180 to 190 ° C., the upper mold holder 51b is lowered, and the base sheet 10 is placed between the surface plate 54 attached to the lower surface of the mold holder 51b and the shaping mold 52. Is pressed for 3 to 5 minutes at a pressure of 2 to 20 kg / cm 2 to form negative irregularities corresponding to the irregularities of the shaping die 52 on the lower surface of the base sheet 10, and then both mold holders 51a and 51b Cool the substrate with water for 3 to 5 minutes. After the sheet 10 is cooled, the upper die holder 51b is raised and the base sheet 10 is taken out.
　なお、付形型５２はエポキシ樹脂やエッチングした鉄板やＮｉ，Ｃｕ，Ｆｅ等の金属製の電鋳板で製作しても良い。鉄板や電鋳板を用いる場合は、加熱蒸気の温度を上記の値より少し低めにする。なお、型ホルダ５１ａ，５１ｂを電熱で加熱することも可能である。 Note that the shaping mold 52 may be made of an epoxy resin, an etched iron plate, or an electroformed plate made of a metal such as Ni, Cu, or Fe. When using an iron plate or an electroformed plate, the temperature of the heating steam is made slightly lower than the above value. The mold holders 51a and 51b can be heated by electric heating.
　ところで、熱プレス機５０を用いる場合は、予め所要の長さに切断した基体シート１０を１枚ずつ熱プレス機５０にセットし、熱プレス後に取り外す必要があるのに対し、上記挟みローラ３０を用いる場合は、シート送り出しロール３１から繰り出される長尺の基体シート１０に対し、連続して凹凸形状面１１を形成でき、生産性の向上を図ることができる。 By the way, when using the hot press machine 50, it is necessary to set the base sheet 10 cut in advance to a required length one by one in the hot press machine 50 and remove it after the hot press. When used, the uneven surface 11 can be continuously formed on the long base sheet 10 fed from the sheet feed roll 31, and productivity can be improved.
　一方、加飾シート１のサイズが小さい場合、付形型５２の方が付形ローラ３０に比し短期間で安価に製作できるから、多品種を少量生産する場合や試作レベルの製造を行うような場合には、熱プレス機５０を用いた方が、製造効率が良く、更に、熱プレス機５０を用いて同時に冷却工程も行うことができるため広いスペースを必要としない点で有利である。 On the other hand, when the size of the decorative sheet 1 is small, the shaping die 52 can be produced in a shorter period of time and at a lower cost than the shaping roller 30. In such a case, the use of the hot press machine 50 is advantageous in that the manufacturing efficiency is good and the cooling process can be simultaneously performed using the hot press machine 50, so that a large space is not required.
　また、付形型５２は平板にポジ形状の凹凸を形成したものであるから、基体シート１０にネガ形状の凹凸形状面１１を鮮明に形成し易く、したがって、加飾シート１の品質も向上する。 Further, since the shaping die 52 is formed with positive unevenness on the flat plate, it is easy to clearly form the negative uneven surface 11 on the base sheet 10, and thus the quality of the decorative sheet 1 is improved. .
　ＵＶ硬化性インキ層１２として使用する樹脂は、反応性二重結合または反応性エポキシ基を有するプレポリマーと反応性希釈剤とを含むものである。 The resin used as the UV curable ink layer 12 contains a prepolymer having a reactive double bond or a reactive epoxy group and a reactive diluent.
　反応性二重結合を有するプレポリマーとしては、たとえば不飽和ポリエステル・アルキッドアクリレート・ポリエステルアクリレート・ウレタンアクリレート・シリコンアクリレート・ジエン系アクリレート・メラミンアクリレート・低分子量のビニル共重合体の側鎖の官能基を利用してアクリロイル基を導入したもの、あるいはこれらのプレポリマーをイソシアネート化合物で変性したものなどがある。 Examples of prepolymers having reactive double bonds include unsaturated polyesters, alkyd acrylates, polyester acrylates, urethane acrylates, silicon acrylates, diene acrylates, melamine acrylates, and low molecular weight vinyl copolymer functional groups. There are those in which an acryloyl group is introduced by use, or those in which these prepolymers are modified with an isocyanate compound.
　また、反応性エポキシ基を有するプレポリマーとしては、たとえば反応性エポキシアクリレート、光によって分解してルイス酸を発生させる化合物を光重合開始剤として反応性エポキシ化合物を開環重合させた組成物などがある。 Examples of the prepolymer having a reactive epoxy group include a reactive epoxy acrylate, a composition obtained by ring-opening polymerization of a reactive epoxy compound using a compound that decomposes by light to generate a Lewis acid as a photopolymerization initiator, and the like. is there.
　反応性希釈剤としては、２－エチルヘキシルアクリレート・２－ヒドロキシエチルアクリレート・テトラフルフリールアクリレートなどの単官能性モノマー、１－３ブタジオールジアクリレート・ジエチレングリコールジアクリレート、トリメチロールプロパントリアクリレート、ペンタエリスリトールトリアクリレートなどの多官能性モノマーなどをあげることができる。 Examples of reactive diluents include monofunctional monomers such as 2-ethylhexyl acrylate, 2-hydroxyethyl acrylate, and tetrafurfryl acrylate, 1-3 butadiol diacrylate, diethylene glycol diacrylate, trimethylolpropane triacrylate, and pentaerythritol. Examples thereof include multifunctional monomers such as triacrylate.
　反応性希釈剤は、ＵＶ硬化用インキの粘度調製、プレポリマーとの架橋、次に積層される絵柄層１３との密着性の向上などの目的で使用される。 The reactive diluent is used for the purpose of, for example, adjusting the viscosity of the UV curing ink, crosslinking with the prepolymer, and improving the adhesion with the picture layer 13 to be laminated next.
　前記したプレポリマーおよび反応性希釈剤には、必要により光重合開始剤を添加する。光重合開始剤は、紫外線により重合反応を開始させるために使用するものである。このような光重合開始剤としては、たとえばアセトフェノン・ベンゾフェノンなどのカルボニル化合物、エトラメチル－チウラムモノサルファイト・チオキサンソンなどのイオウ化合物、アリルアゾニウム塩などのアゾ化合物などが使用できる。 If necessary, a photopolymerization initiator is added to the prepolymer and the reactive diluent. The photopolymerization initiator is used for initiating a polymerization reaction with ultraviolet rays. Examples of such photopolymerization initiators include carbonyl compounds such as acetophenone and benzophenone, sulfur compounds such as etramethyl-thiuram monosulfite and thioxanthone, and azo compounds such as allylazonium salts.
　また、凹凸形状面１１を表面より見た場合の視認性を高めるため、ＵＶ硬化性インキ層１２には着色剤を添加する。 Also, a colorant is added to the UV curable ink layer 12 in order to enhance the visibility when the uneven surface 11 is viewed from the surface.
　着色剤としては適切な色の顔料または染料を添加してもよいが、光輝材を添加してもよい。 As the colorant, a pigment or dye of an appropriate color may be added, but a bright material may be added.
　光輝材としては、マイカ等のパール顔料やアルミ片等のメタリック顔料を使用することができる。このように着色剤または光輝材を使用すると、凹凸形状面１１の形成面を裏面にして加飾シート１を見たとき、加飾シート１の表面から入射した光線が凹凸形状面１１の表面に密着するＵＶ硬化性インキ層１２の密着側表面にてＵＶ硬化性インキ層１２に含まれる光輝材により乱反射され、その結果、加飾シート１の表面に凹凸形状面１１が鮮明に浮び上り、目標とするエンボス模様が忠実に再現される。 As the glittering material, pearl pigments such as mica and metallic pigments such as aluminum pieces can be used. When the coloring agent or the glittering material is used in this way, when the decorative sheet 1 is viewed with the formation surface of the uneven surface 11 as the back surface, the light incident from the surface of the decorative sheet 1 is incident on the surface of the uneven surface 11. The irregular surface 11 is clearly floated on the surface of the decorative sheet 1 as a result of irregular reflection by the glittering material contained in the UV curable ink layer 12 on the adhesion side surface of the closely contacting UV curable ink layer 12. The embossed pattern is reproduced faithfully.
　絵柄層１３は、成形品を加飾するための柄を表現する機能を持つ層である。 The pattern layer 13 is a layer having a function of expressing a pattern for decorating a molded product.
　絵柄層１３の材質としては、ポリビニル系樹脂、ポリアミド系樹脂、ポリエステル系樹脂、アクリル系樹脂、ポリウレタン系樹脂、ポリビニルアセタール系樹脂、ポリエステルウレタン系樹脂、セルロースエステル系樹脂、アルキド樹脂などの樹脂をバインダーとし、適切な色の顔料または染料を着色剤として含有する着色インキを用いるとよい。 As a material of the pattern layer 13, 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, or an alkyd resin is used as a binder. And a color ink containing an appropriate color pigment or dye as a colorant may be used.
　絵柄層１３の形成方法としては、グラビア印刷法、スクリーン印刷法、オフセット印刷法などの通常の印刷法などを用いることができる。 As a method for forming the pattern layer 13, a normal printing method such as a gravure printing method, a screen printing method, or an offset printing method can be used.
　絵柄層１３の厚さとしては、１～３０μｍが好ましい。また、絵柄層１３は着色インキに限らず、金属蒸着層等を形成して金属光沢のある模様を表現することもできる。 The thickness of the pattern layer 13 is preferably 1 to 30 μm. In addition, the pattern layer 13 is not limited to colored ink, and a metal vapor deposition layer or the like can be formed to express a metallic gloss pattern.
　金属蒸着層の材質としては、アルミ、クロム、銅、スズなどを用いることができる。金属蒸着層の形成は、真空蒸着法、スパッタリング法、イオンプレーティング法などを用いればよい。 Aluminum, chromium, copper, tin, etc. can be used as the material for the metal vapor deposition layer. The metal vapor deposition layer may be formed by using a vacuum vapor deposition method, a sputtering method, an ion plating method, or the like.
　必要に応じて形成される接着層１４の材質としては、ウレタン樹脂、塩化ビニル酢酸ビニル共重合体樹脂、アクリル－ケトン樹脂、アクリル－ビニル樹脂、アクリル樹脂などがある。接着層１４の形成方式としては、例えばグラビア印刷がある。 The material of the adhesive layer 14 formed as necessary includes urethane resin, vinyl chloride vinyl acetate copolymer resin, acrylic-ketone resin, acrylic-vinyl resin, acrylic resin, and the like. As a method of forming the adhesive layer 14, for example, there is gravure printing.
　上述した加飾シートの製造方法で形成された加飾シート１をインサート成形法により樹脂成形品２の表面と接着すれば、エンボス模様付きの加飾成形品３を形成することができる。 If the decorative sheet 1 formed by the method for manufacturing a decorative sheet described above is bonded to the surface of the resin molded product 2 by an insert molding method, the decorative molded product 3 with an embossed pattern can be formed.
　以下、そのエンボス模様付き加飾成形品３を形成する方法について説明する。 Hereinafter, a method of forming the decorative molded product 3 with the embossed pattern will be described.
　加飾成形品３を構成する樹脂成形品２としては、例えばポリエチレン、ポリプロピレン等のポリオレフィン系樹脂、ポリスチレン系樹脂、ポリ塩化ビニル系樹脂、ポリ（メタ）アクリレート系樹脂、アクリル系樹脂、ポリアセタール樹脂、ポリエチレンテレフタレート、ポリブチレンテレフタレート等のポリエステル樹脂、ポリアミド樹脂、ポリカーボネート樹脂、ポリフェニレンサルファイド樹脂、ポリイミド樹脂等の公知の熱可塑性樹脂がいずれも使用できる。これらの樹脂は単独あるいは２種以上を混合して使用することも可能である。 Examples of the resin molded product 2 constituting the decorative molded product 3 include polyolefin resins such as polyethylene and polypropylene, polystyrene resins, polyvinyl chloride resins, poly (meth) acrylate resins, acrylic resins, polyacetal resins, Known thermoplastic resins such as polyester resins such as polyethylene terephthalate and polybutylene terephthalate, polyamide resins, polycarbonate resins, polyphenylene sulfide resins, and polyimide resins can be used. These resins can be used alone or in admixture of two or more.
　次に、インサート成形法によって加飾シート１を樹脂成形品２の表面に接着させ、一体化させる方法について図４を参照しながら説明する。 Next, a method of adhering the decorative sheet 1 to the surface of the resin molded product 2 by an insert molding method and integrating them will be described with reference to FIG.
　まず、加飾シート１を構成している基体シート１０の表面が金型キャビティに面するように、可動型２１ａと固定型２１ｂとからなる樹脂成形用の金型２１内に配置する。 First, it arrange | positions in the metal mold | die 21 for resin molding which consists of the movable mold | type 21a and the fixed mold | type 21b so that the surface of the base sheet 10 which comprises the decorating sheet 1 may face a mold cavity.
　その際、加飾シート１を枚葉のシートとして１枚ずつ金型２１内に送り込んでもよいし、連続する長尺シートのうちの加飾に必要な部分を間欠的に送り込んでもよい。 At that time, the decorative sheet 1 may be fed into the mold 21 one by one as a sheet, or a portion of the continuous long sheet necessary for decoration may be intermittently fed.
　枚葉のシートとして送り込む場合、予め金型キャビティ面の三次元形状に沿うように予備成形してもよい。 When the sheet is fed as a single sheet, it may be preformed in advance so as to follow the three-dimensional shape of the mold cavity surface.
　長尺シートの場合、位置決め機構を有する送り装置を使用して、長尺シートと金型２１との見当が一致するようにするとよい。また、長尺シートを金型内に間欠的に送り込む際に、シートの位置をセンサーで検出した後にシートを可動型と固定型とで固定するようにしてもよい。 In the case of a long sheet, it is preferable to use a feeding device having a positioning mechanism so that the registration of the long sheet and the mold 21 is the same. Further, when the long sheet is intermittently fed into the mold, the sheet may be fixed by the movable mold and the fixed mold after the position of the sheet is detected by a sensor.
　前者の方法は、長尺シートにおける成形済み部分が金型キャビティにかからないようにする点に留意して長尺シートをタイマー制御で送る方法であり、例えば、成形品の表面全面に抽象柄を形成する場合のように、正確な位置合わせが特に求められない場合に用いることができる。 The former method is a method of feeding the long sheet under timer control while keeping in mind that the molded part of the long sheet does not enter the mold cavity. For example, an abstract pattern is formed on the entire surface of the molded product. It can be used when accurate alignment is not particularly required, as in the case of performing.
　また、後者の方法は、長尺シートの縦横の位置をセンサーで捉えて正確にシート上の柄を金型キャビティに合わせる方法であり、例えば成形品の窓枠形状に窓枠パターンを合わせるような、正確な位置合わせが求められる場合に用いることができる。 The latter method is a method in which the vertical and horizontal positions of the long sheet are captured by a sensor and the pattern on the sheet is accurately aligned with the mold cavity. For example, the window frame pattern is adjusted to the window frame shape of the molded product. It can be used when accurate alignment is required.
　加飾シート１を金型２１内に配置した後、型閉じする（図４Ａ参照）。 The decorative sheet 1 is placed in the mold 21 and then closed (see FIG. 4A).
　次いで金型内に溶融した成形用樹脂を流し込み、冷却固化して樹脂成形品２を形成する（図４Ｂ参照）。 Next, a molten molding resin is poured into the mold, and the resin molding 2 is formed by cooling and solidifying (see FIG. 4B).
　最後に金型２１を開いて樹脂成形品２の表面に加飾シート１が接着され一体化された加飾成形品３を取り出す（図４Ｃ参照）。 Finally, the mold 21 is opened, and the decorative molded product 3 in which the decorative sheet 1 is bonded and integrated on the surface of the resin molded product 2 is taken out (see FIG. 4C).
　図５は上記の方法で製造された加飾成形品３の拡大図である。 FIG. 5 is an enlarged view of the decorative molded product 3 manufactured by the above method.
　同図に示す加飾成形品３は、樹脂成形品２の表面に加飾シート１が積層されその表面に基体シート１０が保護層として残るものである。 In the decorative molded product 3 shown in the figure, the decorative sheet 1 is laminated on the surface of the resin molded product 2 and the base sheet 10 remains as a protective layer on the surface.
　また、凹凸形成面１１を埋めるようにして形成されるＵＶ硬化性インキ層１１の背面は平滑面に形成されているため、絵柄層１３を確実に接着することができ、且つ絵柄の変形を防止することができるという利点もある。 In addition, since the back surface of the UV curable ink layer 11 formed so as to fill the uneven surface 11 is formed as a smooth surface, the pattern layer 13 can be securely bonded and the deformation of the pattern is prevented. There is also an advantage that it can be done.
　なお、本発明は、添付図面を参照しながら好ましい実施形態に関連して充分に記載しているが、当該技術分野の熟練者にとっては種々の変形や修正を加えて実施することは可能である。そのような変形や修正は、本発明の技術的範囲を逸脱しない限りにおいて、本発明に含まれると理解されるべきである。 Although the present invention has been fully described in connection with the preferred embodiments with reference to the accompanying drawings, those skilled in the art can implement the invention with various changes and modifications. . It should be understood that such variations and modifications are included in the present invention without departing from the technical scope of the present invention.
　本発明は、車両の内装材等をインサート成形により形成するための加飾シートを製造する場合に利用することができる。 The present invention can be used when manufacturing a decorative sheet for forming an interior material of a vehicle by insert molding.
　　１　加飾シート
　　２　樹脂成形品
　　３　加飾成形品
　１０　基体シート
　１１　凹凸形状面
　１２　ＵＶ硬化性インキ層
　１３　絵柄層
　１４　接着層
　２１　金型
　３１　シート送り出しロール
　３２　シート巻き取りロール
　３０　挟みローラ
　３０ａ　押圧ローラ
　３０ｂ　付形ローラ
　３３　冷却区間
　３４　ＵＶ硬化性インキ塗装機
　３５　ＵＶ照射装置
　４０　加飾シート製造装置
　５０　熱プレス機
　５１ａ　型ホルダ
　５１ｂ　型ホルダ
　５２　付形型
　５３　定盤
　５４　定盤 DESCRIPTION OF SYMBOLS 1 Decorative sheet 2 Resin molded product 3 Decorative molded product 10 Base sheet 11 Uneven shape surface 12 UV curable ink layer 13 Picture layer 14 Adhesive layer 21 Mold 31 Sheet feeding roll 32 Sheet take-up roll 30 Pinch roller 30a Press roller 30b Shaped roller 33 Cooling section 34 UV curable ink coating machine 35 UV irradiation device 40 Decorating sheet manufacturing device 50 Heat press machine 51a Type holder 51b Type holder 52 Forming type 53 Surface plate 54 Surface plate

Claims (3)

  1. 　基体シートの一方面にエンボス加工により凹凸形状面を形成し、
    　上記凹凸形状面上にＵＶ硬化性インキ層を形成し、
    　上記ＵＶ硬化性インキ層にＵＶ光を照射して上記ＵＶ硬化性インキ層を硬化させ、
    　硬化した上記ＵＶ硬化性インキ層上に絵柄層を形成することを特徴とする加飾シートの製造方法。     Form an uneven surface on one side of the base sheet by embossing,
    A UV curable ink layer is formed on the uneven surface,
    The UV curable ink layer is irradiated with UV light to cure the UV curable ink layer,
    A method for producing a decorative sheet, wherein a pattern layer is formed on the cured UV curable ink layer.
  2. 　上記基体シートの凹凸形状面側からＵＶ照射を行うことにより、上記ＵＶ硬化性インキ層を硬化させる請求項１に記載の加飾シートの製造方法。 The method for producing a decorative sheet according to claim 1, wherein the UV curable ink layer is cured by performing UV irradiation from the concave-convex surface side of the base sheet.
  3. 　請求項１または２に記載の加飾シートの製造方法で形成された加飾シートを、上記基体シートの表面が金型キャビティに面するように金型内に配置した後、型閉じして金型内に成形用樹脂を流し込み、冷却固化することにより、成形樹脂の表面に加飾が施された加飾成形品を形成することを特徴とする加飾成形品の製造方法。 A decorative sheet formed by the method for producing a decorative sheet according to claim 1 or 2 is placed in a mold so that the surface of the base sheet faces the mold cavity, and then the mold is closed to form a mold. A method for producing a decorative molded product, characterized by forming a decorative molded product in which a surface of the molded resin is decorated by pouring a molding resin into a mold and solidifying by cooling.
PCT/JP2010/062611 2009-07-31 2010-07-27 Method for producing decorative sheet WO2011013659A1 (en)

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WO2012046531A1 (en) * 2010-10-05 2012-04-12 株式会社カネカ Decorative resin sheet, and molded resin article and process for production thereof
US20170217123A1 (en) * 2014-09-30 2017-08-03 Dai Nippon Printing Co., Ltd. Decorative sheet

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FR3076245A1 (en) * 2017-12-28 2019-07-05 Compagnie Plastic Omnium MODULAR COMPONENT COMPRISING A FUNCTIONAL FILM
JP6677329B2 (en) * 2019-02-14 2020-04-08 大日本印刷株式会社 Decorative sheet

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JPH04128041A (en) * 1990-09-19 1992-04-28 Dainippon Printing Co Ltd Decorative sheet and manufacture thereof
JP2000135756A (en) * 1998-10-30 2000-05-16 Honda Motor Co Ltd Decorative sheet, production thereof and production of molded product fitted with decorative sheet

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JPS5718211A (en) * 1980-07-07 1982-01-30 Toppan Printing Co Ltd Production of embossed decorative sheet
JPH04128041A (en) * 1990-09-19 1992-04-28 Dainippon Printing Co Ltd Decorative sheet and manufacture thereof
JP2000135756A (en) * 1998-10-30 2000-05-16 Honda Motor Co Ltd Decorative sheet, production thereof and production of molded product fitted with decorative sheet

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Publication number Priority date Publication date Assignee Title
WO2012046531A1 (en) * 2010-10-05 2012-04-12 株式会社カネカ Decorative resin sheet, and molded resin article and process for production thereof
JP5269255B2 (en) * 2010-10-05 2013-08-21 株式会社カネカ Decorative resin sheet, resin molded body, and method for producing the same
US9434096B2 (en) 2010-10-05 2016-09-06 Kaneka Corporation Decorative resin sheet, and molded resin article and process for production thereof
US20170217123A1 (en) * 2014-09-30 2017-08-03 Dai Nippon Printing Co., Ltd. Decorative sheet
US10792887B2 (en) * 2014-09-30 2020-10-06 Dai Nippon Printing Co., Ltd. Decorative sheet

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