JP5895606B2 - Manufacturing method of film insert molded product - Google Patents

Description

The present invention, apparatus body, such as daily necessities and household goods, those related to food and containers for various goods, electronic equipment and office supplies housing such film insert molded article prepared how used for such.

In film insert molding, a decorative film for insert molding in which, for example, a printing layer and an adhesive layer are formed on a base film serving as a base material is supplied between a pair of injection molds, and these injection molds After filling the cavity formed by heating and pressurizing molding resin, a pair of injection molding dies are opened, and a decorative film for insert molding is formed on the surface of the resin molded product.
Since the conventional film insert molded product formed by this film insert molding method has a structure in which characters, designs, etc. are simply printed on a base film, there is a problem that the surface of the molded product has a poor three-dimensional effect. there were.

In order to solve this problem, as a method for giving a three-dimensional feeling to the surface of the molded product, for example, unevenness is previously formed on the side where the base film inside the pair of injection molds that constitute the cavity at the time of molding contacts. There is a way to keep it.
However, in such a method for manufacturing a film insert molded product, only one uneven pattern can be supported for one injection mold, and in order to support various uneven patterns, a large number of injection molds are used. There was a problem that the mold had to be prepared and the manufacturing cost was high.

  Therefore, as a method of forming irregularities on the surface of a molded product for solving this problem, for example, a method shown in FIGS. 7 to 9 (see Patent Document 1) is conventionally known. FIG. 7 is a schematic explanatory view showing a method for producing an insert sheet in a conventional method for producing a film insert molded article. FIG. 8 is a schematic explanatory view showing a method for producing a film insert molded article using the insert sheet obtained in FIG. FIG. 9 is a schematic explanatory view of a film insert molded product.

  When the insert sheet 107 shown in FIG. 7 is manufactured, a laminate 103 (FIG. 7 () A) and a shaping mold 104 having a fine uneven surface 104a on the surface (see FIG. 7B), the surface on the surface protective layer 102 side of the laminate 103 and the fine unevenness of the shaping die 104. It arrange | positions so that the surface 104a may oppose (refer FIG. 7 (B)). Then, the surface on the surface protective layer 102 side of the laminate 103 is shaped by the heating pressure by the fine uneven surface 104a of the shaping mold 104 (see FIG. 7C), and then irradiated with the ionizing radiation 105 (FIG. 7). (D)), the surface protective layer 102 having the fine unevenness pattern 102a is cured, and the laminate 103 is removed from the shaping mold 104 (see FIG. 7E). After that, a decorative layer 106 having a pattern-like pattern 106a synchronized with the fine concavo-convex pattern 102a is provided on the surface of the laminate 103 on the base sheet 101 side (see FIG. 7F). In FIG. 7F, reference numeral 108 denotes an adhesive layer for adhering the insert sheet 107 to the resin molded product 109 (see FIG. 9).

The insert sheet 107 thus obtained is integrated with the surface of the resin molded product 109 to produce a film insert molded product 110 having a fine concavo-convex pattern 102a. In this production, the insert sheet 107 is fed into a pair of injection molds 111 and 112 having a desired cavity shape (see FIG. 8), and the injection molds 111 and 112 are closed. Thereafter, molten resin is filled into the cavity from the side opposite to the surface protective layer 102 of the insert sheet 107 and cooled to obtain a resin molded product 109. At the same time, the insert sheet 107 is integrated on the surface. Thereafter, the injection molds 111 and 112 are opened, and the film insert molded product 110 is taken out (see FIG. 9).
According to the method for manufacturing the film insert molded article 110 shown in FIGS. 7 to 9, various irregularities are formed on the surface of the film insert molded article 110 using the injection molds 111 and 112 having no irregular pattern. be able to.

Japanese Patent No. 4031305

However, the conventional method for manufacturing a film insert molded product shown in FIGS. 7 to 9 has the following problems.
That is, in the case of the method for producing a film insert molded product shown in FIGS. 7 to 9, the step of forming the fine uneven pattern 102a on the surface of the base sheet 101 (surface protective layer 102) using the shaping mold 104, Since it is required before the molding step using the pair of injection molds 111 and 112, there is a problem that productivity is low. Further, there is a problem that the manufacturing cost increases due to an increase in the number of steps.
Accordingly, the present invention has been made to solve the above-mentioned problems, and the object thereof is to form film insert molding capable of forming irregularities on the surface of a molded product at low cost and having excellent productivity. It is to provide an article of manufacture how.

In order to solve the above-described problems, a method for producing a film insert molded product according to claim 1 of the present invention includes a base film and a decorative layer comprising at least one layer provided on one surface of the base film. The insert molding decorative film is supplied between a pair of injection molding dies, and the base film of the insert molding decorative film is formed in a cavity formed by the pair of injection molding dies. In the method for producing a film insert molded product, after filling the molten resin heated and pressurized from the opposite side, opening the pair of injection molds and forming the decorative film for insert molding on the surface of the resin molded product, the decorative film for molded the insert, when supplied between a pair of injection mold, the uneven pattern height difference of unevenness is 10μm or more on one side Irregularities formed film made form, between the base film side surface and injection mold opposed to said surface of the insert molding decorative film, supplied with decorative film for molded the insert, The insert molding decorative film includes a hard coat layer on the surface of the base film opposite to the surface on the decorative layer side, and the thickness of the resin forming the uneven pattern of the uneven film, According to the pattern, irregularities are formed on the surface of the hard coat layer .

  According to the method for manufacturing a film insert molded article according to claim 1, when the decorative film for insert molding is supplied between the pair of injection molds, the uneven pattern is formed on one surface. Since the concavo-convex forming film is supplied together with the insert molding decorative film between the surface on the base film side of the insert molding decorative film and the injection mold facing the surface, a pair of injection molding molds After filling the cavity formed by the mold with molten resin heated and pressurized from the opposite side of the insert molding decorative film, open a pair of injection molds and insert the decorative film for insert molding. When formed on the surface of the resin molded product, the unevenness according to the uneven pattern of the unevenness forming film can be simultaneously formed on the surface of the molded product (base film). For this reason, the process which forms an unevenness | corrugation on the surface of a molded article becomes unnecessary other than an insert molding process, and the manufacturing method of the film insert molded article excellent in productivity can be provided. Moreover, since the process of forming unevenness on the surface of the molded product becomes unnecessary other than the insert molding process, the manufacturing cost can be reduced.

In addition, according to the method for manufacturing a film insert molded product according to claim 1, since an unevenness can be formed on the surface of the molded product by using an injection mold without an uneven pattern, the uneven shape is changed. Therefore, there is no need to change the injection mold, and the cost required for replacing the injection mold can be reduced.
Furthermore, according to the manufacturing method of the film insert molded product according to claim 1, since the uneven pattern of the uneven film can be formed by printing, various uneven patterns can be easily formed.

Moreover, according to the manufacturing method of the film insert molded article which concerns on Claim 1 , the surface (surface on the opposite side to the surface of a decoration layer side) in which the unevenness | corrugation of a film insert molded article is formed is made hard by a hard-coat layer. Can be increased.

According to the manufacturing how the film insert molded article according to the present invention, it is possible to form irregularities on the surface of the molded article at low cost and can provide excellent film insert molding manufacturing how productivity .

It is a cross-sectional schematic diagram of 1st Embodiment of the film insert molded article which concerns on this invention. It is a cross-sectional schematic diagram of the decorative film for insert molding used when manufacturing the film insert molded product shown in FIG. 1 is a schematic cross-sectional view showing a state in which a decorative film for insert molding and a concavo-convex forming film are supplied between a pair of injection molds when a film insert molded product shown in FIG. FIG. It is a cross-sectional schematic diagram of 2nd Embodiment of the film insert molded article which concerns on this invention. It is a cross-sectional schematic diagram of the decorative film for insert molding used when manufacturing the film insert molded article shown in FIG. 4, and an unevenness | corrugation formation film. 4 is a schematic cross-sectional view showing a state in which a decorative film for insert molding and a concavo-convex forming film are supplied between a pair of injection molds when a film insert molded product shown in FIG. FIG. It is a schematic explanatory drawing which shows the manufacturing method of the insert sheet in the manufacturing method of the conventional film insert molded article. It is a schematic explanatory drawing which shows the method of manufacturing a film insert molded article using the insert sheet obtained with the manufacturing method shown in FIG. It is a schematic explanatory drawing of the film insert molded product obtained with the manufacturing method shown in FIG.

Below, the manufacturing method of the film insert molded article and film insert molded article which concern on embodiment of this invention are demonstrated with reference to drawings. FIG. 1 is a schematic cross-sectional view of a first embodiment of a film insert molded article according to the present invention.
A film insert molded product 1 shown in FIG. 1 is formed by forming a decorative film 5 for insert molding on the surface (upper surface in FIG. 1) of a resin molded product 6.
Here, the decorative film 5 for insert molding includes a base film 2, a decorative layer 3 composed of at least one layer provided on one surface (the lower surface in FIG. 1) of the base film 2, and a decorative material. An adhesive layer 4 formed on the surface of the layer 3 opposite to the surface on the base film 2 side (the lower surface in FIG. 1) for adhering the decorative layer 3 to the surface of the resin molded product 6; I have.

  The base film 2 supports the decorative layer 3 and enables decoration on the resin molded product 6 having a three-dimensional shape. Further, the thickness of the base film 2 increases the depth of decoration by the insert molding decorative film 5. Give. The material of the base film 2 can be polyester (polyethylene terephthalate, polyethylene naphthalate), olefin, acrylic, or polyimide.

As a material for the decorative layer 3, a colored ink containing a pigment or dye of an appropriate color as a colorant is used. As a method for forming the decorative layer 3, a normal printing method such as an offset printing method, a gravure printing method, or a screen printing method can be used.
The decorative layer 3 may be composed of only a metal thin film layer or a combination of an ink layer and a metal thin film layer. Examples of the method for forming the metal thin film layer include a vacuum deposition method, a sputtering method, and an ion plating method. The vacuum vapor deposition method is a method in which a vapor deposition material is heated and evaporated in a vacuum and deposited on the surface of a vapor deposition object. The sputtering method is a method of generating argon ions by performing glow discharge in argon gas, accelerating the generated argon ions to collide with the target, scattering the target, and attaching the scattered raw material to the object. . The ion plating method evaporates the deposition material in low-pressure argon gas, and passes the atoms and molecules of the deposition material through the glow discharge region to ionize and excite them. It is the method of making it deposit on the vapor deposition target object which applied the voltage.

  The adhesive layer 4 adheres the base film 2 and the decorative layer 3 to the surface of the resin molded product 6. As the adhesive layer 4, a heat-sensitive or pressure-sensitive resin suitable for a molten resin for molding the resin molded product 6 is appropriately used. As a method for forming the adhesive layer 4, a printing method such as a gravure printing method or a screen printing method can be used. In addition, when the decorating layer 3 has sufficient adhesiveness with respect to the resin molded product 6, and has the effect as an adhesive layer, it is not necessary to provide the adhesive layer 4 separately.

  Next, the manufacturing method of the film insert molded article 1 shown in FIG. 1 will be described with reference to FIGS. FIG. 2 is a schematic cross-sectional view of a decorative film for insert molding and a concavo-convex forming film used when the film insert molded article shown in FIG. 1 is manufactured. FIG. 3 shows a state in which a decorative film for insert molding and a concavo-convex forming film are supplied between a pair of injection molds when a film insert molded product shown in FIG. It is a cross-sectional schematic diagram which shows.

The manufacturing method of the film insert molded product 1 shown in FIG. 1 includes (1) a step of preparing a decorative film 5 for insert molding, (2) a step of preparing an unevenness forming film 7, and (3) a film insert molded product. 1 insert molding process.
In the above-described step (1) of preparing the insert molding decorative film 5, as shown in FIG. 2, a single decorative layer 3 is provided on one surface (the lower surface in FIG. 2) of the base film 2. Further, the adhesive layer 4 is formed on the surface of the decorative layer 3 opposite to the surface on the base film 2 side (the lower surface in FIG. 2). Thereby, the decorative film 5 for insert molding is completed.

Next, in the above-described step (2) of preparing the concavo-convex film 7, the concavo-convex pattern 7 a is formed on one surface (the lower surface in FIG. 2) constituting the concavo-convex film 7. The concavo-convex film 7 is formed by printing the concavo-convex pattern 7a on one surface of a polyester film (polyethylene terephthalate, polyethylene naphthalate), an olefin film, a polyimide film, or an acrylic film by a gravure printing method or a screen printing method. Can do. The difference in height of the irregularities is preferably 10 μm or more. As a material for forming the concavo-convex pattern 7a, a thermosetting resin or an ultraviolet curable resin that can withstand heat and pressure received during molding can be used.
The unevenness forming film 7 is formed by applying the above-mentioned material by a gravure printing method, a gravure coating method, a roll coating method, a knife coating method, a silk screen printing method, or other ordinary coating methods or printing methods, and then embossing the material. You may form by doing.

  Next, in the above-described (3) insert molding step of the film insert molded product 1, as shown in FIG. 3, the insert molding decorative film 5 is supplied between a pair of injection molds 8 and 9. At this time, the concave / convex forming film 7 is placed between the surface of the insert molding decorative film 5 on the base film 2 side and the injection molding die 8 facing the surface, together with the insert molding decorative film 5. Supply. Then, the injection molds 8 and 9 are closed. Thereafter, molten resin is filled into the cavity from the side opposite to the base film 2 of the insert molding decorative film 5 and cooled to obtain a resin molded product 6. At the same time, the insert molding decorative film 5 is placed on the surface. Integrate. Thereafter, the injection molds 8 and 9 are opened, and the film insert molded product 1 is taken out. Thereby, as shown in FIG. 1, the unevenness 2a is formed on the surface of the film insert molded product 1 (base film 2) according to the thickness of the resin forming the unevenness pattern 7a of the unevenness forming film 7. Become.

  According to the method for manufacturing the film insert molded product 1, when the decorative film 5 for insert molding is supplied between the pair of injection molds 8 and 9, the uneven pattern 7 a is formed on one surface. The concavo-convex forming film 7 is supplied together with the insert molding decorative film 5 between the surface on the base film 2 side of the insert molding decorative film 5 and the injection mold 8 facing the surface. For this reason, after filling the cavity formed by the pair of injection molds 8 and 9 with the molten resin heated and pressurized from the opposite side of the base film 2 of the decorative film 5 for insert molding, a pair of injection molding is performed. When the molds 8 and 9 are opened and the insert molding decorative film 5 is formed on the surface of the resin molded product 6, the projections and depressions 2 a according to the projections and depressions 7 a of the projection and depression forming film 7 are simultaneously formed. It can form on the surface of (base film 2). For this reason, the process which forms the unevenness | corrugation 2a on the surface of the film insert molded article 1 becomes unnecessary other than an insert molding process, and the manufacturing method of the film insert molded article 1 excellent in productivity can be provided. Moreover, since the process of forming the unevenness | corrugation 2a on the surface of the film insert molded product 1 becomes unnecessary other than an insert molding process, manufacturing cost can also be reduced.

Moreover, according to the manufacturing method of the above-mentioned film insert molded article 1, the unevenness | corrugation 2a can be formed in the surface of the film insert molded article 1 using the injection molds 8 and 9 without the uneven | corrugated pattern 7a. Therefore, it is not necessary to change the injection molding dies 8 and 9 in order to change the shape of the unevenness 2a, and the cost for replacing the injection molding dies can be reduced.
Furthermore, according to the manufacturing method of the film insert molded article 1 described above, since the uneven pattern 7a of the uneven film 7 can be formed by printing, various uneven patterns can be easily formed.

  FIG. 4 is a schematic cross-sectional view of a second embodiment of a film insert molded article according to the present invention. FIG. 5 is a schematic cross-sectional view of a decorative film for insert molding and a concavo-convex forming film used when the film insert molded article shown in FIG. 4 is manufactured. FIG. 6 shows a state in which a decorative film for insert molding and a concavo-convex forming film are supplied between a pair of injection molds when a film insert molded product shown in FIG. 4 is manufactured, and a molten resin is filled in the cavity. It is a cross-sectional schematic diagram which shows. 4 to 6, the same members as those shown in FIGS. 1 to 3 are denoted by the same reference numerals, and the description thereof may be omitted.

A film insert molded product 1 shown in FIG. 4 is formed by forming a decorative film 11 for insert molding on the surface of the resin product 6 (upper surface in FIG. 4).
Here, the decorative film 11 for insert molding has the same basic configuration as the decorative film 5 for insert molding shown in FIG. 1, but the surface of the base film 2 opposite to the surface on the decorative layer 3 side ( The upper surface in FIG. 4 is different in that a hard coat layer 10 is provided.
The hard coat layer 10 is a layer that becomes the outermost surface of the film insert molded article 1. The hard coat layer 10 may be either an ultraviolet curable resin or a thermosetting resin, and the hardness is preferably H or more in a pencil hardness test (JIS-K5600).
The manufacturing method of the film insert molded product 1 shown in FIG. 4 is the same as the manufacturing method of the film insert molded product 1 shown in FIGS. 1 to 3, (1) a step of preparing a decorative film 11 for insert molding; 2) The process which prepares the unevenness | corrugation formation film 7, and (3) The insert molding process of the film insert molded article 1 are comprised.

In the step of preparing the above-mentioned (1) the decorative film 11 for insert molding, as shown in FIG. 5, a single decorative layer 3 is provided on one surface (the lower surface in FIG. 2) of the base film 2. Further, the adhesive layer 4 is formed on the surface of the decorative layer 3 opposite to the surface on the base film 2 side (the lower surface in FIG. 2). Moreover, the hard-coat layer 10 is formed in the surface (upper surface in FIG. 4) on the opposite side to the surface by the side of the decoration layer 3 of the base film 2. As shown in FIG. Thereby, the decorative film 11 for insert molding is completed.
The process of preparing the above-mentioned (2) uneven | corrugated formation film 7 is the same as that of the description mentioned above, The description is abbreviate | omitted.

Moreover, in the above-mentioned (3) insert molding step of the film insert molded article 1, as shown in FIG. 6, the insert molding decorative film 11 is supplied between a pair of injection molds 8 and 9. At this time, the concave / convex forming film 7 is inserted between the surface on the hard coat layer 10 side of the decorative film 11 for insert molding and the injection mold 8 facing the surface. Supply with. Then, the injection molds 8 and 9 are closed. Thereafter, molten resin is filled into the cavity from the side opposite to the base film 2 of the insert molding decorative film 11 and cooled to obtain a resin molded product 6. At the same time, the insert molding decorative film 5 is placed on the surface. Integrate. Thereafter, the injection molds 8 and 9 are opened, and the film insert molded product 1 is taken out. Thereby, as shown in FIG. 4, the unevenness | corrugation 10a is formed in the surface of the film insert molded product 1 (hard-coat layer 10) according to the pattern by the thickness of the resin which forms the uneven | corrugated pattern 7a of the uneven | corrugated film 7 as shown in FIG. become.
Thus, the decorative film 11 for insert molding is provided with the hard coat layer 10 on the surface of the base film 2 opposite to the surface on the decorative layer 3 side. Hardness can be increased by the hard coat layer 10 on the surface on which the unevenness 10a is formed (surface opposite to the surface on the decorative layer 3 side).

Hereinafter, although an example is given and demonstrated about the Example of this invention, this invention is not limited to this.
(Process of preparing the decorative film 11 for insert molding)
A polyethylene terephthalate resin film was used as the base film 2, and an ultraviolet curable acrylic resin hard coat layer 10 was formed on the upper surface of the base film 2. Next, two layers of the base film 2 in the order of the polyester resin-based decorative layer 3 and the vinyl chloride / acrylic resin-based adhesive layer 4 are provided on the surface (lower surface) opposite to the surface on the hard coat layer 10 side. An ink layer was formed by screen printing.

(Step of preparing the unevenness forming film 7)
After the concavo-convex pattern 7a is printed on the polyethylene terephthalate resin film with an ultraviolet curable acrylic resin by screen printing, the acrylic resin is cured by irradiating with an ultraviolet ray with an integrated light quantity of 1000 mJ / cm ² using a high-pressure mercury lamp. By doing, the uneven | corrugated formation film 7 was obtained.
(Insert molding process of film insert molded product 1)
Together with the insert molding decorative film 11 obtained in this way, the concavo-convex forming film 7 is supplied between a pair of injection molds 8 and 9, and the mold is clamped to injection-mold PC / ABS resin. After the molds 8 and 9 are opened, the surface of the film insert molded product 1 is irradiated with ultraviolet rays with an integrated light quantity of 1000 mJ / cm ² using a high-pressure mercury lamp, the hard coat layer 10 is crosslinked and cured, and the surface has irregularities 10a. A film insert molded article 1 was obtained.

DESCRIPTION OF SYMBOLS 1 Film insert molded product 2 Base film 2a Concavity and convexity 3 Decorating layer 4 Adhesive layer 5 Insert molding decorative film 6 Resin molded product 7 Concavity and convexity forming film 7a Concavity and convexity pattern 8,9 Injection mold 10 Hard coat layer 10a Concavity and convexity 11 Decorative film for insert molding

Claims (1)

An insert molding decorative film provided with a base film and a decorative layer composed of at least one layer provided on one surface of the base film is supplied between a pair of injection molds, After filling the molten resin heated and pressurized from the side opposite to the base film of the insert molding decorative film into the cavity formed by the injection molding mold, the pair of injection molding molds are opened, In the manufacturing method of the film insert molded product for forming the decorative film for insert molding on the surface of the resin molded product,
When supplying the insert molding decorative film between a pair of injection molds , an unevenness-forming film formed by forming an unevenness pattern having an unevenness height difference of 10 μm or more on one surface, the insert Supplied with the decorative film for insert molding between the surface on the base film side of the decorative film for molding and the injection mold facing the surface ,
The insert molding decorative film includes a hard coat layer on the surface of the base film opposite to the surface on the decorative layer side, and the thickness of the resin forming the uneven pattern of the uneven film, According to the pattern, irregularities are formed on the surface of the hard coat layer .

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