CN101544157A - 用于成型的装饰膜 - Google Patents
用于成型的装饰膜 Download PDFInfo
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- CN101544157A CN101544157A CN200910129890A CN200910129890A CN101544157A CN 101544157 A CN101544157 A CN 101544157A CN 200910129890 A CN200910129890 A CN 200910129890A CN 200910129890 A CN200910129890 A CN 200910129890A CN 101544157 A CN101544157 A CN 101544157A
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- Prior art keywords
- moulding
- methyl
- resin
- decorating film
- jut
- Prior art date
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Abstract
本发明涉及用于成型的装饰膜,在嵌件成型的真空成型时或注射成型时、或热套管成型的注射成型时,装饰膜表面的凹凸图案无裂纹出现。本发明提供在基材片上具有突起部的用于成型的装饰膜,相对于该基材片的整个面,该突起部的总面积为45%以下,且单个突起部的面积为2mm2以下。
Description
技术领域
本发明涉及用于成型的装饰膜,该装饰膜用于嵌件成型或热套管(thermo jecket)成型中。
背景技术
目前为止,装饰树脂成型体表面的装饰成型品被使用于各种用途。例如,在专利文献1中,公开了一种通过所谓嵌件成型制备成型品的方法,该方法包括以下步骤:在模具内壁面形成了层压有背衬层的成型用装饰片材,然后,通过将成型用树脂注射成型,从而得到使用片材将表面包覆的成型品。
通常,在该嵌件成型中,施加到用于成型的装饰膜上的图案是如下形成的:使用丙烯酸树脂等热塑性树脂为粘合剂树脂,通过凹版印刷等形成平面图案,为了提高图案的耐久性(耐磨损性等),在基材片的背面侧(树脂成型物侧)印刷图案,结果嵌件成型品变成表面平坦、且具有均匀光泽的外观,无法直接得到使成型品表面呈现凹凸的设计感。此外,在用热套管成型(サ—モジエクト成形)时也存在同样的问题。
对于该问题,应该在成型品表面赋予凹凸感、立体感、纵深感,尝试了在基材片背面印刷图案、在表面侧通过压花(压型出型)加工表面而赋予凹凸的方法。但通过压花加工在表面形成凹凸时,由于在注射成型时或之前预成型(真空成型)时的热和应力的作用,有时使表面凹凸恢复为平坦面,此外,由于是由热塑性树脂形成的凹凸,有时易因磨损而消失、出现划痕。
另外,专利文献2公开了下述发明,在热塑性树脂基材片的表面侧,使用电离辐射固化性树脂的固化物,部分地形成了树脂图案层,得到装饰片材,使用该装饰片材进行热套管成型(注射成型的同时进行装饰)。而且,专利文献3公开了下述方法,在基材片上设置包含未固化的电离辐射固化型树脂的表面保护层,利用加热加压通过赋形用模具的微细凹凸对表面保护层侧的面进行赋形,随后,照射电离辐射,使具有微细凹凸图案的表面保护层固化,制备具有微细凹凸图案的嵌件片。
进一步,专利文献4公开了下述凹凸嵌件片,所述凹凸嵌件片如下形成:在表面具有微细凹凸的凹版的凹部填充未固化的电离辐射固化型树脂,在从上方按压基体片材的状态下,照射电离辐射,由此在基体片材的一面形成厚2μm以上的固化后的微细凹凸层。
但是,使用这些片材进行嵌件成型的情况下,在真空成型时或注射成型时,存在片材表面的凹凸图案出现裂纹的问题;或者使用这些片材进行热套管成型的情况下,在注射成型时,也存在片材表面的凹凸图案出现裂纹的问题。
[专利文献1]特公平8-2550号公报
[专利文献2]特开2002-240078号公报
[专利文献3]特开2004-42409号公报
[专利文献4]特开2004-276416号公报
发明内容
发明要解决的问题
在这样的情况下,本发明的目的在于提供用于成型的装饰膜,其在嵌件成型的真空成型时或注射成型时、或热套管成型的注射成型时,装饰膜表面的凹凸图案不会出现裂纹。
解决问题的方法
为了实现上述目的,本发明者潜心进行了反复研究,结果发现,通过改善形成用于成型的装饰膜的表面凹凸图案的突起部的配置和大小,可以解决上述问题。基于所述发现完成了本发明。
也就是说,本发明为:
[1]一种用于成型的装饰膜,该装饰膜包括基材片和位于基材片上的突起部,其中,相对于该基材片的整个面,该突起部的总面积为45%以下,且一个突起部的面积为2mm2以下。
[2]上述[1]所述的用于成型的装饰膜,其中,所述突起部之间的距离为0.2mm以上。
[3]上述[1]或[2]所述的用于成型的装饰膜,其中,所述突起部通过使电离辐射固化性树脂组合物发生交联固化而得到。
[4]上述[1]~[3]任一项所述的用于成型的装饰膜,其中,在所述基材片的背面依次层压着色层、粘结剂层以及背衬层。
发明效果
本发明可提供在嵌件成型的真空成型时或注射成型时、或热套管成型的注射成型时,装饰膜表面的凹凸图案不会出现裂纹的用于成型的装饰膜。
附图说明
图1示出本发明中用于成型的装饰膜的实施方式的剖面示意图。
符号说明
10 用于成型的装饰膜
11 基材片
12 突起部
13 着色层
14 粘结剂层
15 背衬层
具体实施方式
以下,参考附图对本发明进行说明。图1示出本发明中用于成型的装饰膜的实施方式的剖面示意图。
本发明的用于成型的装饰膜10(以下,有时简称为“装饰膜10”)在基材片11上具有突起部12,相对于基材片11的整个面,该突起部12的总面积为45%以下,且单个突起部的面积为2mm2以下。相对于基材片11的整个面,使突起部12的总面积为45%以下,这是为了防止各突起部12彼此之间过于接近,从这个角度考虑,优选将突起部12的总面积控制为40%以下。虽然对突起部12的总面积没有限定下限,但若突起部12的总面积过小,则视觉上很难辨认为是凹凸图案,因此优选突起部12的总面积为1%以上。此外,要求单个突起部的面积为2mm2以下,这是为了防止应力集中于个别的突起部12上。虽然对单个突起部的面积未限定下限,但若单个突起部12的面积过小,则视觉上很难辨认为是凹凸图案,因此优选单个突起部12的面积为0.01mm2以上。
通过对突起部12的总面积和单个突起部的面积进行上述限定,可防止在嵌件成型的真空成型时或注射成型时、或热套管成型的注射成型时(以下,有时称为“装饰成型时”)装饰膜10表面的凹凸图案出现裂纹。
另外,通过使突起部12之间距L为0.2mm以上,可以进一步防止装饰膜10表面的凹凸图案出现裂纹。从该角度考虑,更优选突起部12之间距为0.4mm以上。此处,如图1所示,突起部12之间距L是指各突起部12端部间的最短距离。
关于本发明的装饰膜10,对于基材片11上的各突起部12的形状没有特别限制,可以是圆形、椭圆形、三角形、四边形、5~10边形等相同形状,也可以是不同形状的集合。此外,各突起部12可以是规则排列的规则(定形)图案,也可以是不规则图案。从触感、消光感、光泽感以及设计性良好的角度考虑,优选不规则图案;从装饰成型时的应力不易集中于特定部分,表面的凹凸图案不易出现裂纹的角度考虑,优选为规则排列的规则图案。
此外,更优选突起部12之一的形状的最长部分为1.5mm以下。可根据用途,从圆形、椭圆形、多边形、线条、水珠、条纹、格子等几何图案、文字、木纹图案、竹纹图案、石纹图案、仿瓷砖图案、砌砖图案、布纹图案、皮纹图案等中选择一种或两种以上作为图案使用。
如图1所示,优选在与基材片11具有突起部12的面相反侧即基材片11的背面上依次层压着色层13、粘结剂层14和背衬层15,由此形成装饰膜10,并用于嵌件成型中。
另一方面,热套管成型时,通常不在装饰膜10上层压背衬层15。
作为用于本发明装饰膜10的基材片11,可适当使用热塑性树脂片材。因为,在装饰膜10成型后使用时容易获得成型性。作为用于基材片11的热塑性树脂,优选丙烯酸树脂、氯乙烯树脂、ABS树脂(丙烯腈-苯乙烯-丁二烯共聚物)、苯乙烯树脂、聚碳酸酯树脂;或聚对苯二甲酸乙二醇酯、成型性聚酯树脂等聚酯树脂;或聚乙烯、聚丙烯、聚甲基戊烯、聚丁烯、乙烯-丙烯共聚物、丙烯-丁烯共聚物、烯烃类热塑性弹性体等聚烯烃类树脂等。
其中,特别优选丙烯酸树脂、成型性聚酯树脂等。
作为丙烯酸树脂,例如,可以单独或两种以上混合使用聚(甲基)丙烯酸甲酯、聚(甲基)丙烯酸丁酯、(甲基)丙烯酸甲酯-(甲基)丙烯酸丁酯共聚物、(甲基)丙烯酸甲酯-苯乙烯共聚物等丙烯酸树脂。此外,(甲基)丙烯酸酯是指丙烯酸酯或甲基丙烯酸酯。
此外,作为成型性聚酯树脂,可以使用聚酯类热塑性弹性体、无定形聚酯等。作为上述聚酯类热塑性弹性体,可例如,硬链段包括高结晶且高熔点的芳香族聚酯,软链段包括使用玻璃化转变温度为-70℃以下的无定形聚醚等的嵌段共聚物等,作为上述高结晶且高熔点的芳香族聚酯,可使用例如聚对苯二甲酸丁二醇酯,作为上述无定形聚醚,可使用聚丁二醇等。此外,作为上述无定形聚酯的代表例,可列举乙二醇-1,4-二羟甲基环己烷-对苯二甲酸共聚物。
关于基材片11,可使用例如包含上述树脂的单层或多层结构的树脂片材。此外,根据需要,基材片11中还可适当添加稳定剂、增塑剂、着色剂、紫外线吸收剂、受阻胺类光稳定剂、填充颜料等各种添加剂,用于调整物性。另外,将基材片11着色时,可以是透明或不透明的,但在基材片11的背面侧设置可见的着色层时,使其透明度为可视觉辨认的程度以上。着色时可以使用例如后述着色层中列举的公知着色剂。
此外,从成本、对嵌件成型品或热套管成型品性能的要求、用于成型的装饰膜的成型适性等观点考虑,通常优选基材片11的厚度为30~300μm左右(多层时为总厚度),没有特别限定。
此外,为了提高基材片11以及与基材片11相接的其它层的紧密结合性,视需要,可对基材片11的表面、背面、或表面与背面双面上,进行适当的电晕放电处理、等离子体处理、由聚氨酯树脂形成底层涂料层等公知的易粘结处理。
配置于本发明装饰膜10上的突起部12优选为由电离辐射固化性树脂组合物交联固化而形成的固化物。这能够提高耐磨损性等耐久性,特别是能够防止图案易因磨损而消失、出现划痕。作为用于电离辐射固化性树脂组合物的电离辐射固化性树脂,根据用途的不同,可使用经紫外线、可见光线或电子束等电离辐射交联固化的树脂。
关于电离辐射固化性树脂,具体可以优选使用如下的可经电离辐射固化组合物,该组合物适当混合了在分子中具有可自由基聚合的不饱和键、或具有可阳离子聚合的官能团的预聚物(包括所谓的低聚物)和/或单体。这些预聚物或单体可单独使用,也可将多种混合后使用。
上述预聚物或单体具体包括:在分子中具有(甲基)丙烯酰基、(甲基)丙烯酰氧基等可自由基聚合的不饱和基团,环氧基等可阳离子聚合的官能团的化合物。此外,还优选使用多烯和聚硫醇组合而成的多烯/硫醇类预聚物。需要说明的是,(甲基)丙烯酰基是指丙烯酰基或甲基丙烯酰基。作为具有可自由基聚合的不饱和基团的预聚物的例子,可以使用聚酯型(甲基)丙烯酸酯类、聚氨酯型(甲基)丙烯酸酯类、环氧型(甲基)丙烯酸酯类、聚醚型(甲基)丙烯酸酯类、三聚氰胺型(甲基)丙烯酸酯、三嗪型(甲基)丙烯酸酯类、硅酮型(甲基)丙烯酸酯类等。通常使用分子量为250~100,000左右的树脂。
此处,关于环氧型(甲基)丙烯酸酯类预聚物,例如,可以通过使较低分子量的双酚型环氧树脂或酚醛清漆型环氧树脂的环氧乙烷环与(甲基)丙烯酸的酯化反应得到。此外,还可使用由二元羧酸酐将该环氧型(甲基)丙烯酸酯类低聚物部分改性得到的羧基改性型环氧型(甲基)丙烯酸酯预聚物。关于聚氨酯型(甲基)丙烯酸酯类预聚物,可通过例如将聚氨酯预聚物与(甲基)丙烯酸的酯化而得到,所述聚氨酯预聚物是聚醚多醇或聚酯多醇与聚异氰酸酯反应而得到的。关于聚酯型(甲基)丙烯酸酯类预聚物,可通过例如使下述聚酯预聚物的羟基与(甲基)丙烯酸的酯化、或使多元羧酸和氧化烯加成得到的预聚物的末端羟基进行(甲基)丙烯酸酯化而得到,所述聚酯预聚物由多元羧酸和多元醇缩合得到,且其两末端具有羟基。关于聚醚型(甲基)丙烯酸酯类预聚物,可通过用(甲基)丙烯酸将聚醚型多元醇的羟基进行酯化而得到。
另外,聚合性预聚物还包括:聚丁二烯低聚物侧链上具有(甲基)丙烯酸酯基的高疏水性聚丁二烯(甲基)丙烯酸酯类预聚物、主链上具有聚硅氧烷键的硅酮型(甲基)丙烯酸酯类预聚物、在小分子内具有大量反应性基团的氨基塑性树脂经改性得到的氨基塑性树脂(甲基)丙烯酸酯类预聚物、或酚醛清漆型环氧树脂、双酚型环氧树脂、脂肪族乙烯基醚、芳香族乙烯基醚等分子中具有可阳离子聚合的官能团的预聚物等。
作为具有可自由基聚合的不饱和基团的单体,优选在分子中具有可自由基聚合的不饱和基团的(甲基)丙烯酸酯类单体,其中尤其优选多官能性(甲基)丙烯酸酯。此外,在这里所述的“(甲基)丙烯酸酯”是指“丙烯酸酯或甲基丙烯酸酯”。作为多官能性(甲基)丙烯酸酯,只要是分子内具有两个以上烯属不饱和键的(甲基)丙烯酸酯即可,没有特别限制。具体可以列举,二(甲基)丙烯酸乙二醇酯、二(甲基)丙烯酸丙二醇酯、二(甲基)丙烯酸-1,4-丁二醇酯、二(甲基)丙烯酸-1,6-己二醇酯、二(甲基)丙烯酸新戊二醇酯、二(甲基)丙烯酸聚乙二醇酯、羟基三甲基乙酸新戊二醇二(甲基)丙烯酸酯、二(甲基)丙烯酸二环戊酯、己内酯改性二环戊烯基二(甲基)丙烯酸酯、环氧乙烷改性磷酸二(甲基)丙烯酸酯、烯丙基化环己基二(甲基)丙烯酸酯、异氰尿酸酯二(甲基)丙烯酸酯、三羟甲基丙烷三(甲基)丙烯酸酯、环氧乙烷改性三羟甲基丙烷三(甲基)丙烯酸酯、二季戊四醇三(甲基)丙烯酸酯、丙酸改性二季戊四醇三(甲基)丙烯酸酯、季戊四醇三(甲基)丙烯酸酯、环氧丙烷改性三羟甲基丙烷三(甲基)丙烯酸酯、三(丙烯酰氧基乙基)异氰尿酸酯、丙酸改性二季戊四醇五(甲基)丙烯酸酯、二季戊四醇六(甲基)丙烯酸酯、环氧乙烷改性二季戊四醇六(甲基)丙烯酸酯、己内酯改性二季戊四醇六(甲基)丙烯酸酯等。这些多官能性(甲基)丙烯酸酯可单独使用一种,也可将两种以上组合使用。
在使用上述预聚物、多官能性(甲基)丙烯酸酯的同时,为了达到降低其粘度等目的,在不影响本发明目的的范围内,本发明还可适当组合使用单官能性(甲基)丙烯酸酯。作为单官能性(甲基)丙烯酸酯,可以列举,(甲基)丙烯酸甲酯、(甲基)丙烯酸乙酯、(甲基)丙烯酸丙酯、(甲基)丙烯酸丁酯、(甲基)丙烯酸戊酯、(甲基)丙烯酸己酯、(甲基)丙烯酸环己酯、(甲基)丙烯酸-2-乙基己酯、(甲基)丙烯酸月桂酯、(甲基)丙烯酸硬脂酯、(甲基)丙烯酸异冰片酯、(甲基)丙烯酸苯氧基乙酯等。可单独使用这些单官能性(甲基)丙烯酸酯中的一种,也可将两种以上组合使用。
此外,通过紫外线或可见光线固化时,上述电离辐射固化性树脂组合物中还可添加光聚合引发剂。当树脂组合物为具有可自由基聚合的不饱和基团的树脂类时,作为光聚合引发剂,可单独或混合使用苯乙酮类、二苯甲酮类、噻吨酮类、苯偶姻、苯偶姻甲醚类。此外,当树脂组合物为具有可阳离子聚合的官能团的树脂类时,作为光聚合引发剂,可单独或混合使用芳香族重氮鎓、芳香族锍盐、芳香族碘鎓盐、金属茂化合物、苯偶姻磺酸酯等。此外,相对于电离辐射固化性树脂100质量份,这些光聚合引发剂的添加量为0.1~10质量份左右。
另外,必要时上述电离辐射固化性树脂组合物中还可添加氯乙烯-乙酸乙烯酯共聚物、聚乙酸乙烯酯、丙烯酸类树脂、纤维素类树脂等热塑性树脂。此外,根据需要,上述电离辐射固化性树脂中还可添加各种添加剂。例如,可添加由二氧化硅、氧化铝、碳酸钙、铝硅酸盐、硫酸钡等无机物,聚乙烯、聚氨酯树脂、聚碳酸酯、聚酰胺(尼龙)等有机高分子等构成的粒子作为退光剂或填充颜料(填充剂)。所用粒子的平均粒径为1~10μm左右,添加量为5~30质量%左右。此外,粒子的形状为多面体、球形、鳞片状等。
关于配置于本发明装饰膜10上的突起部12,可使用上述电离辐射固化性树脂组合物的液态组合物,通过丝网印刷、凹版突起印刷(グラビア盛上印刷)或专利文献2所述成型版体法等印刷或涂布法等公知的形成方法,在基材片11上形成。对于突起部12的厚度没有特别限制,通常为1~200μm左右。为了加强在视觉上的凹凸感、立体感时,特别优选厚度为10μm以上。
此外,作为电离辐射,可使用具有使电离辐射固化性树脂组合物中的分子发生固化反应的能量的电磁波或带电粒子。通常使用的制品为紫外线或电子束,此外还可使用可见光线、X射线、离子线等。作为紫外线源,可使用超高压水银灯、高压水银灯、低压水银灯、碳弧灯、黑光灯、金属卤化物灯等光源。使用的紫外线通常是以波长在190~380nm范围的紫外线为主。作为电子束源,使用考克罗福特-沃尔顿型、范德格拉夫特型、共振变压器型、绝缘芯变压器型或直线型、地拉米(DYNAMITRON)型、高频率型等各种电子束加速器,使用照射具有100~1000keV、优选100~300keV能量的电子的电子束源。
在本发明装饰膜10的背面,视需要层压着色层13,该着色层13包括图案层和/或掩蔽层。图案层的图案为任意的,根据用途的不同,可单独使用木纹图案、石纹图案、布纹图案、砂纹图案、皮纹图案、仿瓷砖图案、砌砖图案、几何图形、文字、符号、全面涂布(全面ベタ)中的一种,或是将两种以上图案组合后使用。掩蔽层通常为全面涂布的着色层。
用于形成着色层13的油墨包含了下述组分:由粘合剂等构成的载色剂、颜料或染料等着色剂、适当添加的各种添加剂,作为粘合剂树脂,可以单独使用选自丙烯酸树脂、氯乙烯-乙酸乙烯酯共聚物、聚酯树脂、纤维素类树脂、氯化聚丙烯、聚氨酯树脂、聚酰胺树脂等中的一种树脂,或使用两种以上的混合树脂。
此外,作为着色剂,可以使用例如:钛白、锌白、炭黑、铁黑、氧化铁红、钼红、镉红、群青、钴蓝、铬黄、钛黄等无机颜料、酞菁蓝、靛蒽醌蓝(Indanthrene Blue)、异吲哚啉酮黄、联苯胺黄、喹吖啶酮红、多偶氮红、苝红等有机颜料(或者也包括染料)、或由铝、黄铜等鳞片状箔粉构成的金属颜料、由二氧化钛包覆云母、碱性碳酸铅等鳞片状箔粉构成的珠光(珍珠色)颜料等。
着色层13可通过凹版印刷、丝网印刷、胶版印刷等印刷法,或辊涂等公知的涂布法等以往公知的形成方法形成。
着色层13的厚度没有特别限制,但通常为0.5~20μm左右。
在本发明中,根据需要,为了提高基材片11或着色层13与背衬层15或注射树脂的粘贴性,可在基材片11或着色层13的背面侧设置粘结剂层14。粘结剂层14的材料可在以下宽范的树脂中选择,即与着色层13具有紧密结合性、印刷适合性、成型适合性的树脂中选择。具体来讲,优选粘结剂层14的材料选自以嵌段异氰酸酯为固化剂的双液固化型聚氨酯树脂、氯化聚丙烯等氯化聚烯烃、(甲基)丙烯酸树脂、氯乙烯-乙酸乙烯酯共聚物以及(甲基)丙烯酸树脂和氯乙烯-乙酸乙烯酯共聚物的混合物。作为粘结剂层14中的(甲基)丙烯酸树脂、氯乙烯-乙酸乙烯酯共聚物,可使用与上述着色层13中使用的树脂相同的树脂。背衬层15或注射树脂为ABS树脂或聚烯烃树脂时,作为粘结剂层14,优选以嵌段异氰酸酯为固化剂的双液固化型聚氨酯树脂、氯化聚丙烯等氯化聚烯烃等。
此外,在副成分范围内,粘结剂层14中还可组合使用除上述以外的树脂。主要是根据与注射树脂的紧密结合性来选择组合使用的树脂。另外,为了调整/提高印刷(或涂布)适性等各物性,必要时可适当添加填充颜料、保存稳定剂等公知的各种添加剂。
需要说明的是,使用包含上述树脂等的粘结剂,通过凹版印刷、辊涂等公知的印刷或涂布法形成粘结剂层14。此外,对于粘结剂层的厚度没有特别限制,通常为1~50μm左右。
在本发明的装饰膜10的粘结剂层14的背面,视需要层压背衬层15,背衬层15的材料优选为ABS树脂、聚烯烃树脂、苯乙烯树脂、(甲基)丙烯酸树脂、氯乙烯树脂、聚碳酸酯树脂等。作为聚烯烃树脂,优选聚丙烯树脂。在这些树脂中,特别优选ABS树脂和聚丙烯树脂。当注射树脂为ABS树脂时,背衬层优选使用ABS树脂;当注射树脂为聚丙烯树脂时,背衬层优选使用聚丙烯树脂。背衬层15是用来增强装饰膜10、保持一体化物形态而层压的,因此使用0.1~0.5mm左右的片材。
关于本发明的装饰膜10的制备方法,例如,可通过凹版印刷、辊涂等公知的印刷或涂布方法在基材片11上依次层压着色层13和粘结剂层14,然后对背衬层15进行干式层压。当着色层13为多层时,可在层压图案层之后进行干燥,然后层压掩蔽层等。在本发明的装饰膜10中,优选将背衬层15进行干式层压,然后在与背衬层15相反侧的基材片11的面上按照上述方法形成突起部12。
以下,说明使用本发明的装饰膜10制备嵌件成型品的方法。对按照上述方法制备的本发明的装饰膜10,通过真空成型赋予规定的压纹。
首先,用加热器加热固定于固定架上的装饰膜10,直至达到装饰膜10发生软化的规定温度,将真空成型模具按压在经加热软化的装饰膜10上,同时用真空泵等抽出真空成型模具中的空气,使装饰膜10牢固而紧密结合在真空成型模具上。
使装饰膜10紧密结合于真空成型模具上,然后冷却装饰膜10,从真空成型模具上剥离已成型的装饰膜10,从固定架剥离已成型的装饰膜10。真空成型通常在160~180℃左右进行。
然后,根据需要剪去真空成型后的装饰膜10的多余部分,将修剪后的装饰膜10装入注射成型模具中,在装饰膜10的背面(背衬层15侧,即图1的下面侧)注入注射树脂。最后,将装饰膜10从注射成型模具中取出,得到嵌件成型品。注射成型的温度只要在注射树脂的熔融温度以上即可,例如,当注射树脂为聚丙烯类树脂时,注射是在180~210℃左右进行;当注射树脂为丙烯腈-苯乙烯-丁二烯共聚物(ABS)、PCABS时,注射是在220~260℃左右的注射温度下进行。
此外,使用本发明的装饰膜10,制备热套管成型品时,固定于注射成型模具上后,根据需要进行真空成型,随后,注射树脂,在注射成型的同时进行装饰。注射成型通常是在220~260℃左右的注射温度下进行。
实施例
下面,通过实施例对本发明进行详细说明,但本发明并不限于这些例子。
此外,按照下述方法测定用于成型的装饰膜表面是否出现裂纹。
<用于成型的装饰膜表面是否出现裂纹>
通过目测观察用于成型的装饰膜表面的凹凸图案是否出现裂纹,按照以下标准进行判断。
◎:真空成型后的用于成型的装饰膜以及注射成型后的成型品表面完全未产生裂纹。
○:真空成型后的用于成型的装饰膜以及注射成型后的成型品表面产生细微的裂纹,但不影响实际应用。
×:真空成型后的用于成型的装饰膜以及注射成型后的成型品表面产生明显裂纹,成型品的商品价值低。
实施例1~3以及比较例1
在由以聚甲基丙烯酸甲酯为主要组分、厚度为75μm的无着色透明丙烯酸树脂片材制成的基材片背面,分别依次层压由聚甲基丙烯酸丁酯/氯乙烯-乙酸乙烯酯共聚物(质量比:2/1)制成的图案层(厚度1μm),由聚甲基丙烯酸甲酯、聚甲基丙烯酸丁酯的混合物和无机颜料制成的掩蔽层(厚度2μm),以及由双液固化型聚氨酯树脂类粘结剂制成的粘结剂层(厚度10μm),然后,通过干式层压法层压了由ABS树脂制成的背衬层(厚度400μm),再通过凹版印刷将下述电离辐射固化性树脂组合物(无溶剂型)印刷成排列多个圆形突起部的平面图案,并在160W/cm的条件下照射紫外线,在保持凹版的版形状的状态下,进行交联固化,形成厚30μm且突出于基材片上的突起部12,由此得到四种用于成型的装饰膜,所述电离辐射固化性树脂组合物(无溶剂型)包含29质量份聚氨酯丙烯酸酯预聚物、6质量份聚乙二醇二丙烯酸酯、8质量份乙基卡必醇丙烯酸酯、7质量份丙烯酸-2-乙基己酯、4质量份硅酮丙烯酸酯、2质量份光聚合引发剂(甲基苯偶姻型)、适量溶剂(异丙醇)。单个突起部12为直径1.0mm的圆形,其相对于基材整个面的总面积(%)、单个突起部的面积(mm2)以及突起部间的距离(mm)如表1所示。
随后,将这四种用于成型的装饰膜固定在固定架上,用约300℃的加热器进加热,直至用于成型的装饰膜的温度达到约为160℃。如上所述,将加热软化的用于成型的装饰膜经真空成型步骤、修剪步骤以及在240℃将ABS树脂作为注射树脂的注射成型步骤,得到四种嵌件成型品。
评价这四种真空成型后的用于成型的装饰膜以及注射成型后的成型品的凹凸图案是否出现裂纹。结果如表1所示。
[表1]
由表1可知,关于实施例1和2的用于成型的装饰膜,在真空成型后的用于成型的装饰膜以及注射成型后的成型品表面完全未出现裂纹,良好。关于实施例3的用于成型的装饰膜,在真空成型后的用于成型的装饰膜以及注射成型后的成型品表面出现细微裂纹,但不明显,不影响实际应用。
另一方面,比较例1的用于成型的装饰膜,在真空成型后的用于成型的装饰膜以及注射成型后的成型品表面出现明显的裂纹,降低了成型品的商品价值。
工业实用性
本发明的用于成型的装饰膜即使经过真空成型步骤和注射成型步骤,在用于成型的装饰膜的表面以及嵌件成型品的凹凸图案中也未出现裂纹,或者即使经过注射成型步骤,在热套管成型品的凹凸图案中也未出现裂纹,因此适用于嵌件成型品或热套管成型品。
Claims (4)
1.一种用于成型的装饰膜,该装饰膜包括基材片和位于基材片上的突起部,其中,相对于该基材片的整个面,该突起部的总面积为45%以下,且一个突起部的面积为2mm2以下。
2.权利要求1所述的用于成型的装饰膜,其中,所述突起部之间的距离为0.2mm以上。
3.权利要求1所述的用于成型的装饰膜,其中,所述突起部通过使电离辐射固化性树脂组合物发生交联固化而得到。
4.权利要求1~3中任一项所述的用于成型的装饰膜,其中,在所述基材片的背面依次层压着色层、粘结剂层以及背衬层。
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US20090246475A1 (en) | 2009-10-01 |
KR20150042771A (ko) | 2015-04-21 |
JP2009234159A (ja) | 2009-10-15 |
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