CN110172306A - 一种用于模内注塑的刻字预涂膜及制备工艺 - Google Patents

一种用于模内注塑的刻字预涂膜及制备工艺 Download PDF

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CN110172306A
CN110172306A CN201910501932.7A CN201910501932A CN110172306A CN 110172306 A CN110172306 A CN 110172306A CN 201910501932 A CN201910501932 A CN 201910501932A CN 110172306 A CN110172306 A CN 110172306A
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coating
layer
film
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mould injection
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许文虓
张震鲁
赵斌
曹华
董子尧
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ZHANGJIAGANG FREE TRADE ZONE KANGDE FILM INDUSTRY CO., LTD.
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BEIJING KANGDEXIN FUNCTION MATERIAL Co Ltd
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Abstract

本发明公开了一种用于模内注塑的刻字预涂膜，包括依次设置的表面有UV固化耐摩擦涂层的薄膜基材、真空镀铝层、针对ABS或PC的胶粘剂涂层和增粘层，在所述真空镀铝层的上、下表面分别设置有用于增强所述真空镀铝层表面涂布结合力的上底涂层和增强与ABS或PC胶粘剂涂层结合力的下底涂层；还包括制备工艺；本发明在真空镀铝层的上下表面进行双面涂布树脂，增强上底涂层和下底涂层等各层之间的结合力，以及在镀铝面的下底涂层上涂布胶结剂涂层和增粘层，提高了与ABS或PC树脂粘接后的剥离力，便于准确实现模内注塑操作，该预涂膜是一种表面具有预涂效果，适用于ABS或PC等注塑树脂在模内注塑工艺的包装制品。

Description

一种用于模内注塑的刻字预涂膜及制备工艺
技术领域
本发明实施例涉及家电、日化、电子、汽车等包装技术领域，具体涉及一种用于模内注塑的刻字预涂膜及制备工艺。
背景技术
包装市场用的预涂膜，其原定义是指预先将塑料薄膜通过挤出复合机或涂布机上涂上热熔胶和复卷后，它先由预涂膜加工厂根据使用规格、幅面，在薄膜上复卷后供使用厂家选择，再与纸张印刷品覆膜贴合的包装产品。
覆膜就是将塑料薄膜涂上黏合剂，与纸印刷品经加热、加压后使之黏合在一起，形成纸塑合一产品的加工技术，经覆膜的印刷品，由于表面多了一层薄而透明的塑料薄膜，表面更平滑光亮，从而提高印刷品的光泽度和牢度，图文颜色更鲜艳，富有立体感，同时更起到防水、防污、耐磨、耐摺、耐化学腐蚀等作用。
现有模内注塑用预涂膜通常只包含有一层聚氨酯基层结构、单张作业方式、彩色丝印以及用金属油墨丝印以仿制电镀方式，结构简单，因此，效率极低和导致成本较高。据了解，对于IMD行业高端产品，涉及底涂层、热熔胶涂布、镀膜、高温阻隔、预涂膜制作等产品制造工艺，由于企业之间涉及跨行业的多种技术工艺，行业内部出于涉及的技术工艺保密需要，无法整合属于各行业的部分技术工艺于一体，因此，采用单一制备工艺生产出的模内注塑行业使用的预涂膜，其产品性能也往往满足不了使用需求。比如，在模内注塑过程中，以丝印工艺为主的IMD预涂膜由于工艺落后，表面气泡和粘性较差，无法保证与ABS、PC等模内注塑使用树脂有良好的粘接，存在薄膜与镀铝层及彩印油墨之间剥离力低等问题，导致不能承担模内注塑产品的使用要求，还有铝层高温脱落、变色、耐温性能不足变形，导致产品外观不良等不足。
发明内容
为此，本发明实施例提供一种用于模内注塑的刻字预涂膜及制备工艺，通过对镀铝面双面涂层、真空镀膜、涂布针对ABS或PC注塑粘接的胶粘剂、增粘层等多项工艺结合，解决现有模内注塑技术中预涂膜制备工艺单一，导致生产的预涂膜产品功能单一、产品应用范围窄、以及用于模内注塑时与ABS或PC树脂粘接效果差、气泡、镀铝层高温变色和彩印褪色等问题。同时，也替代了以丝印单张方式的低效率作业。
为了实现上述目的，本发明实施例提供如下技术方案：
一种用于模内注塑的刻字预涂膜，包括依次设置的薄膜基材、真空镀铝层、ABS胶粘剂涂层和增粘层，在所述真空镀铝层的上、下表面分别设置有用于增强所述真空镀铝层表面涂布结合力的上底涂层和下底涂层。
本发明实施例的特征还在于，所述上底涂层和下底涂层分别为聚甲基丙烯酸甲酯和聚氨酯树脂。
本发明实施例的特征还在于，所述下底涂层和ABS胶粘剂涂层之间设有预涂布膜，所述预涂布膜为聚氨酯热熔胶树脂。
本发明实施例的特征还在于，所述增粘层具体为丙烯酸树脂。
另外，本发明还提供了一种用于模内注塑的刻字预涂膜的制备工艺，包括如下步骤：
步骤100、在薄膜基材的里层上涂布一层聚甲基丙烯酸甲酯树脂作为镀铝前的增强镀铝涂层；
步骤200、一次真空镀铝得到双向拉伸聚丙烯镀铝薄膜；
步骤300、在双向拉伸聚丙烯镀铝薄膜表面分别涂布有增强薄膜表面涂布结合力的上底涂层和下底涂层；
步骤400、在下底涂层的表面一次涂布热溶胶预涂膜，并且在热熔胶预涂膜的表面依次涂布ABS胶粘剂涂层和增粘层；
步骤500、在依次涂布完成之后在加热加压的状态下粘结和覆盖以形成一体化结构。
本发明实施例的特征还在于，在步骤100中，薄膜基材的宽度为1250mm、厚度为25μm。
本发明实施例的特征还在于，在步骤300中，上底涂层和下底涂层干重均为0.07g/m2，厚度为0.02-0.04μm。
本发明实施例的特征还在于，在步骤400中，热熔胶预涂膜的制备方法具体为：
用涂布机或干式复合机涂布热熔胶树脂，且热熔胶树脂的涂布厚度为3-5μm；
将涂布后的热熔胶树脂和增粘层经过网辊涂布在基材上，再经过85-90℃的烘道干燥，并在经冷却辊筒中降温，之后收卷。
本发明实施例的特征还在于，热熔胶树脂的干重为5-8g/m2。
本发明实施例具有如下优点：
本发明在真空镀铝层的上下表面进行双面涂布树脂，增强上底涂层和下底涂层等各层之间的结合力，以及在镀铝面的下底涂层上涂布胶结剂涂层和增粘层，提高了与ABS或PC树脂粘接后的剥离力，便于准确实现模内注塑操作，该预涂膜是一种表面具有预涂效果，适用于ABS或PC等注塑树脂在模内注塑工艺的包装制品。
附图说明
为了更清楚地说明本发明的实施方式或现有技术中的技术方案，下面将对实施方式或现有技术描述中所需要使用的附图作简单地介绍。显而易见地，下面描述中的附图仅仅是示例性的，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据提供的附图引伸获得其它的实施附图。
本说明书所绘示的结构、比例、大小等，均仅用以配合说明书所揭示的内容，以供熟悉此技术的人士了解与阅读，并非用以限定本发明可实施的限定条件，故不具技术上的实质意义，任何结构的修饰、比例关系的改变或大小的调整，在不影响本发明所能产生的功效及所能达成的目的下，均应仍落在本发明所揭示的技术内容得能涵盖的范围内。
图1为本发明的结构示意图；
图2为本发明制备工艺流程示意图。
图中：1-薄膜基材；2-上底涂层；3-真空镀铝层；4-下底涂层；5-胶粘剂涂层；6-增粘层。
具体实施方式
以下由特定的具体实施例说明本发明的实施方式，熟悉此技术的人士可由本说明书所揭露的内容轻易地了解本发明的其他优点及功效，显然，所描述的实施例是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
如图1所示，本发明提供的一种以连续涂布方式制作的、具有增加聚酯薄膜与镀铝层之间剥离力、以及增加镀铝层与ABS或PC注塑件剥离力、用于模内注塑的预涂膜，包括依次设置的表面有UV固化耐摩擦涂层的薄膜基材1、真空镀铝层3、针对ABS或PC的胶粘剂涂层5和增粘层6，在所述真空镀铝层3的上、下表面分别设置有用于增强所述真空镀铝层3表面涂布结合力的上底涂层2和增强与ABS或PC胶粘剂涂层5结合力的下底涂层4。
所述薄膜基材1具体为BOPET、BOPA、PC、BOPP薄膜中的任意一种。所述上底涂层2是聚氨酯树脂、共聚酯、丙烯酸酯酯类树脂中的一种或几种，所述下底涂层4是丙烯酸、烷烃类树脂中的一种或几种，所述胶粘剂涂层5是针对提高ABS或PC注塑树脂粘接用的热熔胶涂层。所述增粘层6具体是丙烯酸酯树脂、改性聚酯多元醇混合物、改性异氰酸酯加成物中的一种或几种。
其中，胶粘剂涂层5是在模内注塑过程中、在高温条件下发生化学反应后粘接ABS或PC树脂；在所述胶粘剂涂层5的表面涂有丙烯酸酯、改性聚酯多元醇混合物、改性异氰酸酯的加成物中的一种或几种，作为增粘层6，是为了增加该产品的初始剥离力。
表面有UV固化耐摩擦涂层的薄膜基材1宽度优选500-1800mm、厚度优选15-100μm。在步骤100和步骤300中，上底涂层2和下底涂层4的干重优选0.01-0.5g/m2，厚度优选0.01-0.1μm。
另外，基于上述结构，本发明的制备工艺不同于普通预涂膜由挤出复合工艺方法制备，本发明采用多种涂布胶粘剂工艺制作。如图2所示，该制备工艺具体包括如下步骤：
步骤100、在表面有UV固化耐摩擦涂层的薄膜基材里层上，涂布一层聚氨酯、共聚酯、丙烯酸酯类树脂中的一种或几种作为增加真空镀铝层表面涂布结合力的上底涂层；
步骤200、一次真空镀铝得到镀铝型薄膜；
步骤300、在表面有UV固化耐摩擦涂层的镀铝型薄膜表面上，涂布一层丙烯酸、烷烃类树脂中的一种或几种，作为增加镀铝表面与胶粘剂树脂结合力的下底涂层；
步骤400、在下底涂层的表面涂布针对ABS或PC树脂注塑用的胶粘剂层和增粘层；
步骤500、复卷和分切后，将模切成型后的产品放在模具内，进行模具内注塑ABS或PC树脂，在加热加压的状态下粘结和覆盖以形成一体化结构。
在上述模内注塑工艺中，在镀铝面采用双面涂层工艺，成为各层间的链接层，是模内注塑用预涂膜制作的一个新方法。
针对ABS或PC树脂型模内注塑预涂膜，采用涂布增粘层工艺方法，可以提高与ABS或PC树脂粘接的剥离力，本发明在热熔胶层表面涂布增粘层，是增加初始粘接力的一项工艺设计。
其中，在步骤400中，ABS或PC树脂的模内注塑用预涂膜的制备方法具体为：
使用涂布机或干式复合机将胶粘剂和增粘层的涂布液经过网辊按序涂布在镀铝薄膜上，经过烘道85-90℃的干燥，再经过冷却辊筒中降温之后收卷。胶粘剂涂层厚度为5μm。
在上述聚氨酯热熔胶树脂预涂膜的制备过程中，采用涂布工艺或者使用干式复合机、并与在线电晕处理结合。利用干式复合机和涂布热熔胶工艺，并与在线电晕处理结合，以及各工序链接所做的薄膜材料参数的调整配合，这是一种特殊的热熔胶涂布方式。本发明使用的涂胶网辊100#和60#网辊二次结合方式涂布ABS注塑工艺配合的粘接用热熔胶树脂，利用干式复合机制作热熔胶预涂膜，这是模内注塑用膜制作的又一个新方法。
其中，ABS或PC树脂模内注塑使用的预涂膜在生产加工的过程中无苯类添加物，溶剂残留总量≤5.0mg/m2，符合GB/T10004-2008包装用塑料复合膜、袋干法复合、挤出复合国家标准中苯类溶剂不允许检出的规定。
在本发明的上述技术方案中，包括如下四个方面的特征：
特征1：对镀铝层的上、下表面涂布增强结合力的底涂层。
第一工序是采用激光雕刻的工艺制作网版辊，即上述的网版辊基材，在该透明的BOPET基材的表面上涂布一次聚氨酯树脂，这是作为镀铝前的增强镀铝涂层。
第二工序是在透明的薄膜基材的表面上涂布一次聚氨酯、共聚酯、丙烯酸酯树脂中的一种或几种，这是作为镀铝前的增强镀铝涂层上涂层，然后真空镀铝成为镀铝型薄膜。
第三工序是在真空镀铝层的下表面涂布下涂层，这是作为镀铝面与胶粘剂粘接时，增强结合力的链接层。在镀铝面采用的双面涂层工艺是模内注塑用膜制作的一个新方法。
特征2：涂布胶粘剂，以匹配ABS或PC树脂的注塑工艺。
本发明使用干式复合机和网辊二次涂布与ABS或PC注塑工艺配合的粘接用热熔胶树脂连续涂布，制作模内注塑用预涂膜，解决了丝印工艺、效率低质量差问题。是模内注塑用膜制作的一个新方法和技术提升。
特征3：热熔胶树脂预涂膜的表面具有增粘层。
为了提高注塑工艺用ABS或PC树脂与本发明产品的剥离力，本发明采用了在胶粘剂表面涂布初粘接层的技术设计，将其作为增粘层。
特征4：涂布工艺使用干式复合机、并与在线电晕处理结合，产品应用范围广泛。
本发明中薄膜基材经过表面UV固化涂布耐摩擦处理、二次底涂层涂布、一次真空镀膜、一次匹配ABS或PC胶粘剂涂布、一次增粘涂层的技术工艺过程，制作表面具有预涂效果和适合ABS或PC等模内注塑工艺的预涂膜。
特征5：本发明内容的模内注塑产品，其表面可以利用凹版印刷/涂布工艺实现特定效果的UV固化树脂涂层。
本发明的产品，除具备基本IMD功能和镀铝层、耐高温、不褪色不变色的本发明的特点外，还具有表面硬化、耐摩擦、亚光或亮光及凹印图案3D触感等装饰功能。
结合上述技术工艺制造的模内注塑用预涂膜，是一种综合多了特种涂布技术工艺的新型包装产品。应用于家电、电子、汽车、日化、食品包装等行业。如文具、服饰、家具装饰、汽车内饰、食品盒、饰品盒、奢侈品的注塑包装和覆膜。尤其是通过特种底涂层树脂的配制、以及涂布热熔胶工艺的使用，所制造的ABS或PC树脂模内注塑用预涂膜，是一种综合多项技术工艺的新型包装产品。因此，本项发明也涵盖如无纺布、纸塑复合膜等能够做成卷材的薄带类产品，在采用多次底涂层和其他金属或蒸镀金属氧化物高阻隔镀层、增粘层技术工艺后，将成为特定功能的模内注塑用预涂膜产品。
虽然，上文中已经用一般性说明及具体实施例对本发明作了详尽的描述，但在本发明基础上，可以对之作一些修改或改进，这对本领域技术人员而言是显而易见的。因此，在不偏离本发明精神的基础上所做的这些修改或改进，均属于本发明要求保护的范围。

Claims (9)

1.一种用于模内注塑的刻字预涂膜，其特征在于，包括依次设置的表面有UV固化耐摩擦涂层的薄膜基材(1)、真空镀铝层(3)、针对ABS或PC的胶粘剂涂层(5)和增粘层(6)，在所述真空镀铝层(3)的上、下表面分别设置有用于增强所述真空镀铝层(3)表面涂布结合力的上底涂层(2)和增强与ABS或PC胶粘剂涂层(5)结合力的下底涂层(4)。
2.根据权利要求1所述的一种用于模内注塑的刻字预涂膜，其特征在于，所述薄膜基材(1)具体为BOPET、BOPA、PC、BOPP薄膜中的任意一种。
3.根据权利要求1所述的一种用于模内注塑的刻字预涂膜，其特征在于，所述上底涂层(2)是聚氨酯树脂、共聚酯、丙烯酸酯酯类树脂中的一种或几种，所述下底涂层(4)是丙烯酸、烷烃类树脂中的一种或几种，所述胶粘剂涂层(5)是针对提高ABS或PC注塑树脂粘接用的热熔胶涂层。
4.根据权利要求1所述的一种用于模内注塑的刻字预涂膜，其特征在于，所述增粘层(6)具体是丙烯酸酯树脂、改性聚酯多元醇混合物、改性异氰酸酯加成物中的一种或几种。
5.一种用于模内注塑的刻字预涂膜的制备工艺，其特征在于，包括如下步骤：
步骤100、在表面有UV固化耐摩擦涂层的薄膜基材里层上，涂布一层聚氨酯、共聚酯、丙烯酸酯类树脂中的一种或几种作为增加真空镀铝层表面涂布结合力的上底涂层；
步骤200、一次真空镀铝得到镀铝型薄膜；
步骤300、在表面有UV固化耐摩擦涂层的镀铝型薄膜表面上，涂布一层丙烯酸、烷烃类树脂中的一种或几种，作为增加镀铝表面与胶粘剂树脂结合力的下底涂层；
步骤400、在下底涂层的表面涂布针对ABS或PC树脂注塑用的胶粘剂层和增粘层；
步骤500、复卷和分切后，将模切成型后的产品放在模具内，进行模具内注塑ABS或PC树脂，在加热加压的状态下粘结和覆盖以形成一体化结构。
6.根据权利要求5所述的一种用于模内注塑的刻字预涂膜的制备工艺，其特征在于，在步骤100中，表面有UV固化耐摩擦涂层的薄膜基材宽度优选500-1800mm、厚度优选15-100μm。
7.根据权利要求5所述的一种用于模内注塑的刻字预涂膜的制备工艺，其特征在于，在步骤100和步骤300中，上底涂层和下底涂层的干重优选0.01-0.5g/m2，厚度优选0.01-0.1μm。
8.根据权利要求5所述的一种用于模内注塑的刻字预涂膜的制备工艺，其特征在于，胶粘剂涂层和增粘层的制备方法为：使用涂布机或干式复合机将胶粘剂和增粘层的涂布液经过网辊按序涂布在镀铝薄膜上，经过烘道85-90℃的干燥，再经过冷却辊筒中降温之后收卷。
9.根据权利要求8所述的一种用于模内注塑的刻字预涂膜的制备工艺，其特征在于，所涂布的胶粘剂层(5)的干重为1-5g/m2，涂布厚度为1-8μm。
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