CN1213838C - 通过薄膜镶嵌模塑制备的装饰制品 - Google Patents

通过薄膜镶嵌模塑制备的装饰制品 Download PDF

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CN1213838C
CN1213838C CNB011232455A CN01123245A CN1213838C CN 1213838 C CN1213838 C CN 1213838C CN B011232455 A CNB011232455 A CN B011232455A CN 01123245 A CN01123245 A CN 01123245A CN 1213838 C CN1213838 C CN 1213838C
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base material
mould
dicoration
layer
pattern
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CN1334206A (zh
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S·G·史密斯
P·J·格里芬
K·R·赫夫利
D·D·杜赫蒂
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Bayer Corp
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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
    • 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
    • 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
    • B29C45/14688—Coating articles provided with a decoration
    • 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
    • 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
    • B29C45/14688—Coating articles provided with a decoration
    • B29C2045/14696—Coating articles provided with a decoration transparent decorated inserts
    • 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
    • B29C45/14688—Coating articles provided with a decoration
    • B29C2045/14704—Coating articles provided with a decoration ink decorations
    • 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
    • B29C45/14688—Coating articles provided with a decoration
    • B29C2045/14713—Coating articles provided with a decoration decorations in contact with injected material
    • 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
    • B29C45/14688—Coating articles provided with a decoration
    • B29C2045/14721—Coating articles provided with a decoration decorations transferred by diffusion or sublimation
    • 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
    • B29C45/14688—Coating articles provided with a decoration
    • B29C2045/14737—Coating articles provided with a decoration decorations printed on the insert by a digital imaging technique

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Decoration By Transfer Pictures (AREA)

Abstract

描述了制备装饰制品的方法。该方法包括采用高温油墨在转印纸表面上印刷图样，并通过升华将图样转印到透明片型基材表面上以获得装饰基材。然后将经过这样装饰的表面放入模具中，注射热塑性树脂以形成制品。装饰基材在模具内的放置使得带有图样的表面面对模具的内部。另一个实施方案包括在放入模具中之前使装饰基材成型以获得三维装饰基材。

Description

通过薄膜镶嵌模塑制备的装饰制品
                         技术领域
本发明涉及一种制备热塑性组合物的装饰制品的方法，更具体地，该方法包括薄膜镶嵌模塑。
                         背景技术
带有装饰性图样的热塑模塑制品的制备方法是已知的。已知这样的制品是通过将热塑性模塑组合物注射到模具中而制备的。装饰性图样是通过众所周知的任何丝网或胶版印刷技术覆盖到制品表面上的。这样制备的制品常常在受到摩擦时失去装饰性图样，或由于在使用时产生的擦痕使它们的美感受到破坏。
包括在本发明中的一般形式的产品，许多年来已经通过现有技术中的已知方法如模内装饰方法或膜镶嵌模塑法进行制备。这些使用了约30年的方法被用于在树脂片材上生产印刷图案，该树脂片材被用于形成最终产品的注塑过程中。在这个现有技术的方法中，通过平版印刷和/或丝网印刷生产贴面或模内装饰片材，部件是片型的且通过如静电荷的方法稳固地置于模具中。该方法的特征在于它要求特殊的浇口设计和由于塑料的引入需要被限制到没有油墨的区域而被限制的印刷图样的自由度；图样和油墨的交互作用倾向于使图形移动或失真。
值得注意的现有技术包括美国专利2,811,744，该专利描述了避免现有技术中一些缺点的方法。相应地，这样描述的方法包括将热塑性组合物直接注射到已经被放入注射模具中的带有用可转印油墨印刷的装饰图样的纸片上。在注塑过程中普遍存在的热条件下，油墨可以和纸分离。在注射过程中，可转印油墨和纸分离并粘合到模塑的热塑性组合物上，得到表面装饰的制品。该方法的缺点在于这样装饰的制品常常具有变形或破坏的装饰的特征。该缺点是在注射过程中熔融的组合物沿纸移动的结果。
美国专利4,931,248公开了通过注塑法制造装饰制品的另一种方法。该方法包括以可转印油墨在载体表面上印刷图样。该油墨的特征在于受热时可以和载体分离。将印刷的载体引入到模具中，然后将隔离膜也引入到模具中使得隔离膜覆盖到载体的印刷表面上。在引入载体和膜之后，将热塑性材料注入模具中。载体的引入使得至少在注射过程中(i)将载体覆盖到模具壁上并使印刷表面转向模具的内部和(ii)膜的引入使膜的一面覆盖到载体的印刷表面上，膜的另一面将其自身粘合到热塑性材料上。在熔融树脂的注射过程中，在普遍存在的热条件下可转印油墨和载体分离并沉积到膜上。
美国专利5,264,172公开了由合成树脂制造且其上具有印饰类型的嵌饰产品的制备方法。该方法包括采用可成形油墨在合成树脂基材的表面上印刷，将基材以稳固的位置放入模具腔中使基材的前表面和模具的表面接触，将熔融树脂注射到模具腔空间中。相关的方法还有在美国专利4,917,927中公开的模内装饰方法，该方法包括一个新颖的印刷步骤。
                       发明内容
描述了制备装饰制品的方法。该方法包括采用高温油墨在转印纸表面上印刷图样，通过升华将图样转印到透明的片型基材表面上以获得装饰基材。然后将经过这样装饰的表面放入模具中，注射热塑性树脂以形成制品。装饰基材在模具内的放置使得带有图样的表面面向模具的内部。另一个实施方案包括在放入模具中之前使装饰基材成型以获得三维装饰基材。
根据本发明，提供了一种用于制备装饰的热塑模塑制品的方法。该方法生产出在使用一些时间之后装饰性图样的清晰度一点也不损失的制品。
本方法包括采用高温可转印油墨将用于装饰模塑制品的图样或图例(此处称作“图样”)印刷到转印纸的一个表面上。这样的印刷，以及转印纸和高温可转印油墨是已知的。然而，简单地讲，适合的转印纸是可以从商业上获得的以优质喷墨纸为通称的那些。作为这样适合的转印纸的例子，Mile High Engineering的产品，AccuPlot EPQ 8511C是非常合适的。可以通过任何已知技术包括丝网印刷和胶版印刷进行装饰或图例的印刷。在尤其优选的实施方案中，装饰性图样或图例可以进行数字印刷。在这个优选的实施方案中，印刷的分辨率优选不低于1440×720dpi(点/英寸)。通过采用如Epson Stylus Color 3000打印机达到这样的分辨率。在本发明中，适合的高温油墨其特征在于能够升华且在注塑过程中普遍存在的条件下基本上保持没有热降解。这样适合的高温油墨是可从Sawgrass商购的以Sublijet为商标的产品。
在本发明方法的随后步骤中将这样装饰的转印纸以图例面面对塑料基材放置，施加足够的热量和任选地压力使油墨升华，并将图样转印到塑料基材上。
本发明的塑料基材优选是厚度为0.0035″到0.040″的膜的形式；塑料基材优选包括透光(transparent)和/或透明(clear)的树脂。适合的组成基材的树脂包括以下聚合物中的任何一种：聚碳酸酯均聚物，共聚碳酸酯，丙烯腈-丁二烯-苯乙烯树脂(ABS)，苯乙烯/丙烯腈(SAN)，聚酰胺，热塑性聚氨酯，以及聚碳酸酯的共混物，包括与ABS的共混物。含有丙烯酸树脂和聚碳酸酯树脂的热塑性组合物是优选的。在优选的实施方案中，基材是包含至少两层的层压材料的形式。在这样的实施方案中，一层是PVF(聚氟乙烯)或PVDF(聚偏二氟乙烯)。
现在可以将带有印刷装饰或图例的基材以其片型未成型的形式放入注塑模具中，或成型为与注射模具内表面相同的三维形状，经过修边以除去多余的材料后放入模具中。当模具闭合时，模具的壁形成了具有被模塑的制品的形状和尺寸的腔室。装饰的基材放入模具中的方式使得它的带有图样的表面面对模具的内部。在注射热塑性组合物的过程中，基材将被注射材料的压力压在模具的壁上。不象美国专利4,931,248中公开的方法，在本发明方法中，形成装饰图样的油墨直接和熔融的热塑性组合物接触。在注射后，打开模具，移出模塑制品。
基材包括与组成注射模塑制品的树脂牢固地粘合的材料。优化基材对由注射模塑步骤得到的模塑制品的粘合是在熟练技术人员的能力范围内的。此处可以提到，按照本发明的方法，采用聚碳酸酯基组合物作为注射材料，聚碳酸酯膜作为基材可以获得良好的结果。在另外的成功的实施方案中，采用的基材是聚碳酸酯(0.020″的厚度)和PVDF(具有0.0015″的厚度)的双层层压材料。
                    具体实施方式
实施例
在按照本发明制备装饰制品中，采用了如下材料和设备：
打印机：Epson Stylus Color 3000
转印纸：AccuPlot EPQ，来自Mile High Engineering，优质喷墨纸。
油墨：用于Epson Stylus Color 3000的Sublijet，来自SawgrassInc。
传热压力机：Astex 1350，手动平床式传热压力机，Astechnologies的产品。
首先通过计算机图形应用软件Photoshop，Corel Draw制作数字图像。将4 Sublijet彩色墨粉鼓和转印纸装入打印机。以优质模式1440×720dpi打印数字图像。将聚碳酸酯膜放在热压机的台架上。将要升华在其上面的面放置成面对加热的压板。将包含升华的图像的纸放置在膜的上边：油墨面面对膜，非印刷的面面对加热的压板。将压板加热到约300°F。然后闭合压板并夹紧。夹紧压力是40psi。传热时间(升华时间)是约15到60秒。然后打开压板。手动将转印纸从膜上剥落。油墨已经升华到膜的表面。这样形成了包含图像的膜，将其修边并放置在注射模具中。通过常规注射进行模塑。
按照本发明模塑的其它制品采用共挤出层压材料作为基材进行制备。层压材料包含由聚碳酸酯和ABS的共混物制成的一层和PVDF的第二层。如上所述，按照本发明技术对膜进行装饰，成型，模头切割，并用于模塑装饰的制品中。
尽管以上为说明的目的已经对本发明进行了详细描述，应当理解这样的详细描述只是为说明的目的，其中本领域技术人员可以在不离开可由权利要求限定的本发明的本质和范围情况下进行变化。

Claims (13)

1.一种制备装饰制品的方法，该方法包括：
(i)采用高温颜料基的喷墨油墨在转印纸表面上印刷图样，
(ii)通过升华将该图样转印到透明片型基材的第二表面上以获得装饰基材，所述基材包含选自聚碳酸酯均聚物、共聚碳酸酯、丙烯腈-丁二烯-苯乙烯树脂、苯乙烯/丙烯腈、聚酰胺、热塑性聚氨酯、以及聚碳酸酯的共混物的至少一种，
(iii)将该装饰基材放入模具中，该装饰基材的第二表面面对该模具的内部，和
(iv)向该模具中注射热塑性组合物以形成制品。
2.权利要求1的方法，其中所述基材包括选自聚碳酸酯均聚物、共聚碳酸酯以及热塑性聚氨酯的至少一种。
3.权利要求1的方法，其中所述基材包含一种包括至少一层聚碳酸酯树脂层的多层层压材料。
4.权利要求3的方法，其中所述层压材料包含至少一层含有聚氟乙烯的层。
5.权利要求3的方法，其中层压材料包含至少一层含有聚偏二氟乙烯的层。
6.权利要求1的方法，其中所述热塑性组合物包含聚碳酸酯树脂。
7.权利要求1的方法，其中所述印刷是通过数字方式经喷墨印饰。
8.一种制备装饰制品的方法，该方法包括：
(i)采用高温颜料基的喷墨油墨在转印纸表面上印刷图样，
(ii)通过升华将该图样转印到透明片型基材第二表面上以获得装饰基材，该基材包括选自聚碳酸酯均聚物、共聚碳酸酯、丙烯腈-丁二烯-苯乙烯树脂、苯乙烯/丙烯腈、聚酰胺、热塑性聚氨酯、以及聚碳酸酯的共混物的至少一种，
(iii)将装饰基材成型以获得三维装饰基材，
(iv)将该三维装饰基材放入模具中，该三维装饰基材的第二表面面对该模具的内部，和
(v)向该模具中注射热塑性组合物以形成制品。
9.权利要求8的方法，其中所述基材包含选自聚碳酸酯均聚物、共聚碳酸酯以及热塑性聚氨酯的至少一种。
10.权利要求8的方法，其中所述基材包含至少一层含有聚氟乙烯层的层压材料。
11.权利要求8的方法，其中所述基材包含至少一层含有聚偏二氟乙烯层的层压材料。
12.权利要求8的方法，其中所述热塑性组合物包含聚碳酸酯树脂。
13.权利要求8的方法，其中所述印刷是通过数字方式经喷墨印饰。
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