JP5134795B2 - Manufacturing method for simultaneously molded decorative molded products - Google Patents

Manufacturing method for simultaneously molded decorative molded products Download PDF

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JP5134795B2
JP5134795B2 JP2006226803A JP2006226803A JP5134795B2 JP 5134795 B2 JP5134795 B2 JP 5134795B2 JP 2006226803 A JP2006226803 A JP 2006226803A JP 2006226803 A JP2006226803 A JP 2006226803A JP 5134795 B2 JP5134795 B2 JP 5134795B2
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resin
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JP2008049545A (en
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富士男 森
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Nissha Printing Co Ltd
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本発明は、自動車部品（例えば、コンソールパネルやスイッチパネルなど）や電気製品などの加飾部品（例えば、携帯電話や各種調理器具の入力パネルなど）の製造に使用する成形同時加飾用シートと、これを用いた加飾成形品の製法に関するものである。   The present invention relates to a molded simultaneous decorating sheet for use in the manufacture of decorative parts such as automobile parts (for example, console panels and switch panels) and electrical products (for example, input panels for mobile phones and various cooking utensils) The present invention relates to a method for producing a decorative molded product using the same.

自動車部品や電気製品などに用いられる加飾成形品は、一般に絞りの深い形状の製品が多いことから、通常、加熱成形によって絞り加工された加飾用シートが用いられている。そして最近では、深絞り性や外観の意匠性だけでなく、表面に触れたときの触感を高めるため微細な凹凸を形成しようとする要望も強くなっている。こうした要望に沿うべく表面に微細な凹凸を形成した加飾用シートとしては、例えば特許文献１に記載されている様な、エンボス加工により表面に凹凸を形成した化粧用シートが知られている。   Since decorative molded products used for automobile parts, electrical products, and the like are generally products having a deeply drawn shape, a decorative sheet that has been drawn by heat forming is usually used. Recently, there is an increasing demand for forming fine irregularities in order to enhance not only the deep drawability and the design of the appearance, but also the touch feeling when touching the surface. As a decorative sheet in which fine irregularities are formed on the surface to meet such demands, a cosmetic sheet having irregularities formed on the surface by embossing as described in Patent Document 1, for example, is known.

しかし、この特許文献１に記載されたエンボス加工技術は、表面の熱可塑性樹脂フィルムを熱加工して凹凸を設ける方法であるため、微細な凹凸になると、加熱成形する際の熱で表面の熱可塑性樹脂フィルムが軟化し、せっかく形成した微細な凹凸が変形したり消失したりする問題があった。また、加飾用シートの加熱成形時に凹凸を維持できたとしても、その後で受ける成形同時加飾時の熱と圧力で凹凸が変形したり消失し、設計通りの表面凹凸を得ることができない。そのため上記特許文献１に記載の化粧用シートは、絞りの深い形状の製品を製造するための加飾用シートとしては使用できなかった。
特開２００５−０８１６７６号公報 However, since the embossing technique described in Patent Document 1 is a method in which a thermoplastic resin film on the surface is heat-processed to provide irregularities, if the irregularities become fine, the heat of the surface is generated by heat at the time of thermoforming. There was a problem that the plastic resin film was softened and fine irregularities formed were deformed or disappeared. Moreover, even if the unevenness can be maintained during the heat forming of the decorative sheet, the unevenness is deformed or disappears due to heat and pressure at the time of simultaneous decorating, and thus the surface unevenness as designed cannot be obtained. Therefore, the cosmetic sheet described in Patent Document 1 cannot be used as a decorative sheet for producing a product with a deeply drawn shape.
JP 2005-081676 A

本発明は上記の様な従来技術の問題点に鑑みてなされたものであり、その目的は、微細な凹凸模様の加飾成形品を製造する際に用いる加飾用シートであって、それ自身を製造する際は勿論のこと、該シートを用いて加飾成形品を製造する際に熱や圧力を受けたときでも、また、絞りの深い形状の製品に微細な凹凸模様を形成する場合でも、微細な凹凸が変形したり消失したりすることなく設計通りの凹凸を確実に形成することのできる加飾用シートを提供し、更には、該加飾用シートを用いた加飾成形品の製法を提供することにある。   The present invention has been made in view of the problems of the prior art as described above, and its purpose is a decorative sheet used when producing a decorative molded product having a fine uneven pattern, which is itself When manufacturing a decorative molded product using the sheet, of course, even when subjected to heat or pressure, or when forming a fine concavo-convex pattern on a deeply drawn product , Providing a decorative sheet that can reliably form the irregularities as designed without deformation or disappearance of fine irregularities, and further, a decorative molded product using the decorative sheet To provide a manufacturing method.

上記課題を解決することのできた本発明の加飾用シートは、基材シートの片面に加飾層が形成された加熱成形可能な成形同時加飾用シートであって、基材シートの加飾層形成面とは反対側の面がエンボス加工され、該エンボス加工面の凹凸が水溶性樹脂層で埋められているところに要旨を有している。   The decorative sheet of the present invention that has been able to solve the above-mentioned problems is a heat-moldable simultaneous molding decorative sheet in which a decorative layer is formed on one side of a base sheet, and the base sheet is decorated. The gist is that the surface opposite to the layer forming surface is embossed, and the unevenness of the embossed surface is filled with a water-soluble resin layer.

本発明に係る成形同時加飾用シートにおける上記水溶性樹脂層は、量産を図るため押出成形法によって形成することができ、また、成形同時加飾用シートの前記加飾層は、基材シートをエンボス加工した後に形成するのがよい。   The water-soluble resin layer in the simultaneous molding decorative sheet according to the present invention can be formed by an extrusion molding method for mass production, and the decorative layer of the simultaneous molding decorative sheet is a base sheet. It is good to form after embossing.

更に本発明の製法は、上記の成形同時加飾用シートを用いて加飾成形品を製造するための有用な方法として位置付けられる発明であり、第１の製法は、上記の成形同時加飾用シートを加熱成形する工程、加熱成形した該加飾用シートの不要部分を切除する工程、該加飾用シートにおける水溶性樹脂層を成形金型の内壁面側にして該加飾用シートを成形金型内に装入配置する工程、成形金型内に成形用樹脂を射出して成形する工程、成形金型から該加飾成形品を取り出す工程、取り出した該加飾成形品表面の水溶性樹脂層を水洗除去する工程、を順次実施するところに特徴を有している。   Furthermore, the manufacturing method of the present invention is an invention that is positioned as a useful method for producing a decorative molded product using the above-mentioned simultaneous decorative sheet, and the first manufacturing method is for the simultaneous simultaneous decoration described above. The step of heat-molding the sheet, the step of cutting out unnecessary portions of the thermoformed decorative sheet, and molding the decorative sheet with the water-soluble resin layer in the decorative sheet as the inner wall surface of the molding die The process of charging and placing in the mold, the process of injecting the molding resin into the mold, the process of taking out the decorative molded product from the mold, and the water solubility of the surface of the decorative molded product taken out It is characterized in that the step of removing the resin layer with water is sequentially performed.

また第２の製法は、上記の成形同時加飾用シートを加熱成形する工程、該加飾用シートにおける水溶性樹脂層を成形金型の内壁面側にして該加飾用シートを成形金型内に装入配置する工程、成形金型内に成形用樹脂を射出して成形する工程、成形金型から該加飾成形品を取り出す工程、取り出した該加飾成形品の表面の水溶性樹脂層を水洗除去する工程、水溶性樹脂層が除去された成形同時加飾用シートの不要部分を切除する工程、を順次実施するところに特徴を有し、更に第３の製法は、上記の成形同時加飾用シートを加熱成形する工程、該加飾用シートの水溶性樹脂層を成形金型の内壁面側にして該加飾用シートを成形金型内に装入配置する工程、成形金型内に成形用樹脂を射出して成形する工程、成形金型から該加飾成形品を取り出す工程、取り出した該加飾成形品から成形同時加飾用シートの不要部分を切除する工程、該加飾成形品の表面の水溶性樹脂層を水洗除去する工程、を順次実施するところに特徴を有している。   Further, the second production method includes a step of heat-molding the above-mentioned simultaneous decoration sheet, the water-soluble resin layer in the decoration sheet as the inner wall surface of the mold, and the decoration sheet is molded The step of charging and arranging in the step, the step of injecting and molding a molding resin into the molding die, the step of taking out the decorative molded product from the molding die, and the water-soluble resin on the surface of the taken out decorative molded product It is characterized in that the step of washing and removing the layer and the step of cutting off the unnecessary portion of the sheet for simultaneous decorating from which the water-soluble resin layer has been removed are characterized in that the third manufacturing method is the above-mentioned molding A step of heat-molding the sheet for simultaneous decoration, a step of placing and placing the sheet for decoration in the molding die with the water-soluble resin layer of the sheet for decoration as the inner wall surface of the molding die, A process of injecting a molding resin into the mold and molding, and taking out the decorative molded product from the mold The characteristic feature is that the step of removing unnecessary portions of the sheet for simultaneous decorative decoration from the removed decorative molded product and the step of washing and removing the water-soluble resin layer on the surface of the decorative molded product are sequentially performed. Have.

本発明の成形同時加飾用シートは、エンボス加工面の凹凸が水溶性樹脂層で埋められているので、該シートを加熱成形する際に表面の熱可塑性樹脂フィルムが軟化しても、固化した水溶性樹脂層によって凹凸が背面側から支持され、軟化した熱可塑性樹脂の行き場がないので、凹凸が微細であっても変形したり消失したりすることがない。また、この加飾用シートを用いて成形同時加飾品を製造する際にも、成形樹脂の熱や圧力を水溶性樹脂層が吸収すると共に凹凸を支持するので、凹凸が変形したり消失したりすることもない。従って、本発明の成形同時加飾用シートは、成形同時加飾成形によって深い絞り加工を行った場合でも、成形の後で水溶性樹脂層を水洗除去することで微細な凹凸を確実に顕出させることができ、優れた感触の凹凸を有する同時加飾成形品を容易に得ることができる。   The sheet for simultaneous decorating of the present invention is solidified even when the thermoplastic resin film on the surface is softened when the sheet is thermoformed because the unevenness of the embossed surface is filled with the water-soluble resin layer. Since the unevenness is supported from the back side by the water-soluble resin layer and there is no place for the softened thermoplastic resin, even if the unevenness is fine, it does not deform or disappear. In addition, when manufacturing a simultaneous decorative article using this decorative sheet, the water-soluble resin layer absorbs the heat and pressure of the molding resin and supports the unevenness, so that the unevenness is deformed or disappears. I don't have to. Therefore, the sheet for simultaneous decorating of the present invention reliably reveals fine irregularities by removing the water-soluble resin layer with water after molding even when deep drawing is performed by simultaneous molding. It is possible to obtain a simultaneous decorative molded product having unevenness with excellent feel.

また本発明の製法によれば、上記成形同時加飾用シートを使用し、加熱成形後に不要部分をカットしてから成形金型に装入して成形用樹脂の射出成形を行い、該成形金型から該加飾成形品を取り出した後に、該加飾成形品の表面の水溶性樹脂層を剥離除去するか、或は、加熱成形後に成形金型に装入して成形用樹脂の射出成形を行い、該成形金型から該加飾成形品を取り出した後に、加飾用シート表面の水溶性樹脂層の水洗除去と加飾用シートの不要部分の切除を行うことにより、絞りの深い成形品であっても、表面に設計通りの微細な凹凸が形成された同時加飾成形品を容易に得ることができる。   Further, according to the production method of the present invention, the above-mentioned sheet for simultaneous decorating is used, an unnecessary portion is cut after heat molding, and then inserted into a molding die to perform injection molding of the molding resin. After taking out the decorative molded product from the mold, the water-soluble resin layer on the surface of the decorative molded product is peeled off or inserted into a molding die after heat molding and injection molding of a molding resin And after removing the decorative molded product from the molding die, the water-soluble resin layer on the surface of the decorative sheet is washed away and unnecessary portions of the decorative sheet are removed, thereby forming a deeply drawn sheet. Even if it is a product, it is possible to easily obtain a simultaneously decorated molded product having fine irregularities as designed on the surface.

本発明の加飾用シートは、上記の様に基材シートの片面に加熱成形可能な熱可塑性樹脂シートであって、例えば図１（断面拡大説明図）に示す如く、基材シート１の片面側に加飾層２が形成されると共に、該加飾層２とは反対側の面はエンボス加工によって凹凸模様３が形成され、更に該凹凸模様３の凹凸は水溶性樹脂４で埋められている。   The decorative sheet of the present invention is a thermoplastic resin sheet that can be thermoformed on one side of the base sheet as described above. For example, as shown in FIG. The decorative layer 2 is formed on the side, and the surface opposite to the decorative layer 2 is formed with a concavo-convex pattern 3 by embossing, and the concavo-convex pattern 3 is filled with a water-soluble resin 4. Yes.

ここで基材シート１の構成素材は、加熱成形で任意の形状に成形可能な熱変形性（熱可塑性）の素材であれば種類の如何は問わないが、好ましい素材としては、アクリル系樹脂、ポリカーボネート系樹脂、無延伸または低延伸のポリエステル系樹脂、ポリブチレンテレフタレート系樹脂、無延伸または低延伸のポリオレフィン系樹脂（中でもポリエチレン系樹脂やポリプロピレン系樹脂など）、ポリウレタン系樹脂、ポリフッ化ビニル系樹脂の如き、熱変形の容易な熱可塑性樹脂が例示される。
Here, the constituent material of the base sheet 1 may be any material as long as it is a heat-deformable (thermoplastic) material that can be formed into an arbitrary shape by thermoforming. Preferred materials include acrylic resins, polycarbonate resin, unstretched or low-stretched polyester-based resin, polybutylene terephthalate resin, polyolefin-based unstretched or low-stretched resin (particularly, such as polyethylene resin and polypropylene resin), polyurethane resin, Po Rifu' vinylic Examples thereof include thermoplastic resins that are easily thermally deformed, such as resins.

基材シート１の厚さも特に制限されないが、成形同時加飾に用いられるシートとして好ましいのは１０〜１０００μｍの範囲である。   The thickness of the base sheet 1 is not particularly limited, but is preferably in the range of 10 to 1000 μm as a sheet used for simultaneous molding.

該基材シート１の片面側に形成される加飾層２の具体例としては、単色もしくは２色以上の抽象柄、幾何学的な連続もしくは不連続模様柄、全面べた印刷、プライマー印刷絵柄、凹凸模様柄など、意匠性を高めるための様々の模様柄を挙げることができ、これらは基材シート１に対してグラビア印刷、スクリーン印刷、凸版印刷、インキジェット印刷、レーザー印刷など、任意の印刷法によって形成することができ、またこれらは単独印刷のほか任意の組合せで複合印刷することも可能である。   Specific examples of the decorative layer 2 formed on one side of the base sheet 1 include an abstract pattern of one color or two or more colors, a geometric continuous or discontinuous pattern pattern, a whole surface solid print, a primer print pattern, Various design patterns such as concavo-convex pattern patterns can be listed, and these can be printed on the base sheet 1 by any means such as gravure printing, screen printing, letterpress printing, ink jet printing, and laser printing. These can be formed by a method, and these can be combined and printed in any combination as well as single printing.

またエンボス加工とは、基材シートの表面に任意の凹凸模様を形成する加工を言い、例えば木目導管模様、ドット模様、ヘアライン模様、ストライプ模様など、需要者の希望に応じた任意の凹凸模様を採用できる。これらの模様は、基材シート１の全面に設けてもよく、或は部分的に設けてもよい。凹凸模様３がヘアライン模様やストライプ模様の場合、好ましくは、例えば線幅０．０５〜０．１５ｍｍの線状パターンで５〜２００μｍ程度の深さに形成するのがよい。   Embossing refers to the process of forming an arbitrary uneven pattern on the surface of a base sheet. For example, an arbitrary uneven pattern according to a customer's request, such as a wood grain conduit pattern, a dot pattern, a hairline pattern, or a stripe pattern. Can be adopted. These patterns may be provided on the entire surface of the substrate sheet 1 or may be provided partially. When the concavo-convex pattern 3 is a hairline pattern or a stripe pattern, it is preferably formed to a depth of about 5 to 200 μm, for example, as a linear pattern having a line width of 0.05 to 0.15 mm.

本発明では、上記エンボス加工部を構成する凹凸模様３を水溶性樹脂４で埋めておくことで、追って詳述する如く、該加飾用シート自体の成形時もしくは該加飾用シートを用いた同時加飾成形時における、該凹凸模様３の安定保持を図るところに最大の特徴を有している。   In the present invention, by embedding the uneven pattern 3 constituting the embossed portion with a water-soluble resin 4, as described in detail later, the decorative sheet itself was used during molding or the decorative sheet was used. The greatest feature is that the uneven pattern 3 is stably maintained at the time of simultaneous decorative molding.

即ち、凹凸模様３をそのままの状態で加熱成形した場合、該シートの加熱成形によって凹凸部分も同時に軟化し、凹凸模様３が引き伸ばされて変形したり消失し、設計通りの凹凸模様３を確保できないことがある。ところが、該凹凸模様３の外面側が水溶性樹脂４で埋められていると、加熱成形時に該凹凸模様３の部分でシート素材が軟化しても、その背面側で固化している水溶性樹脂４がシート素材の軟化流動を阻止して凹凸を保持するため、該凹凸模様３は設計通りの深さと形状に維持される。従って、同時加飾成形後に該凹凸模様３の外面側に位置する水溶性樹脂４を水洗除去してやれば、同時加飾成形品の表面には、設計通りの形状と深さの凹凸模様３を有する加飾成形品を得ることができる。   That is, when the concavo-convex pattern 3 is heat-formed as it is, the concavo-convex portion is simultaneously softened by the heat forming of the sheet, and the concavo-convex pattern 3 is stretched and deformed or disappears, and the concavo-convex pattern 3 as designed cannot be secured. Sometimes. However, if the outer surface side of the concavo-convex pattern 3 is filled with the water-soluble resin 4, even if the sheet material is softened in the portion of the concavo-convex pattern 3 during heat molding, the water-soluble resin 4 solidified on the back side. However, since the softening flow of the sheet material is prevented and the unevenness is retained, the uneven pattern 3 is maintained at the designed depth and shape. Therefore, if the water-soluble resin 4 located on the outer surface side of the concavo-convex pattern 3 is removed by washing after the simultaneous decorative molding, the concavo-convex pattern 3 having the shape and depth as designed is provided on the surface of the simultaneous decorative molded product. A decorative molded product can be obtained.

上記エンボス加工の方法は特に制限されないが、代表的なのは次の様な方法である。即ち図２は、エンボス加工法を例示する側面説明図であり、表面に所望の凹凸模様を形成したエンボスロール５と、通常の平滑円状の表面を有するバックアップロール６を使用し、これらエンボスロール５とバックアップロール６の間に基材シート１を導き、エンボスロール５とバックアップロール６とで基材シート１を適当な温度と圧力で加熱加圧することで、エンボスロール５の表面に設けられた凹凸を基材シート１の表面に転写する例を示している。   The embossing method is not particularly limited, but a typical method is as follows. That is, FIG. 2 is an explanatory side view illustrating an embossing method, using an embossing roll 5 having a desired uneven pattern on the surface and a backup roll 6 having a normal smooth circular surface. The base sheet 1 was guided between the backup roll 6 and the back-up roll 6, and the base sheet 1 was heated and pressed at an appropriate temperature and pressure with the emboss roll 5 and the backup roll 6. The example which transfers an unevenness | corrugation to the surface of the base material sheet 1 is shown.

エンボスロール５として一般的に用いられるのは、鋼などの金属製で外周面に任意の凹凸が彫刻されたロールである。ロール外周面に凹凸を刻設する方法としては、機械加工によって凹凸を形成する方法、マスキング材とエッチング材を用いた化学的処理法などを採用することも可能であるが、様々の凹凸パターンの形成可能性や作業効率などを考慮して工業的に有用な方法は、例えば２次元方向もしくは３次元方向に制御動される高エネルギービーム（電子ビームやレーザービームなど）照射装置を使用し、設計された制御パターンで金属ロール表面に高エネルギービームを照射し、ロール表面を加熱溶融させて所定の凹凸模様を形成する方法である。即ち、該高エネルギービームを制御動させることによってロール表面に所定の凹凸模様が彫刻され、また該ビームの強度を調整することで凹凸模様の深さ等を任意に調整することができる。該凹凸模様を形成したエンボスロールには、必要によりクロムメッキ等で表面処理したり、或は炭窒化処理などの表面硬化処理を施したりすることで耐久性を高めることも有効である。   Generally used as the embossing roll 5 is a roll made of metal such as steel and engraved with arbitrary irregularities on the outer peripheral surface. As a method for engraving irregularities on the outer peripheral surface of the roll, it is possible to adopt a method of forming irregularities by machining, a chemical treatment method using a masking material and an etching material, etc. An industrially useful method considering the possibility of formation and work efficiency is designed using, for example, a high-energy beam (electron beam, laser beam, etc.) irradiation device that is controlled in two or three dimensions. In this method, the surface of the metal roll is irradiated with a high energy beam with the controlled pattern, and the roll surface is heated and melted to form a predetermined uneven pattern. That is, a predetermined uneven pattern is engraved on the roll surface by controlling the high energy beam, and the depth of the uneven pattern can be arbitrarily adjusted by adjusting the intensity of the beam. It is also effective to enhance the durability of the embossing roll on which the uneven pattern is formed by subjecting the embossing roll to a surface treatment such as chrome plating or a surface hardening treatment such as a carbonitriding treatment.

バックアップロール６の素材も特に制限されないが、一般的なのは、鋼製ロールの表面にゴム系材料を被覆して付勢力を与えたものが好ましく使用される。ゴム系材料としては、シリコーンゴム、エチレンプロピレンゴム、クロロプレンゴム、ニトリルゴム、ブチルゴム、フッ素ゴム、ウレタンゴム等の合成ゴムや天然ゴム、半合成ゴムなどが特に制限なく使用できる。   The material of the backup roll 6 is not particularly limited, but generally, a steel roll whose surface is coated with a rubber-based material and applied with an urging force is preferably used. As the rubber material, synthetic rubber such as silicone rubber, ethylene propylene rubber, chloroprene rubber, nitrile rubber, butyl rubber, fluorine rubber, and urethane rubber, natural rubber, semi-synthetic rubber and the like can be used without particular limitation.

上記エンボス加工によって形成される凹凸３を埋める様に形成される水溶性樹脂４は、前述した如く凹凸３が形成された基材シート１を加熱成形する際に、凹凸３が熱で溶融乃至軟化して変形したり平坦化して接触感が失われるのを阻止するために設けられるもので、１）固化前の状態ではエンボス部の凹凸を埋め得る流動性を有し、２）凹凸を埋めた後は、乾燥などで固化することにより硬質化して該凹凸を表面側から支持する機能を果たし、３）加熱成形後は温水などで処理することで容易に除去し得る特性を備えたものであればよく、種類の如何は特に問わない。   The water-soluble resin 4 formed so as to fill the unevenness 3 formed by the embossing is melted or softened by heat when the base sheet 1 on which the unevenness 3 is formed as described above is thermoformed. It is provided to prevent the contact feeling from being lost due to deformation or flattening. 1) It has fluidity that can fill the unevenness of the embossed part in the state before solidification. 2) The unevenness is filled After that, it is hardened by solidifying by drying or the like and functions to support the unevenness from the surface side. 3) After heat forming, it has a characteristic that can be easily removed by processing with hot water or the like. There is no particular limitation on the type.

しかし、工業的規模での実用性を考慮して好ましい素材は、水溶性のアクリル系樹脂、ポリビニルアルコール系樹脂、ポリエステル系樹脂、ポリアミド系樹脂、ポリウレタン系樹脂などの合成樹脂や、各種澱粉やアルギン酸ソーダ、ゼラチンなどの天然水溶性高分子、或はそれらの各種変性物などが例示される。それら合成樹脂や天然高分子、或はそれらの変性物は、固化後に加湿もしくは水と接触させることで水に可溶化するものであれば、部分的に架橋構造を有するものであっても構わない。また場合によっては、前記凹凸部の内面側に水溶性の高い薄膜を形成した後、その外面側に水に難溶性の樹脂を充填し、水溶性の高い薄膜を水溶化させることで全体を凹凸のエンボス部から剥離除去できる様にすることも可能である。   However, in view of practicality on an industrial scale, preferred materials are water-soluble acrylic resins, polyvinyl alcohol resins, polyester resins, polyamide resins, polyurethane resins, and other synthetic resins, as well as various starches and alginic acids. Examples include natural water-soluble polymers such as soda and gelatin, and various modified products thereof. These synthetic resins, natural polymers, or modified products thereof may have a partially crosslinked structure as long as they are solubilized in water by humidification or contact with water after solidification. . In some cases, after forming a highly water-soluble thin film on the inner surface side of the concavo-convex portion, the outer surface side is filled with water-insoluble resin, and the water-soluble thin film is water-solubilized to make the entire surface uneven. It is also possible to peel and remove from the embossed part.

水溶性樹脂層の厚みは、エンボスの凹部を埋めることができる厚さがあればよく、エンボスの凸部には水溶性樹脂層が形成されていなくともよい。また、エンボスの凹部の深さの半分程度を埋める厚さであってもそれなりの効果が発揮される。   The water-soluble resin layer may be thick enough to fill the embossed recess, and the water-soluble resin layer may not be formed on the embossed protrusion. Even if the thickness is about half the depth of the concave portion of the emboss, a reasonable effect is exhibited.

水溶性樹脂層をエンボスの凹部だけでなく凸部にも形成する場合は、凸部の頂部から１００μｍ未満の範囲に抑えるのがよい。厚さが１００μｍを超えても、エンボス部の凹凸保持効果は飽和してそれ以上に優れた効果が発揮されるわけではなく、むしろ水溶性樹脂層の除去に時間がかかって生産性を低下させるからである。   When the water-soluble resin layer is formed not only on the embossed recesses but also on the protrusions, the water-soluble resin layer is preferably kept within a range of less than 100 μm from the top of the protrusions. Even if the thickness exceeds 100 μm, the unevenness retention effect of the embossed part is saturated and does not exhibit an even better effect. Rather, it takes time to remove the water-soluble resin layer and decreases productivity. Because.

エンボス部を構成する微細な凹凸の表面側に水溶性樹脂層を形成する方法にも格別の制限はなく、例えばディップコート、リップコート、リバースコート、スクリーン印刷、押出コート法、加熱軟化コート法など、様々のコート法を採用できるが、中でも特に好ましいのは押出コート法または加熱軟化コート法である。これらの方法は、基材シートに形成された凹凸に与えるダメージが少なく且つ厚膜に形成し易いため、凹凸の隙間を埋めるのに特に適しているからである。   There is no particular limitation on the method of forming the water-soluble resin layer on the surface side of the fine irregularities constituting the embossed part. For example, dip coating, lip coating, reverse coating, screen printing, extrusion coating method, heat softening coating method, etc. Various coating methods can be adopted, but the extrusion coating method or the heat softening coating method is particularly preferable among them. This is because these methods are particularly suitable for filling the gaps between the projections and depressions because they cause little damage to the projections and depressions formed on the base sheet and are easy to form in a thick film.

成形同時加飾用シートの製法としては、例えば次の様な手順が例示されるが、勿論下記の方法に制限されるものではない。   As a manufacturing method of the sheet | seat for shaping | molding simultaneous decorating, the following procedures are illustrated, for example, Of course, it is not restrict | limited to the following method.

（１）基材シートの片面側に加飾層を形成した後、該加飾層側にゴム製の艶ロールを配置し、加飾層形成面とは反対面側に所望のエンボスロールをセットして加熱加圧することによりエンボス加工し、次いでエンボス加工面に水溶性樹脂層を形成する方法。   (1) After a decorative layer is formed on one side of the base sheet, a glossy roll made of rubber is arranged on the decorative layer side, and a desired emboss roll is set on the side opposite to the decorative layer forming surface And embossing by heating and pressing, and then forming a water-soluble resin layer on the embossed surface.

（２）基材シートの片面側に鏡面艶ロール、その反対面側に所望のエンボスロールをセットし、加熱加圧してエンボス加工し、次いで、基材シートのエンボス加工面とは反対の面に加飾層を形成し、最後にエンボス加工面に水溶性樹脂層を形成する方法。   (2) A mirror gloss roll is set on one side of the base sheet, and a desired emboss roll is set on the opposite side, embossed by heating and pressing, and then on the opposite side of the base sheet from the embossed side. A method of forming a decorative layer and finally forming a water-soluble resin layer on the embossed surface.

（３）基材シートの片面側に鏡面艶ロールをセットし、その反対面側に所望のエンボスロールをセットして加熱加圧することによりエンボス加工し、次いで該エンボス加工面に水溶性樹脂層を形成した後、最後に、基材シートの水溶性樹脂層形成面とは反対側の面に加飾層を形成する方法。   (3) A mirror gloss roll is set on one side of the base sheet, a desired embossing roll is set on the opposite side and embossed by heating and pressing, and then a water-soluble resin layer is formed on the embossed surface. After forming, finally the method of forming a decorating layer in the surface on the opposite side to the water-soluble resin layer formation surface of a base material sheet.

次に、本発明に係る上記成形同時加飾用シートを用いた加飾成形品の製法について説明する。   Next, the manufacturing method of the decoration molded product using the said sheet | seat for simultaneous decorating based on this invention is demonstrated.

まず第1の方法は、上記成形同時加飾用シートを所定の形状に加熱成形する工程、加熱成形した該加飾用シートの不要部分を切除する工程、該加飾用シートの水溶性樹脂層を成形金型の内壁面側にして該加飾用シートを成形金型内に装入配置する工程、成形金型内に成形用樹脂を射出して成形する工程、成形金型から該加飾成形品を取り出す工程、取り出した該加飾成形品表面の水溶性樹脂層を水洗除去する工程、を順次実施する方法である。   First, the first method is a step of heat-molding the above-mentioned simultaneous decorating sheet into a predetermined shape, a step of cutting off unnecessary portions of the thermoformed decorative sheet, a water-soluble resin layer of the decorative sheet The step of inserting and arranging the decorative sheet in the molding die with the inner wall side of the molding die, the step of injecting the molding resin into the molding die and molding, the decoration from the molding die This is a method of sequentially performing a step of taking out the molded product and a step of washing and removing the water-soluble resin layer on the surface of the decorative molded product taken out.

即ち例えば図３の断面概略工程説明図に示す如く、上記の様にして得た成形同時加飾用シートＡを適当な温度に加熱し、該シートＡの加飾層２を内側（従って凹凸模様３と水溶性樹脂層４を外側）にして加熱成形用金型Ｂに押付け、加飾成形品の外形・寸法に応じた形状に成形する［図３（Ａ），（Ｂ）］。次いで、冷却してから成形シートＣを脱型した後、該成形シートＣを打抜用金型Ｄ１，Ｄ２にセットし、これら金型Ｄ１，Ｄ２に設けられたカット用の凹凸Ｅ１〜Ｅ４によって不要部分Ｃ’，Ｃ’を切除する［図３（Ｃ），（Ｄ），（Ｅ）］。 That is, for example, as shown in the schematic cross-sectional process explanatory diagram of FIG. 3, the sheet A for simultaneous decorating obtained as described above is heated to an appropriate temperature, and the decorating layer 2 of the sheet A is arranged on the inner side (therefore, the uneven pattern). 3 and the water-soluble resin layer 4 on the outside) and pressed against the heat-molding mold B to form a shape corresponding to the outer shape and dimensions of the decorative molded product [FIGS. 3A and 3B]. Then, after demolding the molded sheet C is cooled, setting the molding sheet C to punch抜用die D 1, D 2, irregularities for cutting provided on these die D 1, D 2 Unnecessary portions C ′ and C ′ are removed by E 1 to E 4 [FIGS. 3C, 3D, and 3E].

不要部の切除された成形シートＣは、次いで割型構造の同時加飾成形用金型Ｆ，Ｇの内面側に加飾層２を内空側にしてセットし、成形金型Ｇに設けられた射出口Ｇ０から成形用樹脂Ｈを注入することによって射出成形する［図３（Ｆ），（Ｇ）］。その後、樹脂Ｈが冷却固化してから脱型し、成形用樹脂Ｈの表面に成形シートＣが接合一体化した同時加飾成形中間体Ｉを得る［図３（Ｈ）］。 The molding sheet C from which unnecessary portions have been cut is then set on the molding die G with the decorative layer 2 set on the inner surface side of the molds F and G for simultaneous decoration molding with a split mold structure. injection molded by injecting a molding resin H from the injection port G 0 was [FIG 3 (F), (G) ]. Thereafter, the resin H is cooled and solidified, and then demolded to obtain a simultaneous decorative molded intermediate I in which the molded sheet C is joined and integrated on the surface of the molding resin H [FIG. 3 (H)].

この中間体Ｉは、成形シートＣにおけるエンボス加工面を構成する凹凸３の表面側に、先に説明した如く水溶性樹脂層４が形成されており、一連の加熱成形工程で該凹凸３が変形したり消失したりするのを阻止している。しかし、同時加飾成形の終了によって該水溶性樹脂層４の役割は終えているので、その後は同時加飾成形品の表面で一体化した成形シートＣの表面を、温水洗浄もしくは超音波水洗など任意の方法で水洗し、該表面に存在する水溶性樹脂層４を洗浄除去する［図３（Ｉ）］。そうすると、図３（Ｊ）に示す如くエンボス加工の凹凸３が同時加飾成形品の表面に露出し、所定の接触感を有する成形同時加飾製品Ｓを得ることができる。   In this intermediate I, the water-soluble resin layer 4 is formed on the surface side of the unevenness 3 constituting the embossed surface of the molded sheet C as described above, and the unevenness 3 is deformed in a series of heat forming steps. To prevent or disappear. However, since the role of the water-soluble resin layer 4 is finished by the end of the simultaneous decoration molding, the surface of the molded sheet C integrated on the surface of the simultaneous decoration molded product is then washed with warm water or ultrasonic water. The water-soluble resin layer 4 existing on the surface is washed and removed by an arbitrary method [FIG. 3 (I)]. Then, as shown in FIG. 3 (J), the embossed irregularities 3 are exposed on the surface of the simultaneously decorated molded product, and a molded simultaneous decorated product S having a predetermined contact feeling can be obtained.

第２の方法は、上記成形同時加飾用シートを所定の形状に加熱成形する工程、該加飾用シートの水溶性樹脂層を成形金型の内壁面側にして該加飾用シートを成形金型内に装入配置する工程、成形金型内に成形用樹脂を射出して成形する工程、成形金型から該加飾成形品を取り出す工程、該加飾成形品の表面の水溶性樹脂層を水洗除去する工程、水溶性樹脂層が水洗除去された成形同時加飾用シートの不要部分を切除する工程、を順次実施する方法である。   The second method is a step of heat-molding the above-mentioned simultaneous decorating sheet into a predetermined shape, and molding the decorative sheet with the water-soluble resin layer of the decorating sheet as the inner wall surface of the molding die The step of placing and placing in the mold, the step of injecting the molding resin into the molding die, the step of taking out the decorative molded product from the molding die, the water-soluble resin on the surface of the decorative molded product This is a method of sequentially performing the step of removing the layer with water and the step of cutting off unnecessary portions of the sheet for simultaneous decorating from which the water-soluble resin layer has been removed with water.

この方法は、例えば図４の断面概略工程説明図に示す如く、成形同時加飾用シートＡを適当な温度に加熱し、該シートＡの加飾層２を内側（従って凹凸模様３と水溶性樹脂層４を外側）にして加熱成形用金型Ｂに押付け、加飾成形品の外形・寸法に応じた形状に成形する［図４（Ａ），（Ｂ）］。次いで、冷却してから成形シートＣを脱型した後［図４（Ｃ）］、該シートＣを割型構造の同時加飾成形用金型Ｆ，Ｇの内面側に加飾層２を内空側にしてセットし、成形金型Ｇに設けられた射出口Ｇ０から成形樹脂Ｈを注入することによって射出成形する［図４（Ｄ），（Ｅ）］。その後、樹脂Ｈが冷却固化してから脱型し、成形用樹脂Ｈの表面に成形シートＣが接合一体化した同時加飾成形中間体Ｉを得る［図４（Ｆ）］。 In this method, for example, as shown in the schematic cross-sectional process diagram of FIG. 4, the sheet A for simultaneous decorating is heated to an appropriate temperature, and the decorating layer 2 of the sheet A is placed on the inner side (therefore, the uneven pattern 3 and water-soluble). The resin layer 4 is placed on the outside) and pressed against the heat-molding mold B to form a shape corresponding to the outer shape and dimensions of the decorative molded product [FIGS. 4A and 4B]. Next, after cooling, the molded sheet C is removed [FIG. 4C], and the decorative layer 2 is placed on the inner surface side of the molds F and G for simultaneous decorative molding having a split mold structure. set in the empty side, injection molded by injecting a molding resin H from the injection port G 0 provided in the molding die G [FIG. 4 (D), (E) ]. Thereafter, the resin H is cooled and solidified, and then demolded to obtain a simultaneous decorative molded intermediate I in which the molded sheet C is joined and integrated on the surface of the molding resin H [FIG. 4 (F)].

この中間体Ｉは、成形シートＣにおけるエンボス加工面を構成する凹凸３の表面側に、先に説明した如く水溶性樹脂層４が形成されており、一連の加熱成形工程で該凹凸３が変形したり消失するのを阻止している。しかし、この同時加飾成形によって該水溶性樹脂層４の役割は終えているので、その後は同時加飾成形品の表面で一体化した成形シートＣの表面を、温水洗浄もしくは超音波水洗など任意の方法で水洗し、該表面に存在する水溶性樹脂層４を洗浄除去すると［図４（Ｇ）］、エンボス加工の凹凸３が同時加飾成形品の表面に露出する［図４（Ｈ）］。   In this intermediate I, the water-soluble resin layer 4 is formed on the surface side of the unevenness 3 constituting the embossed surface of the molded sheet C as described above, and the unevenness 3 is deformed in a series of heat forming steps. To prevent or disappear. However, since the role of the water-soluble resin layer 4 is finished by this simultaneous decorative molding, the surface of the molded sheet C integrated on the surface of the simultaneous decorative molded product is then arbitrarily washed with warm water or ultrasonic water. When the water-soluble resin layer 4 existing on the surface is washed and removed by the above method [FIG. 4 (G)], the embossed irregularities 3 are exposed on the surface of the simultaneously decorated molded product [FIG. 4 (H)]. ].

次いでこれを打抜用金型Ｄにセットし、金型Ｄに設けられたカット用の刃Ｅ１，Ｅ３によって不要部分Ｃ’，Ｃ’を切除すると、所定の接触感を有する同時加飾成形品Ｓが得られる［図４（Ｉ），（Ｊ），（Ｋ）］。 Next, when this is set in the punching die D and the unnecessary portions C ′ and C ′ are cut off by the cutting blades E 1 and E 3 provided on the die D, simultaneous decoration having a predetermined contact feeling is achieved. A molded product S is obtained [FIGS. 4 (I), (J), (K)].

第３の方法は、上記成形同時加飾用シートを所定の形状に加熱成形する工程、該加飾用シートの水溶性樹脂層を成形金型の内壁面側にして該加飾用シートを成形金型内に装入配置する工程、成形金型内に成形用樹脂を射出して成形する工程、成形金型から該加飾成形品を取り出す工程、成形同時加飾用シートの不要部分を切除する工程、該加飾成形品の表面の水溶性樹脂層を水洗除去する工程、を順次実施する方法である。   The third method is a step of heat-molding the above-mentioned sheet for simultaneous decoration into a predetermined shape, and molding the sheet for decoration with the water-soluble resin layer of the sheet for decoration as the inner wall surface of the molding die The process of charging and placing in the mold, the process of injecting the molding resin into the molding mold, the process of taking out the decorative molded product from the molding mold, and the unnecessary part of the sheet for simultaneous molding are cut off And the step of washing and removing the water-soluble resin layer on the surface of the decorative molded product.

この方法は、例えば図５の断面概略工程説明図に示す如く、成形同時加飾用シートＡを適当な温度に加熱し、該シートＡの加飾層２を内側（従って凹凸模様３と水溶性樹脂層４を外側）にして加熱成形用金型Ｂに押付け、加飾成形品の外形・寸法に応じた形状に成形する［図５（Ａ），（Ｂ）］。次いで、冷却してから成形シートＣを脱型した後［図５（Ｃ）］、該シートＣを割型構造の同時加飾成形用金型Ｆ，Ｇの内面側に加飾層２を内空側にしてセットし、成形金型Ｇに設けられた射出口Ｇ０から成形樹脂Ｈを注入することによって射出成形する［図５（Ｄ），（Ｅ）］。その後、樹脂Ｈが冷却固化してから脱型し、成形用樹脂Ｈの表面に成形シートＣが接合一体化した同時加飾成形中間体Ｉを得る［図５（Ｆ）］。 In this method, for example, as shown in the schematic cross-sectional process explanatory diagram of FIG. 5, the sheet A for simultaneous decoration is heated to an appropriate temperature, and the decoration layer 2 of the sheet A is placed inside (therefore, the uneven pattern 3 and water-soluble). The resin layer 4 is placed on the outside) and is pressed against the heat molding die B to be molded into a shape corresponding to the outer shape and dimensions of the decorative molded product [FIGS. 5A and 5B]. Then, after cooling, the molded sheet C is removed [FIG. 5C], and the decorative layer 2 is placed on the inner surface side of the molds F and G for simultaneous decorative molding having a split mold structure. set in the empty side, injection molded by injecting a molding resin H from the injection port G 0 provided in the molding die G [FIG 5 (D), (E) ]. Thereafter, the resin H is cooled and solidified, and then demolded to obtain a simultaneous decorative molded intermediate I in which the molded sheet C is joined and integrated on the surface of the molding resin H [FIG. 5 (F)].

次いでこれを打抜用金型Ｄにセットし、金型Ｄに設けられたカット用の刃Ｅ１，Ｅ３によって不要部分Ｃ’，Ｃ’を切除する［図５（Ｇ），（Ｈ），（Ｉ）］。 Next, this is set in a punching die D, and unnecessary portions C ′ and C ′ are cut by cutting blades E 1 and E 3 provided in the die D [FIGS. 5G and 5H]. , (I)].

この中間体は、成形シートＣにおけるエンボス加工面を構成する凹凸３の表面側に、先に説明した如く水溶性樹脂層４が形成されており、一連の加熱成形工程で該凹凸３が変形したり消失するのを阻止している［図５（Ｉ）］。しかし、この同時加飾成形によって該水溶性樹脂層４の役割は終えているので、その後は同時加飾成形品の表面で一体化した成形シートＣの表面を、温水洗浄もしくは超音波水洗など任意の方法で水洗し、該表面に存在する水溶性樹脂層４を洗浄除去する。そうすると、図５（Ｊ）に示す如くエンボス加工の凹凸３が製品の表面に露出し、同時加飾成形品Ｓを得ることができる。   In this intermediate body, the water-soluble resin layer 4 is formed on the surface side of the unevenness 3 constituting the embossed surface of the molded sheet C as described above, and the unevenness 3 is deformed by a series of heat forming steps. Or disappearing [FIG. 5 (I)]. However, since the role of the water-soluble resin layer 4 is finished by this simultaneous decorative molding, the surface of the molded sheet C integrated on the surface of the simultaneous decorative molded product is then arbitrarily washed with warm water or ultrasonic water. The water-soluble resin layer 4 present on the surface is removed by washing with the above method. If it does so, as shown in FIG.5 (J), the unevenness | corrugation 3 of embossing will be exposed on the surface of a product, and the simultaneous decorating molded product S can be obtained.

尚、上記製法を実施する際に採用される成形法としては、射出成形法が最も一般的であるが、加飾成形品の形状などによっては圧縮成形法やブロー成形法、更には真空成形法や圧空成形法などを任意に選択して採用することができる。また、加飾用シートの不要部を切除する方法としては、図示した様な圧縮カット法のほか、押出カット法やサンドブラスト法などを採用することも可能であり、水溶性樹脂層の除去法としては、温水洗浄や超音波洗浄、流水洗浄、ジェット水洗浄などが制限なく採用できる。   Incidentally, the injection molding method is the most common molding method employed when the above manufacturing method is carried out, but depending on the shape of the decorative molded product, the compression molding method, the blow molding method, and further the vacuum molding method. Or a pressure forming method can be arbitrarily selected and employed. In addition to the compression cut method shown in the figure, it is possible to adopt an extrusion cut method, a sandblast method, etc. as a method for removing unnecessary portions of the decorative sheet. Can be used without limitation such as hot water cleaning, ultrasonic cleaning, running water cleaning, jet water cleaning.

更に本発明の成形同時加飾用シートは薄いフィルム乃至シート状であり、小サイズから中サイズ、大サイズに亘る様々のサイズの成形品の成形同時加飾用として様々の用途に幅広く活用することができ、場合によっては成形品の一部の加飾にも無理なく適用できる。   Furthermore, the sheet for simultaneous decoration of the present invention is a thin film or sheet, and can be widely used for various applications for simultaneous decoration of molded products of various sizes ranging from small size to medium size and large size. In some cases, it can be applied without difficulty to decoration of a part of a molded product.

特に本発明によれば、微細な凹凸模様からなるエンボス部が、該シートの製造工程や取扱い工程、更には成形同時加飾工程で受ける熱によって変形したり消失するのを確実に防止できるので、様々の製品のエンボス加工による接触感の向上に幅広く活用できる。   In particular, according to the present invention, the embossed portion made of a fine concavo-convex pattern can be reliably prevented from being deformed or disappeared by the heat received in the manufacturing process and handling process of the sheet, and further in the molding simultaneous decorating process. It can be widely used to improve the feeling of contact by embossing various products.

以下、実験例を挙げて本発明をより具体的に説明するが、本発明はもとより下記実験例によって制限を受けるものではなく、前・後記の趣旨に適合し得る範囲で適当に変更を加えて実施することも可能であり、それらは何れも本発明の技術的範囲に含まれる。   Hereinafter, the present invention will be described more specifically with reference to experimental examples.However, the present invention is not limited by the following experimental examples, but may be appropriately modified within a range that can meet the purpose described above and below. It is also possible to implement, and they are all included in the technical scope of the present invention.

実施例１
基材シートとして厚さ１００μｍのアクリル系熱可塑性樹脂フィルムを使用し、その片面に直径２００ｍｍの鋼製鏡面艶ロール、その反対面側に直径２００ｍｍのエンボスロールを配置してエンボス加工を行った。エンボスロールとしては、クロム鋼製ロールの表面に凹凸模様として、線幅０．０８ｍｍ（深さ１２μｍ）から線幅１．２５ｍｍ（深さ８０μｍ）までの線を含む木目導管模様（陰模様）を刻設したロールを使用し、該木目導管模様をアクリル系熱可塑性樹脂フィルムの片面に転写した。 Example 1
An acrylic thermoplastic resin film having a thickness of 100 μm was used as a base sheet, and a steel mirror gloss roll having a diameter of 200 mm was disposed on one side thereof, and an embossing roll having a diameter of 200 mm was disposed on the opposite side to perform embossing. As an embossing roll, a grained pipe pattern (shaded pattern) including a line width from 0.08 mm (depth 12 μm) to a line width 1.25 mm (depth 80 μm) as a concavo-convex pattern on the surface of a chrome steel roll. Using the engraved roll, the grain conduit pattern was transferred to one side of an acrylic thermoplastic resin film.

次いで、該フィルムのエンボス加工面とは反対側の面に、絵柄層としてアクリル樹脂系インキ（大日本インキ化学社製の商品名「ＶＧＳ」）を用いた木目模様印刷を行った。この際、接着剤としては塩化ビニル樹脂系の接着剤（昭和高分子社製の商品名「Ｋ−２」）を使用した。   Next, a wood grain pattern printing using an acrylic resin ink (trade name “VGS” manufactured by Dainippon Ink & Chemicals, Inc.) as a picture layer was performed on the surface opposite to the embossed surface of the film. At this time, a vinyl chloride resin-based adhesive (trade name “K-2” manufactured by Showa High Polymer Co., Ltd.) was used as the adhesive.

その後、エンボス加工により成形した前記木目導管模様部の表面全域に、押出成形法によって水溶性のアクリル系樹脂（大日本インキ化学社製の商品名「ＣＧ５０００」）を全面コート（押出機のダイ下温度は１７０〜１９０℃、コート厚みは８０〜１００μｍ、溶融伸長比：ダイリップ開度／コート厚みは３１、ライン速度は８０ｍ／分）した後、ドクターナイフでエンボス加工面の凸部上の樹脂を掻き取り、実質的にエンボス凹部のみに水溶性樹脂層を残し、本発明の成形同時加飾用シートを得た。   Thereafter, a water-soluble acrylic resin (trade name “CG5000”, manufactured by Dainippon Ink & Chemicals, Inc.) is coated on the entire surface of the wood grain conduit pattern formed by embossing (under the die of the extruder). The temperature is 170 to 190 ° C., the coating thickness is 80 to 100 μm, the melt elongation ratio: die lip opening / coating thickness is 31, line speed is 80 m / min), and then the resin on the convex portion of the embossed surface is applied with a doctor knife. The water-soluble resin layer was left substantially only in the embossed recess, and the sheet for simultaneous decorating of the present invention was obtained.

次に、上記で得た成形同時加飾用シートを用いて成形同時加飾品の成形を行った。即ち、まず、例えば前記図３などでも説明した様に、該加飾用シートを、真空成形により１６０℃で３秒間加熱してから真空吸引し、大気圧で所定の形状に整えてから不要部を切除する。次いでこの成形同時加飾用シートを、２分割構造の成形金型の内面側に、該加飾用シートの絵柄層をキャビティーの内空部側にして装入配置する。次いで、耐熱性アクリロニトリル・ブタジエン・スチレン樹脂（電気化学社製の商品名「マレッカ」）を成形温度２６０℃で圧入して射出成形し、室温まで冷却した後、脱型して金型から同時加飾成形品を取り出す。   Next, the molded simultaneous decorative product was molded using the molded simultaneous decorating sheet obtained above. That is, as described in FIG. 3 and the like, first, the decorative sheet is heated at 160 ° C. for 3 seconds by vacuum forming and then vacuum-sucked, adjusted to a predetermined shape at atmospheric pressure, and then an unnecessary portion. Excise. Next, this simultaneous decorating sheet is placed on the inner surface side of a two-part molding mold with the pattern layer of the decorative sheet on the inner space side of the cavity. Next, heat-resistant acrylonitrile / butadiene / styrene resin (trade name “Marekka” manufactured by Electrochemical Co., Ltd.) was injected at a molding temperature of 260 ° C., injection molded, cooled to room temperature, demolded, and simultaneously added from the mold. Take out the decorative molded product.

その後、６０℃の水を充満させた超音波洗浄機の浴槽内に上記加飾成形品を浸漬し、２５００〜３０００Ｈｚの超音波を３０秒間照射することによって、エンボス部表面の水溶性樹脂層を剥離除去し、エンボス部の前記木目導管模様を露出させた。   Thereafter, the decorative molded product is immersed in a bathtub of an ultrasonic cleaning machine filled with 60 ° C. water and irradiated with an ultrasonic wave of 2500 to 3000 Hz for 30 seconds to form a water-soluble resin layer on the surface of the embossed portion. The wood grain conduit pattern of the embossed part was exposed by peeling off.

得られた加飾成形品は、加飾層の木目模様パターンと表面の木目導管状の凹凸模様がマッチし、本杢様の優れた外観と接触感を有するものであった。   The obtained decorative molded product had a wood grain pattern pattern on the decoration layer and a surface grain-like uneven pattern on the surface, and had an excellent appearance and touch feeling of the main wall.

実施例２
基材シートとして厚さ７５μｍのアクリル系熱可塑性樹脂フィルムを使用し、その片面に、絵柄層として部分マスキングと真空蒸着を採用した部分アルミニウム蒸着層を形成した。次いで該蒸着層の背面側に、接着剤として塩化ビニル系樹脂（昭和高分子社製の商品名「Ｋ−２」）を使用し、バッカーシートとして厚さ１．０ｍｍのアクリロニトリル・ブタジエン・スチレン樹脂シート（筒中プラスチック社製の商品名「タフエースＲ」）を貼り合わせた。 Example 2
An acrylic thermoplastic resin film having a thickness of 75 μm was used as a base sheet, and a partial aluminum vapor deposition layer employing partial masking and vacuum vapor deposition as a picture layer was formed on one surface thereof. Next, a vinyl chloride resin (trade name “K-2” manufactured by Showa Polymer Co., Ltd.) is used as an adhesive on the back side of the deposited layer, and an acrylonitrile butadiene styrene resin having a thickness of 1.0 mm as a backer sheet. A sheet (trade name “Tough Ace R” manufactured by Plastic Co., Ltd.) was attached.

次いで、上記シートのバッカーシート貼り合せ面側に直径２００ｍｍのゴム製艶ロール、その反対面側には直径２００ｍｍのエンボスロールを配置してエンボス加工を行った。エンボスロールとしては、クロム鋼製ロールの表面に凹凸模様として、線幅０．０５ｍｍ（深さ１２μｍ）から線幅０．２５ｍｍ（深さ８０μｍ）までの線を含むヘアライン模様（陰模様）を刻設したロールを使用し、該ヘアライン模様を上記アクリル系熱可塑性樹脂フィルムの片面に転写した。   Next, a rubber glossy roll having a diameter of 200 mm was disposed on the backer sheet bonding surface side of the sheet, and an embossing roll having a diameter of 200 mm was disposed on the opposite surface side for embossing. As an embossing roll, a hairline pattern (shaded pattern) including a line width from 0.05 mm (depth 12 μm) to a line width 0.25 mm (depth 80 μm) is engraved on the surface of the chrome steel roll as an uneven pattern. Using the provided roll, the hairline pattern was transferred to one side of the acrylic thermoplastic resin film.

次いで、エンボス加工により成形した前記ヘアライン模様部の表面全域に、カーテンスプレー型ホットメルト添加装置（サンツール社製）を用いてポリビニルアルコール系の水溶性樹脂（電気化学社製の商品名「デンカポバール」）をスプレーした後、スパイラルコート型ホットメルト添加装置（サンルーツ社製）を用いて上記と同じポリビニルアルコール系水溶性樹脂を、付着量が約４ｇ／ｍ２となる様にコートし、本発明の成形同時加飾用シートを得た。 Next, a polyvinyl alcohol-based water-soluble resin (trade name “Denka Poval” manufactured by Electrochemical Co., Ltd.) is used on the entire surface of the hairline pattern portion formed by embossing using a curtain spray type hot melt addition device (manufactured by Suntool Co., Ltd.). ”), And then coated with the same water-soluble polyvinyl alcohol resin as above using a spiral coat type hot melt addition device (manufactured by Sun Roots Co., Ltd.) so that the adhesion amount is about 4 g / m 2. The sheet | seat for simultaneous decoration of shaping | molding was obtained.

次に、上記で得た成形同時加飾用シートを用いて成形同時加飾品の成形を行った。即ち、上記で得た成形同時加飾用シートを１２０℃で２秒間加熱し、５気圧で圧縮空気成形により加圧成形してから不要部を切除する。加圧成形された該加飾用シートを、２分割構造の成形金型の内面側に、絵柄層をキャビティーの内空部側にして装入配置した後、耐熱性アクリロニトリル・ブタジエン・スチレン樹脂（電気化学社製の商品名「マレッカ」）を成形温度２６０℃で圧入して射出成形し、樹脂が室温まで冷却した後、金型から同時加飾成形品を取り出す。   Next, the molded simultaneous decorative product was molded using the molded simultaneous decorating sheet obtained above. That is, the sheet for simultaneous decorating obtained above is heated at 120 ° C. for 2 seconds, pressure-formed by compressed air molding at 5 atm, and then unnecessary parts are cut off. After the pressure-molded decorative sheet is placed and placed on the inner surface side of a two-part mold, the pattern layer is on the inner cavity side of the cavity, heat-resistant acrylonitrile / butadiene / styrene resin (Product name “Marekka” manufactured by Electrochemical Co., Ltd.) is press-fitted at a molding temperature of 260 ° C. and injection molded. After the resin cools to room temperature, the simultaneously decorated molded product is taken out from the mold.

その後、得られた成形品のエンボス部表面を覆っているポリビニルアルコール系水溶性樹脂層を５０℃の流水で洗い流し、エンボス部の前記ヘアライン模様を露出させることによって同時加飾成形品の製造を終えた。   Thereafter, the polyvinyl alcohol-based water-soluble resin layer covering the surface of the embossed part of the obtained molded product is washed away with running water at 50 ° C., and the production of the simultaneously decorated molded product is completed by exposing the hairline pattern of the embossed part. It was.

得られた成形品は、表面にリアルなヘアライン状の接触感を有する金属調の加飾製品であった。   The obtained molded product was a metallic decorative product having a realistic hairline contact feeling on the surface.

本発明に係る成形同時加飾用シートを例示する一部断面説明図である。It is a partial cross-section explanatory drawing which illustrates the sheet | seat for shaping | molding simultaneous decoration which concerns on this invention. エンボス加工の例を示す一部断面説明図である。It is a partial cross section explanatory view showing an example of embossing. 本発明の製法を例示する断面概略工程説明図である。It is a cross-sectional schematic process explanatory drawing which illustrates the manufacturing method of this invention. 本発明の他の製法を例示する断面概略工程説明図である。It is a cross-sectional schematic process explanatory drawing which illustrates the other manufacturing method of this invention. 本発明の更に他の製法を例示する断面概略工程説明図である。It is a cross-sectional schematic process explanatory drawing which illustrates further another manufacturing method of this invention.

符号の説明Explanation of symbols

１ 基材シート
２ 加飾層
３ 凹凸（エンボス部）（模様）
４ 水溶性樹脂（層）
Ａ 成形同時加飾用シート
Ｂ 成形型
Ｃ 成形シート
Ｄ１，Ｄ２ 打抜き用型
Ｆ，Ｇ 金型
Ｈ 樹脂 DESCRIPTION OF SYMBOLS 1 Base material sheet 2 Decoration layer 3 Concavity and convexity (embossed part) (pattern)
4 Water-soluble resin (layer)
A mold decorating sheet B mold C molded sheet D 1, D 2 punching mold F, G die H resin

Claims (4)

成形同時加飾用シートを用いて加飾成形品を製造する方法であって、基材シートの片面に加飾層が形成された加熱成形可能な成形同時加飾用のシートであり、基材シートの加飾層形成面とは反対側の面がエンボス加工され、該エンボス加工面の凹部及び凸部に水溶性樹脂層が形成されており、前記基材シートの構成素材がアクリル系樹脂、ポリカーボネート系樹脂、無延伸または低延伸のポリエステル系樹脂、ポリブチレンテレフタレート系樹脂、無延伸または低延伸のポリオレフィン系樹脂、ポリウレタン樹脂、及びポリフッ化ビニル系樹脂のいずれかからなるものである成形同時加飾用シートを所定の形状に加熱成形する工程、加熱成形した該加飾用シートの不要部分を切除する工程、該加飾用シートの水溶性樹脂層を成形金型の内壁面側にして該加飾用シートを成形金型内に装入配置する工程、成形金型内に成形用樹脂を射出して成形する工程、成形金型から該加飾成形品を取り出す工程、取り出した該加飾成形品表面の水溶性樹脂層を水洗除去する工程、を順次実施することを特徴とする成形同時加飾成形品の製法。 A method of manufacturing a decorative molded article with a forming shape decorating sheet, a sheet for heat moldable mold decorating that the decorative layer on one side of the substrate sheet is formed, group The surface opposite to the decorative layer forming surface of the material sheet is embossed, and a water-soluble resin layer is formed on the concave and convex portions of the embossed surface, and the constituent material of the base sheet is an acrylic resin Simultaneous molding of polycarbonate resin, non-stretched or low-stretched polyester resin, polybutylene terephthalate-based resin, non-stretched or low-stretched polyolefin-based resin, polyurethane resin, and polyvinyl fluoride-based resin The step of heat-molding the decorative sheet into a predetermined shape, the step of cutting off unnecessary portions of the heat-decorated decorative sheet, the water-soluble resin layer of the decorative sheet as the inner wall surface of the mold The step of charging and arranging the decorative sheet in the molding die, the step of injecting the molding resin into the molding die and molding, the step of taking out the decorative molded product from the molding die, A method for producing a simultaneously molded decorative molded product, comprising sequentially performing a step of washing and removing the water-soluble resin layer on the surface of the decorative molded product. 成形同時加飾用シートを用いて加飾成形品を製造する方法であって、基材シートの片面に加飾層が形成された加熱成形可能な成形同時加飾用のシートであり、基材シートの加飾層形成面とは反対側の面がエンボス加工され、該エンボス加工面の凹部及び凸部に水溶性樹脂層が形成されており、前記基材シートの構成素材がアクリル系樹脂、ポリカーボネート系樹脂、無延伸または低延伸のポリエステル系樹脂、ポリブチレンテレフタレート系樹脂、無延伸または低延伸のポリオレフィン系樹脂、ポリウレタン樹脂、及びポリフッ化ビニル系樹脂のいずれかからなるものである成形同時加飾用シートを所定の形状に加熱成形する工程、該加飾用シートの水溶性樹脂層を成形金型の内壁面側にして該加飾用シートを成形金型内に装入配置する工程、成形金型内に成形用樹脂を射出して成形する工程、成形金型から該加飾成形品を取り出す工程、該加飾成形品の表面の水溶性樹脂層を水洗除去する工程、水溶性樹脂層が水洗除去された成形同時加飾用シートの不要部分を切除する工程、を順次実施することを特徴とする成形同時加飾成形品の製法。 A method of manufacturing a decorative molded article with a forming shape decorating sheet, a sheet for heat moldable mold decorating that the decorative layer on one side of the substrate sheet is formed, group The surface opposite to the decorative layer forming surface of the material sheet is embossed, and a water-soluble resin layer is formed on the concave and convex portions of the embossed surface, and the constituent material of the base sheet is an acrylic resin Simultaneous molding of polycarbonate resin, non-stretched or low-stretched polyester resin, polybutylene terephthalate-based resin, non-stretched or low-stretched polyolefin-based resin, polyurethane resin, and polyvinyl fluoride-based resin The step of heat-molding the decorative sheet into a predetermined shape, the step of charging and arranging the decorative sheet in the molding die with the water-soluble resin layer of the decorative sheet as the inner wall surface of the molding die A step of injecting a molding resin into a molding die, a step of removing the decorative molded product from the molding die, a step of washing and removing the water-soluble resin layer on the surface of the decorative molded product, a water-soluble resin A method for producing a molded and simultaneously decorated molded product, comprising sequentially performing a step of cutting off unnecessary portions of the molded and simultaneously decorated sheet from which the layer has been washed and removed. 成形同時加飾用シートを用いて加飾成形品を製造する方法であって、基材シートの片面に加飾層が形成された加熱成形可能な成形同時加飾用のシートであり、基材シートの加飾層形成面とは反対側の面がエンボス加工され、該エンボス加工面の凹部及び凸部に水溶性樹脂層が形成されており、前記基材シートの構成素材がアクリル系樹脂、ポリカーボネート系樹脂、無延伸または低延伸のポリエステル系樹脂、ポリブチレンテレフタレート系樹脂、無延伸または低延伸のポリオレフィン系樹脂、ポリウレタン樹脂、及びポリフッ化ビニル系樹脂のいずれかからなるものである成形同時加飾用シートを所定の形状に加熱成形する工程、該加飾用シートの水溶性樹脂層を成形金型の内壁面側にして該加飾用シートを成形金型内に装入配置する工程、成形金型内に成形用樹脂を射出して成形する工程、成形金型から該加飾成形品を取り出す工程、成形同時加飾用シートの不要部分を切除する工程、該加飾成形品の表面の水溶性樹脂層を水洗除去する工程、を順次実施することを特徴とする成形同時加飾成形品の製法。 A method of manufacturing a decorative molded article with a forming shape decorating sheet, a sheet for heat moldable mold decorating that the decorative layer on one side of the substrate sheet is formed, group The surface opposite to the decorative layer forming surface of the material sheet is embossed, and a water-soluble resin layer is formed on the concave and convex portions of the embossed surface, and the constituent material of the base sheet is an acrylic resin Simultaneous molding of polycarbonate resin, non-stretched or low-stretched polyester resin, polybutylene terephthalate-based resin, non-stretched or low-stretched polyolefin-based resin, polyurethane resin, and polyvinyl fluoride-based resin The step of heat-molding the decorative sheet into a predetermined shape, the step of charging and arranging the decorative sheet in the molding die with the water-soluble resin layer of the decorative sheet as the inner wall surface of the molding die A step of injecting and molding a molding resin into a molding die, a step of taking out the decorative molded product from the molding die, a step of cutting off unnecessary portions of the simultaneous molding decorative sheet, the surface of the decorative molded product The step of washing and removing the water-soluble resin layer is sequentially performed. 前記水溶性樹脂層が押出成形法により形成されたものである請求項１〜３のいずれか１項に記載の成形同時加飾成形品の製法。 The method for producing a simultaneously molded decorative molded product according to any one of claims 1 to 3, wherein the water-soluble resin layer is formed by an extrusion molding method.
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