WO2006121079A1 - 熱成形用シートの成形方法および成形装置 - Google Patents
熱成形用シートの成形方法および成形装置 Download PDFInfo
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- WO2006121079A1 WO2006121079A1 PCT/JP2006/309403 JP2006309403W WO2006121079A1 WO 2006121079 A1 WO2006121079 A1 WO 2006121079A1 JP 2006309403 W JP2006309403 W JP 2006309403W WO 2006121079 A1 WO2006121079 A1 WO 2006121079A1
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- Prior art keywords
- mold
- sheet
- layer
- frame
- thermoplastic resin
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Classifications
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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
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/08—Deep drawing or matched-mould forming, i.e. using mechanical means only
- B29C51/082—Deep drawing or matched-mould forming, i.e. using mechanical means only by shaping between complementary mould parts
-
- 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
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/08—Deep drawing or matched-mould forming, i.e. using mechanical means only
-
- 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
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/10—Forming by pressure difference, e.g. vacuum
-
- 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
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/14—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets
-
- 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
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/26—Component parts, details or accessories; Auxiliary operations
- B29C51/42—Heating or cooling
- B29C51/421—Heating or cooling of preforms, specially adapted for thermoforming
- B29C51/422—Heating or cooling of preforms, specially adapted for thermoforming to produce a temperature differential
- B29C51/423—Heating or cooling of preforms, specially adapted for thermoforming to produce a temperature differential through the thickness of the preform
-
- 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
- B29C2791/00—Shaping characteristics in general
- B29C2791/004—Shaping under special conditions
- B29C2791/006—Using vacuum
-
- 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
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/26—Component parts, details or accessories; Auxiliary operations
- B29C51/261—Handling means, e.g. transfer means, feeding means
- B29C51/262—Clamping means for the sheets, e.g. clamping frames
Definitions
- the present invention relates to a laminated sheet having a decorative layer, for example, an automobile-related member and a building-related member.
- the present invention relates to a molding method and a molding apparatus for a laminated sheet for molding, which is useful as a sheet that does not require an outer layer coating used for home appliances and the like, and has excellent decorative sharpness.
- the present invention relates to a molding method and a molding apparatus for a laminate sheet for molding having a metallic or printing design.
- the method of applying a complex design such as printing on the surface of the molded body cannot be handled by the coloring method or the coating method.
- thermoforming sheet is formed by a vacuum forming method in which a sheet and a mold are formed in a vacuum state after sufficiently thermoplasticizing the thermoforming sheet, or a sheet is formed into a mold by air pressure.
- a pressure forming method for forming by pressing There are a pressure forming method for forming by pressing, a press forming method (match mold forming method) for forming by sandwiching between a concave mold and a convex mold. Since the press molding method is a mechanical shaping method, the mold reproducibility is good, but the sheet is drawn into the mold during molding. As a result, wrinkles are likely to occur, and there is a problem that the molded product obtained is uneven due to non-uniform elongation of the sheet.
- the boundary between the individual molds of a plurality of male and female molds In order to prevent such excessive stretching of the thermoforming sheet, to maintain the sheet thickness and to reduce wrinkles, etc., for example, at the upper and lower point clamps, the boundary between the individual molds of a plurality of male and female molds. Then, the plasticized thermoplastic foamed resin sheet is clamped by being clamped to the minimum, and then the male and female molds are closed and molded (for example, refer to Patent Document 1), or the periphery of the resin sheet is placed on the resin sheet. The resin sheet is sandwiched between the upper and lower pressing plates at a slightly wider interval, and then the end of the resin sheet is released from the sheet clamper, the plug is lowered, and the peripheral edge of the resin sheet is slid between the upper and lower pressing plates. While pressing down the resin sheet, and then fixing the peripheral edge of the resin sheet with the upper and lower pressing plates and lowering the upper and lower pressing plates, and then performing vacuum and / or pressure forming (for example,
- thermoforming sheet is sufficiently plasticized or softened.
- the term “sufficiently plasticized or softened” as used herein specifically refers to a state after heating to the extent that the held thermoforming sheet is drawn down, and is used at least for the thermoforming sheet. The glass transition temperature of the resin plus the state after sufficient application of heat above 20 ° C.
- the above method cannot be applied to a molded sheet to which a high temperature cannot be applied.
- a sheet having a high-brightness metallic design a laminated sheet having an ink film in which metal thin film strips are dispersed in a binder resin varnish and having excellent spreadability during thermoforming is known.
- the thin metal strip ink used in the sheet loses its gloss due to high heat.
- a laminated sheet having a print-like design uses a pigment in the printed layer, fading or the like may occur due to high temperatures, and the resulting molded product may have uneven color or discoloration.
- thermoforming when molding is performed at a low temperature, for example, near the Tg of the resin used for the thermoforming sheet, the design is maintained, but thermoforming becomes difficult.
- a low temperature for example, near the Tg of the resin used for the thermoforming sheet
- thermoforming becomes difficult.
- an excessive force is applied between the partial clamp and the unclamped part, the sheet is torn, In some cases, wrinkles may enter the molded body obtained by drawing the sheet.
- the method of Patent Document 2 since the sheet is not completely held, the mold does not follow the mold and the mold reproducibility is inferior. I can't get it.
- Patent Document 1 Japanese Patent Laid-Open No. 06-226834
- Patent Document 2 Japanese Patent Laid-Open No. 10-166436
- Patent Document 3 Japanese Patent Laid-Open No. 2002-46230
- An object of the present invention is to obtain a molded body that can be molded at a low temperature that does not affect the design properties and that does not cause wrinkles.
- the present inventors have used a glass transition temperature (herein referred to as glass) of a thermoplastic resin used in a thermoforming sheet. Transition temperature is measured using dynamic viscoelasticity measurement according to JIS K7244-1 method, with a frequency of 1 ⁇ , a measurement start temperature of 0 ° C, and a temperature increase rate of 3 ° C / min.
- the temperature at which the mechanical damping force is the maximum value (hereinafter abbreviated as Tg), specifically, a part of the thermoforming sheet including the portion to be molded is the thermoplasticity.
- thermoforming sheet With respect to the glass transition temperature (Tg (A)) of the resin layer (A), after heat plasticization within the temperature range of (Tg (A)-30) ° C to (Tg (A) + 10) ° C ( In this state, the thermoforming sheet is partially plasticized but does not flow, and viscoelastically, the storage elastic modulus starts to decrease slightly from the transition region to the rubber region.
- Tg (A) glass transition temperature
- the present invention is a method for thermoforming a sheet for thermoforming, in which one or a plurality of thermoplastic resin layers (A) and a decorative layer (B) are laminated, between a pair of molds.
- thermoforming sheet A part of the thermoforming sheet, including a part to be molded, is transferred to the glass transition temperature (Tg (A)) of the thermoplastic resin layer (A) (however, the thermoforming sheet has the thermoplastic resin layer (A ) With multiple layers of thermoplastic resin layer (A), the highest glass transition temperature, with Tg (A) as the temperature) (Tg (A)-30) ° C ⁇ (Tg (A) + 10) After heat plasticization within the temperature range of ° C,
- thermoforming sheet The entire circumference of the portion to be molded of the thermoforming sheet is clamped and fixed from both sides of the thermoforming sheet using a pair of frame clamps,
- the heat plasticized part By pressing a part of one mold against one surface of the heat plasticized part, the heat plasticized part is stretched between the one mold and the frame clamp, and then The other mold is brought into contact with the heat plasticized portion from the opposite direction to the surface of the heat plasticized portion with which the one mold contacts,
- thermoforming sheet molding method in which the thermoplasticized portion is sandwiched and molded by the one mold and the other mold.
- the present invention is based on JIS K7244-1, when the dynamic viscoelasticity is measured under the measurement conditions of a frequency of 1 Hz, a measurement start temperature of 0 ° C, and a temperature increase rate of 3 ° CZ. If the temperature at which the mechanical damping shows the maximum value is the glass transition temperature (Tg),
- thermoforming sheet obtained by laminating one or more thermoplastic resin layers (A) and a decorative layer (B).
- Glass transition temperature (Tg (A)) (However, when the thermoforming sheet has a plurality of the thermoplastic resin layers (A), the highest temperature among the glass transition temperatures of the plurality of thermoplastic resin layers (A). (Tg (A) _30) ° C to (Tg (A) + 10) ° C in the temperature range of (Tg (A) _30) ° C to (Tg (A)).
- thermoforming sheet forming apparatus It is a device that molds a pair of molds in contact with both sides of the part to be molded, A frame-shaped clamp that holds and fixes the entire periphery of the portion to be molded of the thermoforming sheet is provided around each mold, and the frame-shaped clamp is relatively movable with respect to the mold.
- a thermoforming sheet forming apparatus is provided.
- the thermoforming sheet is placed in a temperature range of (Tg (A) — 30) ° C to (Tg (A) + 10) ° C of the Tg of the thermoplastic resin.
- Tg (A) — 30) ° C to (Tg (A) + 10) ° C of the Tg of the thermoplastic resin After the heat plasticization, the entire circumference of the part to be molded of the thermoforming sheet is clamped and fixed with a frame clamp. Therefore, the frame clamp is fixed with the sheet firmly fixed.
- the mold can be pressed against the thermoforming sheet inside.
- the tension of the thermoforming sheet immediately before molding can be optimized (uniformity), and wrinkles are generated by drawing the sheet into a pair of molds, and the design properties are unevenly spread. Can be suppressed.
- the temperature during molding can be controlled by appropriately selecting the Tg of the thermoplastic resin used for the thermoforming sheet, it is possible to set the molding temperature according to the heat resistance of the pigment and ink used in the decorative layer. it can . Since the frame-shaped clamp is movable, the tension of the sheet can be optimized by sandwiching and fixing the thermoforming sheet by the frame-shaped clamp after heat plasticization.
- the apparatus of the present invention can be molded at a low temperature, it is possible to obtain a molded product having a good design.
- FIG. 1A is a schematic cross-sectional view illustrating a forming method A of a first embodiment of the forming method of the present invention, and shows a state in which a sheet is clamped and fixed by a frame-shaped clamp.
- FIG. 1B is a schematic cross-sectional view for explaining molding method A of the first embodiment of the molding method of the present invention, showing a state in which the sandwiched and fixed sheet is brought into contact with one mold.
- FIG. 1C is a schematic cross-sectional view for explaining molding method A of the first embodiment of the molding method of the present invention, and shows a state in which the clamped and fixed sheet is clamped by both molds.
- FIG. 2A is a schematic cross-sectional view illustrating a forming method B of the first embodiment of the forming method of the present invention, and shows a state in which the sheet is clamped and fixed by a frame-shaped clamp.
- FIG. 2B is a schematic cross-sectional view for explaining molding method B of the first embodiment of the molding method of the present invention, showing a state in which the sandwiched sheet is brought into contact with one mold.
- FIG. 2C is a schematic cross-sectional view illustrating the forming method B of the first embodiment of the forming method of the present invention, and shows a state where the sandwiched and fixed sheet is clamped by both molds.
- FIG. 3A is a schematic cross-sectional view for explaining a second embodiment of the forming method of the present invention, showing a state in which the sheet is clamped and fixed by a frame clamp.
- FIG. 3B is a schematic cross-sectional view for explaining a second embodiment of the molding method of the present invention, showing a state in which the sandwiched and fixed sheet is brought into contact with one mold.
- FIG. 3C is a schematic cross-sectional view for explaining a second embodiment of the molding method of the present invention, and shows a state in which the sandwiched and fixed sheet is clamped with both molds.
- FIG. 4A is a perspective view showing an example of a convex mold provided with a frame clamp, and shows a state in which the frame clamp is lowered with respect to the mold.
- FIG. 4B is a perspective view showing an example of a convex mold provided with a frame clamp, showing a state in which the frame clamp is raised with respect to the mold.
- FIG. 5A is a perspective view showing an example of a concave mold provided with a frame clamp, and shows a state in which the frame clamp is lowered with respect to the mold.
- FIG. 5B is a perspective view showing an example of a concave mold provided with a frame clamp, and shows a state in which the frame clamp is raised with respect to the mold.
- FIG. 6A is a perspective view showing another example of a concave mold provided with a frame-shaped clamp, and shows a state in which the frame-shaped clamp (shown partially cut away) is lowered with respect to the mold.
- FIG. 6B is a perspective view showing another example of a concave mold provided with a frame-shaped clamp, showing a state where the frame-shaped clamp is raised with respect to the mold.
- FIG. 7 is a schematic view showing an example of a case where the frame-shaped clamp has a concave portion and a convex portion to be fitted to each other in the molding apparatus of the first embodiment.
- FIG. 8 is a schematic view showing an example of a case where the frame-shaped clamp has a concave portion and a convex portion to be fitted to each other in the molding apparatus of the second embodiment.
- FIG. 9 is a schematic view showing another example of the case where the frame-shaped clamp has a concave portion and a convex portion to be fitted to each other in the molding apparatus of the second embodiment.
- FIG. 1 and 2 are schematic cross-sectional views illustrating a first embodiment of the molding method and molding apparatus of the present invention. Although the molding method is different between Fig. 1 and Fig. 2, the same molding equipment is used.
- reference numeral 1 represents a thermoforming sheet.
- the molding apparatus used in the present invention includes a convex mold 10 and a concave mold 20 as one match mold molding mold, fixing plates 13 and 23 to which the respective molds 10 and 20 are fixed, and a thermoforming mold.
- a pair of frame clamps 14 and 24 that clamp (clamp) the entire periphery of the part 2 of the sheet 1 to be molded from both sides, and a cylinder 16 as a driving means for driving the frame clamp against the mold 16 , 26 As shown in FIG.
- the convex mold 10 includes a convex main body 11 that contacts the thermoforming sheet 1 and forms the shape on the concave side of the molded body, and a box 12 that accommodates the convex main body 11.
- a block 12a (see FIG. 1 and FIG. 2) is inserted between the back surface of the convex body 1 1 and the bottom surface of the box 12 to hold the gap, and the box 12 is fixed to the fixing plate 13.
- the convex body 11 has a horizontal surface 11a provided on the outer periphery, a top surface 11c provided in the center of the convex body 11, and a slope l ib connecting the horizontal surface 11a and the top surface 11c.
- the convex mold 10 is provided with a flow path (not shown) for a medium such as water or oil in order to adjust the temperature of the mold, and can be connected to a mold temperature controller.
- a flow path for a medium such as water or oil in order to adjust the temperature of the mold
- the method for adjusting the temperature of the mold is not particularly limited, and other methods may be used.
- a blow hole or a vacuum hole may be provided at the joint between the horizontal surface 11a of the convex mold 10 and the inclined surface ib.
- These holes are preferably as small as possible so that no traces remain on the molded body.
- the diameter of the hole is preferably in the range of 0.3 to: 2 mm, and more preferably in the range of 0.3 to 0.6 mm.
- a frame-shaped clamp 14 is provided around the convex mold 10.
- a pair of overhanging portions 14a project outward from both sides of the frame-shaped clamp 14, and the tip of a drive shaft (rod) 16a of the cylinder 16 is fixed to the overhanging portion 14a.
- the frame clamp 14 is configured to be movable relative to the convex mold 10.
- FIG. 4A shows a state in which the frame clamp 14 is lowered with respect to the convex mold 10
- FIG. 4B shows a state in which the frame clamp 14 is raised with respect to the convex mold 10.
- a cylinder 16 that drives the frame clamp 14 is fixed to a fixed plate 13 that is common to the box 12 of the convex shape 10. For this reason, by driving the fixing plate 13 with a driving means (not shown), both the convex mold 10 and the frame clamp 14 can be simultaneously approached and moved away from the thermoforming sheet 1.
- the concave mold 20 includes a concave body 21 that contacts the thermoforming sheet 1 to form the shape of the convex side of the molded body, and a box 22 that houses the concave body 21.
- a block 22a (see FIG. 1 and FIG. 2) is inserted between the back surface of the concave body 2 1 and the bottom surface of the box 22 to hold the gap.
- the box 22 is fixed to the fixing plate 23. Yes.
- the concave body 21 includes a horizontal surface 21a provided at the outer periphery and a bottom surface 21c provided at the center of the concave body 21. And a slope 21b connecting between the horizontal surface 21a and the bottom surface 21c.
- This concave mold 20 has a flow path (not shown) for a medium such as water or oil in order to adjust the temperature of the mold, and can be connected to the mold temperature controller.
- the method for adjusting the temperature of the mold is not particularly limited, and other methods may be used.
- an air vent hole or a vacuum hole may be provided at the joint between the inclined surface 21b and the bottom surface 21c of the concave mold 20.
- These holes are preferably as small as possible so that no traces remain on the molded body.
- the diameter of the hole is preferably within a range of 0.3 to 1.2 mm, and more preferably within a range of 0.3 to 0.6 mm.
- a frame-shaped clamp 24 is provided around the concave mold 20.
- a pair of overhanging portions 24a project outward from both sides of the frame-shaped clamp 24, and the tip of a drive shaft (rod) 26a of the cylinder 26 is fixed to the overhanging portion 24a.
- the frame clamp 24 is configured to be movable relative to the concave mold 20.
- 5A shows a state in which the frame-shaped clamp 24 is lowered with respect to the concave mold 20
- FIG. 5B shows a state in which the frame-shaped clamp 24 is raised with respect to the concave mold 20.
- the cylinder 26 that drives the frame clamp 24 is fixed to a fixed plate 23 that is common to the box 22 of the concave mold 20. For this reason, by driving the fixing plate 23 by a driving means (not shown), both the concave mold 20 and the frame-shaped clamp 24 can be simultaneously approached and moved away from the thermoforming sheet 1.
- the surface shape of the convex mold 10 and the surface shape of the concave mold 20 are the same.
- the clearance between the molds when the convex mold 10 and the concave mold 20 are combined needs to be adjusted appropriately in consideration of the thickness of the thermoforming sheet 1 to be used and the unfolding rate during thermoforming.
- the clearance between the convex mold 10 and the concave mold 20 is preferably within a range of 50% to + 30% with respect to the thickness distribution of the actually obtained three-dimensional molded body. , _30 ⁇ + 10. Good design, within the range of / o.
- the clearance between the molds is too large, the sheet cannot be sandwiched between the two molds during thermoforming, resulting in poor mold reproducibility of the molded body and increased deformation due to uneven cooling. . Conversely, if the clearance is too small, compression marks and vacuum hole marks tend to remain on the molded body.
- the clearance is appropriately set. By making it off, the change in the design property at the time of molding becomes small, and it becomes easy to obtain a molded product having the desired design property.
- the specific shapes and dimensions of the molds 10 and 20 can be appropriately designed depending on the shape and dimensions of the molded body, and depend on the thermoformability of the thermoforming sheet 1.
- the R value of the corner of the mold is 0.2 mm or more
- the expansion rate is within 500%
- the maximum The drawing ratio is preferably 1.5 or less and the maximum inclination angle is within 87 °. More preferably, the R value of the corner portion is 0.5 mm or more, the development rate is 350% or less, the maximum aperture ratio is 1.0 or less, and the maximum inclination angle is 85 ° or less.
- the present invention is a problem peculiar to match molding by using a movable frame clamp 14, 24 in addition to the convex mold 10 and the concave mold 20 for molding the thermoforming sheet 1. It is possible to effectively suppress the generation of certain forming flaws (this is caused by drawing the sheet into the mold). In addition, it is possible to suppress the generation of molding flaws due to sheet slack during low-temperature molding.
- thermoforming sheet 1 Since the movable frame clamps 14, 24 are movable, the sheet 1 can be clamped and fixed after heating, so that the thermoforming sheet 1 can be strongly fixed. It is possible to remarkably suppress molding flaws caused by the sheet 1 being pulled into the sheet. In general-purpose continuous molding machines, there are few cases where a frame clamp is used as a method for fixing a sheet during heating, and even when a frame clamp is used, the sheet is clamped to clamp the sheet before heating. The power was insufficient. In addition, the thermoforming sheet 1 generally has a problem that the sheet is loosened due to thermal expansion below the glass transition temperature of the thermoplastic resin layer (A), and molding wrinkles are generated due to this loosening.
- the heated thermoforming sheet 1 is pressed against the convex mold 10 or the concave mold 20 while being held by the frame clamps 14 and 24. It is possible to remove wrinkles before molding (before fitting the concave mold 20 and the convex mold 10).
- the sheet 1 can be fixed after heating, and A shape that does not collide with the convex mold 10 and the concave mold 20 when moving is preferable.
- the distance between the movable frame clamps 14 and 24 and the boxes 12 and 22 is not limited because it depends on the properties and thickness of the sheet. Since the previous wrinkles can be effectively suppressed, it is preferably within the range of 20 mm or less larger than the sheet thickness.
- the frame clamps 14 and 24 are provided on the surfaces of the sheet fixing portions 15 and 25 for sandwiching and fixing the thermoforming sheet 1, for example, as shown in FIG. It is preferable to have a combination of As a result, when the thermoforming sheet 1 is clamped and fixed between the frame clamps 14 and 24, the protrusion 31 protruding from one frame clamp is replaced by the recess formed in the other frame clamp.
- the thermoforming sheet 1 can be fixed more strongly by being fitted into the 32.
- the convex side frame clamp 14 may be provided with the convex portion 31 and the concave side frame clamp 24 may be provided with the concave portion 32.
- a concave portion 32 may be provided on 14 and a convex portion 31 may be provided on the concave side frame clamp 24, or these may be used in combination.
- the shape of the convex portion 31 and the concave portion 32 is not particularly limited.
- various shapes such as a pin shape, a rib shape, a sawtooth shape, a mountain shape, a triangular shape, and a column shape can be adopted.
- As the recess 32 various shapes such as a groove, a hole having a bottom, and a through hole can be adopted.
- a form in which the thermoforming sheet 1 is sandwiched between the convex part 31 and the concave part 32 may be used, or a form in which a hole is made by breaking through the thermoforming sheet 1 may be used.
- the movable direction of the frame clamps 14 and 24 is not particularly limited, but the vertical direction perpendicular to the horizontal planes 1 la and 21 a of the molds 10 and 20 is that the tension of the sheet 1 is the mold. This is preferable because it can be adjusted by the pressure to be brought into contact with the steel sheet, and molding wrinkles can be effectively suppressed and cost is advantageous.
- the power for moving the frame clamps 14, 24 is not particularly limited, but is preferably a pneumatic cylinder (hereinafter referred to as an air cylinder) because the method using the cylinders 16 and 26 using pneumatic pressure or hydraulic pressure is simple. Cylinder) is preferred because the execution speed is faster.
- a pneumatic cylinder hereinafter referred to as an air cylinder
- Cylinder is preferred because the execution speed is faster.
- it is preferable to use two or more cylinders because the clamping force of the sheet becomes uniform. Use of four or more cylinders is more preferable.
- the clamping force to fix the forming sheet using the frame clamps 14, 24 is the thermoforming sheet. 5kgf ⁇ about 50N ⁇ or more is preferred because it can suppress defects due to sheet pulling into the mold when forming a match mold. Les.
- the clamping stress is preferably 0.05 kgf / cm 2 ⁇ about 5 kPa ⁇ or more.
- the materials of the molds 10 and 20 and the movable frame clamps 14 and 24 of the present invention are not particularly limited, and various metals that are conventionally used in molds for match molding can be used. Specific examples include aluminum-based steel materials, iron-based steel materials, thermosetting resins, and the like. In particular, a hard aluminum steel material is preferable as a mold material. If necessary, surface treatment such as polishing treatment, fluorine resin treatment, alumite treatment, nitriding treatment, boride treatment, and plating treatment may be performed.
- the match mold molding die and molding method according to the present invention can be used in various molding machines equipped with a sheet heating device, a lower mold movable device, and an upper mold movable device, but from the viewpoint of operability, Vacuum forming machine (with plug mechanism) or vacuum / pneumatic forming machine is preferred.
- Vacuum forming machine with plug mechanism
- vacuum / pneumatic forming machine is preferred.
- the sheet heating apparatus an indirect heating method from one or both sides of the sheet is preferable because no trace of the heating apparatus remains on the sheet surface.
- at least one of the lower mold movable device and the upper mold movable device is provided with a vacuum mechanism because various molding methods are possible.
- one of the movable devices having a vacuum mechanism may be provided with a pneumatic mechanism.
- the driving method of the lower mold movable device and the upper mold movable device is not particularly limited, and an air cylinder type, a hydraulic cylinder type, a servo motor type, or the like can be used.
- the mold closure of the lower mold and upper mold depends on the properties of the thermoforming sheet 1 and the shape of the mold, but usually requires 10 kgf ⁇ about 100 N ⁇ or more, resulting in good mold reproducibility. More preferably, the force is lOOkgf or more ⁇ about 11 ⁇ or more ⁇ .
- the mold closing stress is preferably 0.05 kgf / cm 2 ⁇ about 5 kPa ⁇ or more.
- the mold closing force mentioned here indicates the maximum compressive force when fitting the concave mold and the convex mold. Specifically, the thrust is obtained by subtracting the larger maximum thrust of the concave and convex movable frame clamps from the smaller maximum thrust of the lower mold movable device and the upper mold movable device.
- the sheet clamp is adjusted by adjusting the thrust of the lower mold movable apparatus, the upper mold movable apparatus, the concave movable frame clamp, and the convex movable frame clamp.
- the lamp force, molding speed, and mold closing can be freely selected. For example, if the thrust of the movable frame clamp is increased, the sheet clamping force is increased and the molding speed is slowed. Conversely, if the thrust of the movable frame clamp is decreased, the sheet clamp is decreased.
- the mold closing force increases as the molding speed decreases as the force decreases.
- thermoforming sheet 1 (2) Fix the thermoforming sheet 1 with the clamp (not shown) attached to the molding machine.
- the predetermined temperature here is preferably a temperature at which the designability of the thermoforming sheet to be used is maintained.
- the thermoforming sheet to be used has at least the thermoplastic resin layer (A) and the decorative layer. (B), and when the glass transition temperature of the thermoplastic resin layer (A) is represented by (Tg (A)), (Tg (A) -30) ° C to (Tg ( A) + 10) It is preferable to be within the temperature range of ° C.
- the heating part of the sheet is at least a force that is a part to be molded. In general, it is preferable that the sheet is uniformly heated to the frame-shaped clamp part.
- the cylinders 16 and 26 are moved up and down manually or by adjusting the height of the frame clamps 14 and 24 by operating the solenoid valve. Contact with the heater can be avoided.
- the sheet 1 may be retracted from between the molds 10 and 20 and moved to the position of a heater (not shown) installed outside the molding machine. In this case, instead of the above step (4), the sheet 1 is moved from the outside of the molding machine to a position between the dies 10 and 20. In (8), if the release speed between the molded product and the convex mold is inferior due to the operation of the cylinder 16, the cylinder 16 is opened manually or by solenoid valve operation. Good if you lower the concave mold.
- convex mold 10 on the upper side of the sheet 1 and the concave mold 20 on the lower side of the sheet 1.
- steps (5) and (6) convex mold 10 is lowered and concave mold 20 is raised, and in procedure (8), convex mold 10 is raised and concave mold 20 is lowered.
- step (6) by selecting the shape of the movable frame clamps 14, 24 and adjusting the thrust
- the following two molding methods A and B can be selected. Any of the molding methods can be applied, and it is desirable to select a more appropriate method in consideration of the mold design and sheet configuration.
- thermoforming sheet 1 As shown in Fig. 1A, after the thermoforming sheet 1 is clamped and fixed from both sides by frame clamps 14, 24, the downward thrust of the concave side frame clamp 24 is reduced to the convex side frame shape as shown in Fig. 1B.
- the thermoforming sheet 1 fixed by the movable frame clamps 14, 24 after heating is pressed against the concave mold 20 first. That is, the horizontal surface 21a of the concave mold 20 is pressed against the center portion of the thermoforming sheet 1, and the portion 2 of the thermoforming sheet 1 to be molded is protruded toward the convex mold 10 side.
- thermoforming sheet 1 a step is generated between the portion of the concave mold 20 in contact with the horizontal surface 21a and the portion clamped and fixed by the frame-shaped clamps 14 and 24, thereby extending the ridges of the sheet 1. Can do. After that, as shown in Figure 1C Then, the sheet 1 is sandwiched between the convex mold 10 and the concave mold 20 to form a three-dimensional shape.
- the height difference between the horizontal surface 21a of the concave mold 20 and the surface 25 on which the concave side frame clamp 24 clamps and fixes the sheet 1 depends on the characteristics of the thermoforming sheet 1 and the mold shape. Although it is not limited, it is preferably in the range of 2 to 30 mm, because it can effectively eliminate sheet slack during low temperature molding.
- the sign of the height difference is positive when the horizontal surface 21a of the concave mold 20 protrudes from the clamp surface 25 of the concave frame clamp 24 toward the convex mold 10 side.
- the decorative sheet having the decorative layer it is easy to obtain a molded article with good decorative sharpness by directing the design surface where the decorative layer becomes visible toward the concave mold 20 side.
- the pattern itself is not easily aligned and the uneven thickness during molding is less likely to occur. The non-uniform deformation is also reduced.
- thermoforming sheet 1 is clamped and fixed from both sides by frame-shaped clamps 14, 24, the downward thrust of concave-side frame-shaped clamp 24 is reduced to a convex-side frame shape as shown in Fig. 2B.
- the thermoforming sheet 1 fixed by the movable frame clamps 14, 24 after heating is pressed against the convex mold 10 first. That is, the top surface 11c of the convex mold 10 is pressed against the center portion of the thermoforming sheet 1, and the portion 2 of the thermoforming sheet 1 to be molded is protruded toward the concave mold 20 side.
- thermoforming sheet 1 has a step 2b between the portion 2a that is in contact with the top surface 11c of the convex mold 10 and the portion that is sandwiched and fixed by the frame clamps 14 and 24. You can stretch your heels. After that, as shown in FIG. 2C, the sheet 1 is sandwiched between the convex mold 10 and the concave mold 20 and formed into a three-dimensional shape.
- the difference in height between the horizontal surface 11a of the convex mold 10 and the surface 15 on which the convex side frame-shaped clamp 14 clamps and fixes the sheet 1 indicates the property of the thermoforming sheet 1 and the mold shape. Although it is not particularly limited, it is possible to effectively remove sheet slack during low-temperature molding, and the power is also preferably in the range of -30 to 15 mm. Note that the height difference sign indicates that the horizontal surface 11a of the convex mold 10 protrudes from the clamp surface 15 of the convex frame clamp 14 to the concave mold 20 side. Is positive, and negative when the horizontal surface 11a is lower than the clamping surface 15. In the example shown in FIG.
- the horizontal surface 11a of the convex mold 10 and the clamp surface 15 of the convex side frame clamp 14 are substantially on the same plane, and the height difference is approximately 0 mm.
- the height difference between the convex side frame clamp 14 and the surface 15 holding and fixing the sheet 1 is less than 0 mm, and the vacuum hole force provided in the convex mold is vacuumed, so that the mold reproducibility is improved. It may be even better.
- the sheet 1 can be stretched between the top surface 11c of the convex mold 10 and the frame-shaped clamps 14, 24 without contacting the slope l ib or the horizontal surface 11a of the convex mold 10.
- a sheet having a larger area can be allocated to the slope portion of the molded body (the portion formed by the inclined surfaces ib and 21b of the molds 10 and 20). Therefore, it is easy to obtain a molded article with good mold reproducibility when using a mold having a part with a high development rate or a part with a large gradient.
- FIG. 3 is a schematic cross-sectional view for explaining a second embodiment of the molding method of the present invention.
- FIG. 6 is a perspective view showing a concave mold provided with a frame-like clamp used in FIG.
- the convex mold 10 and the convex side frame clamp 14 can be the same as those in the first embodiment.
- the concave side frame clamp 24 has a flange portion 27 extending to the inner peripheral edge of the frame clamp 24, and the flange portion 27 is formed inside the convex side frame clamp 14.
- the concave mold 20A a mold in which the height of the horizontal surface 21a of the concave mold body 21 exceeds the thickness of the flange portion 27 and protrudes from the edge of the box 22 is used.
- the box 22 of the concave body 20 in FIG. 6 can be configured simply by adding the plate 22b.
- the frame-shaped clamps 14 and 24 in the present embodiment are provided on the surfaces of the sheet fixing portions 15 and 25 that sandwich and fix the thermoforming sheet 1 in the same manner as described in the molding apparatus of the first embodiment. It is preferable to have a combination of the convex portion 31 and the concave portion 32 (see FIGS. 8 and 9) that fit together. As a result, when the thermoforming sheet 1 is clamped and fixed between the frame clamps 14, 24, one frame The thermoforming sheet 1 can be more strongly fixed by fitting the convex portion 31 projecting from the clamp into the concave portion 32 recessed from the other frame clamp.
- the convex part 31 may be provided with the convex part 31 and the concave part frame 24 may be provided with the concave part 32.
- the concave portion 32 may be provided on the concave side, and the convex portion 31 may be provided on the concave side frame-shaped clamp 24, or these may be used in combination.
- the sheet 1 can be formed by the same method as the above-described forming method B (the convex mold is first pressed against the sheet). That is, as shown in FIG. 3A, after thermoforming sheet 1 is sandwiched and fixed from both sides by frame clamps 14 and 24, the clamp pressure of concave side frame clamp 24 is raised as shown in FIG. 3B.
- the thermoforming sheet 1 fixed by the movable frame clamps 14, 24 after heating is pressed against the convex mold 10 first. That is, the top surface 11c of the convex mold 10 is pressed against the center of the thermoforming sheet 1, and the portion 2 of the thermoforming sheet 1 to be molded is protruded toward the concave mold 20A.
- thermoforming sheet 1 is stepped by creating a step between the portion 2a in contact with the top surface 11c of the convex mold 10 and the portion 2b sandwiched and fixed by the frame clamps 14, 24. Can be stretched. After that, as shown in FIG. 3C, the sheet 1 is sandwiched between the convex mold 10 and the concave mold 20A and formed into a three-dimensional shape. Further, in the stage of FIG.
- thermoforming sheet 1 fixed by the movable frame clamps 14 and 24 after being heated is pressed against the convex mold 10 first, the inner peripheral edge of the concave side frame clamp 24
- the thermoforming sheet 1 is clamped and clamped between the flange portion 27 and the outer peripheral edge portion 17 of the convex mold 10 (here, the edge of the box 12), and the hem portion of the convex mold 10 (horizontal plane)
- the heat-plasticized portion of the thermoforming sheet 1 is vacuum-sucked from the convex mold 10 side through the vacuum hole 18 (see FIG. 3B) provided in the joint portion of 11a and the inclined surface ib).
- the vacuum on the convex side can be used effectively, it is easy to obtain a molded body with better mold reproducibility.
- the distance between the convex part of the convex mold 10 and the flange part 27 (horizontal direction in FIG. 3B) can suppress wrinkles and improve mold reproducibility. Is preferred.
- the shape of the flange 27 does not need to be uniform between the convex part of the convex mold 10 and the flange part 27.
- the distance between the parts with a high unfolding rate is intentionally increased or a bridging failure occurs. If the interval between the easy parts is intentionally shortened, the design retainability and mold reproducibility can be further improved.
- thermoforming temperature is preferably 10 ° C or more lower than the vacuum forming temperature of the sheet (the optimum temperature when forming the sheet by vacuum forming).
- the sheet having design properties is a thermoforming sheet having at least a thermoplastic resin layer (A) and a decorative layer (B)
- the glass transition temperature (Tg) of the thermoplastic resin layer (A) If (A)) is molded within the temperature range where (Tg (A) _ 30) ° C is the lower limit and (Tg (A) + 10) ° C is the upper limit, the design properties are not affected.
- Tg (A) _ 30) ° C is the lower limit
- Tg (A) + 10) ° C is the upper limit
- the design properties are not affected.
- a decorative sheet a molded article having a high brightness can be obtained, and in the case of a printed decorative sheet using a pigment, a molded article having no color unevenness or discoloration can be obtained.
- the glass transition temperature (hereinafter referred to as Tg) referred to here is a film-like shape measured by dynamic viscoelasticity measurement (hereinafter referred to as DMA) measured according to JIS K7244-1 method.
- DMA dynamic viscoelasticity measurement
- tan ⁇ mechanical attenuation measured under the measurement conditions with a frequency of 1 ⁇ ⁇ , a measurement start temperature of 0 ° C, and a heating rate of 3 ° C / min shows a maximum value. It is the temperature at the time (referred to as peak temperature).
- thermoforming sheet has a plurality of thermoplastic resin layers ( ⁇ ⁇ ⁇ )
- the highest temperature among the Tg's of the plurality of thermoplastic resin layers ( ⁇ ⁇ ⁇ ) is defined as Tg (A).
- at least one of the plural thermoplastic resin film layers (A) must be a resin layer having Tg. Therefore, when there is a layer in which tan ⁇ does not show the maximum value among the plural thermoplastic resin layers (A) (crystalline resin such as cocoon), Tg of the layer having Tg is used as the reference of the above temperature range.
- the thermoforming temperature is more preferably set such that (Tg (A) — 25) ° C is the lower limit and (Tg (A) + 5) ° C is the upper limit.
- the heater temperature is 200 to 500 ° C
- the indirect heating time is 5 to 30 seconds
- the temperature at which the sheet can be mold-molded for example, It is preferable to set the temperature so that the storage elastic modulus ( ⁇ ′) of DMA is 10 to 500 MPa.
- the molding temperature of the thermoplastic resin sheet is the temperature at which the storage elastic modulus ( ⁇ ') of DMA is 50 MPa or less in the case of vacuum molding, which is a force depending on the viscoelasticity of the thermoplastic resin and the shape of the molded body. In the case of compressed air molding, the temperature at which the storage elastic modulus ( ⁇ ') of DMA is 250 MPa or less.
- the degree is a standard, and molding is considered difficult below that.
- thermoforming sheet molding method of the present invention can be molded at a temperature at which the storage elastic modulus is 500 MPa or less.
- the thermoforming sheet is formed from the thermoplastic resin layer. Molding is possible by heating to (Tg (A) _ 30) ° C or higher with respect to (Tg (A)) in (A).
- thermoforming when a thermoplastic resin sheet is heated, it often goes through the following processes: primary expansion, thermal contraction, and secondary expansion (draw down).
- general-purpose thermoforming methods such as vacuum forming, the mold is formed in the temperature range from heat shrinkage to secondary expansion, but the molding method of the present invention is to form in the temperature range of primary expansion heat shrinkage. This makes it possible to mold at low temperatures that do not affect the design.
- the bag that is one of the problems of the present invention is different from the bag that is solved and solved in Patent Documents 1 and 2. That is, the occurrence of wrinkles at the time of molding solved in Patent Document 1 and Patent Document 2 described above is caused by sheet slack due to secondary expansion, but wrinkles solved in the present invention are sheet slack due to primary expansion. This is caused by the fact that a sheet that is difficult to stretch due to a relatively low temperature is drawn into the mold, and cannot be solved by a known method such as the above method.
- the mold temperature is not particularly limited because it depends on the properties of the thermoforming sheet 1, and may be appropriately adjusted depending on the appearance, mold reproducibility, molding shrinkage, and deformation of the resulting molded body.
- the mold temperature on the side in contact with the layer is set within the range of (Tg_50) ° C to (Tg_10) ° C. Therefore, a temperature gradient may be provided between the other mold that is preferable because the mold reproducibility becomes good.
- thermoplastic resin layer (A) the side of the design surface where the decoration layer (B) is visible
- the orientation of the metal thin film strips of the decoration layer is aligned. Since it is easy to maintain with a mold, it is easy to obtain a molded article with good decorative sharpness.
- thermoplastic resin layers (A) which will be described later, a transparent or translucent thermoplastic resin layer (A-1), a decorative layer (B), and a thermoplastic resin layer (A -2) is a laminated sheet laminated in this order, the deformation of the decorative layer (B) becomes mild when it is deformed from the thermoplastic resin layer (A-2) side that is the supporting substrate. It is considered that the designability retention effect is high. On the other hand, from the viewpoint of mold reproducibility, it may be better to deform from the side of the thermoplastic resin layer having Tg (AM), that is, the one that is difficult to deform.
- Tg A
- the thermoforming sheet may be a single-layer sheet made of resin or the like, or a laminated sheet formed by laminating a plurality of layers, but it is a decorative sheet having a design.
- the effect of the present invention can be exhibited most preferably.
- the colorant that constitutes the decorative layer that imparts design properties.
- the molding method of the present invention it is possible to use a heat-sensitive colorant.
- the heat-sensitive colorant include metal vapor deposition films, metal inks using metal flakes and metal particles, inorganic pigments such as iron oxide, organic pigments such as azo series, and oil-soluble dyes.
- the decorative layer (B) is obtained by spreading ink or paint on the thermoplastic resin layer (A) by a conventional method.
- the metal thin film may be formed by a vacuum deposition method, a sputtering method or a plating method.
- thermoplastic resin layers (A) described later there are a plurality of thermoplastic resin layers (A) described later, a transparent or translucent thermoplastic resin layer (A-1), a decorative layer (B), and a thermoplastic resin layer (A
- a method of spreading on a transparent or translucent thermoplastic resin layer (A-1) is preferable from the viewpoint of design.
- thermoplastic resin film layer As a method for spreading ink or paint on the thermoplastic resin film layer, for example, Printing methods such as ravia printing, flexographic printing, screen printing, gravure coater, gravure reno coater, flexo coater, blanket coater, ronor coater knife coater, air knife coater, kista cot coater, kistatsu chirinoku kusu coater, comma coater, comma The ability to apply a coating method such as reverse coater or micro gravure coater can be achieved.
- Printing methods such as ravia printing, flexographic printing, screen printing, gravure coater, gravure reno coater, flexo coater, blanket coater, ronor coater knife coater, air knife coater, kista cot coater, kistatsu chirinoku kusu coater, comma coater, comma
- the ability to apply a coating method such as reverse coater or micro gravure coater can be
- the decorative layer is too thin, the concealability may be inferior and the design may be impaired. If the decorative layer is too thick, color unevenness is likely to occur during thermal forming.
- the thickness of 0 ⁇ :! ⁇ 5 ⁇ ⁇ is preferred, more preferably 0 ⁇ 5 ⁇ 3 xm. When using a metal thin layer, it is 0.01 -0.1. More preferably, it is 0.02-0.08 ⁇ m.
- the surface of the thermoplastic resin film may be subjected to a surface treatment such as corona treatment or primer coating.
- the components of the metal thin film include aluminum (A1), gold (Au), white gold (Pt), silver (Ag), copper (Cu), brass (Cu-Zn), titanium (Ti), chromium ( Cr), nickel (Ni), indium (In), molybdenum (Mo), tungsten (W), palladium (Pd), iridium (Ir), silicon (Si), tantalum (Ta), nickel chromium (Ni_Cr), stainless steel Metals such as steel (SUS), chromium copper (Cr_Cu), and aluminum silicon (Al_Si) can be mentioned.
- the high-brightness ink is an ink having a mirror-like metallic luster formed by dispersing metal thin film strips in a binder resin.
- the content of the metal thin film strips with respect to the nonvolatile content in the ink is preferably in the range of 3 to 60% by mass.
- High-gloss inks that use metal thin film strips are metallized using conventional metal powders as a result of the metal thin film strips being oriented parallel to the surface of the object when the ink is printed or applied. A high-brightness mirror-like metallic luster that cannot be obtained with ink is obtained.
- the metal of the metal thin film strip used for the high gloss ink various metals exemplified above can be preferably used as the metal thin film component.
- a method of forming the metal into a thin film vapor deposition is performed in the case of a metal having a low melting point such as aluminum, and foil is formed in the case of a malleable metal such as aluminum, gold, silver, copper, etc. In the case of a poor metal, sputtering or the like can be mentioned.
- a metal thin film strip obtained from a vapor deposited metal thin film is preferably used.
- the thickness of the metal thin film is preferably 0.01 to 0.1 ⁇ m, and more preferably 0.02 ⁇ 0.08 ⁇ 08 ⁇ .
- the size in the plane direction of the metal thin film strip dispersed in the ink is preferably 5 to 25 ⁇ force S, more preferably 10 to 15 ⁇ . If the size of the metal thin-film strip is less than 5 ⁇ m, the brightness of the coating film of high-brightness ink will be reduced, and if the ink is printed or applied by gravure or screen printing, It may cause clogging.
- a method for producing a metal thin film strip will be described using a particularly preferable vapor deposition method as an example.
- a polyolefin film, a polyester film, or the like can be used as the support film on which the metal is deposited.
- a release layer is provided on the support film by coating or the like, and then a metal is deposited on the release layer to have a predetermined thickness.
- a top coat layer is applied to the deposited film surface to prevent oxidation.
- the coating agent for forming the release layer and the topcoat layer the same one can be used, or different ones can be used.
- the resin used for the release layer or the topcoat layer is not particularly limited. Specifically, for example, cellulose derivatives such as nitrocellulose, acrylic resin, bull resin, polyamide, polyester, ethylene-bull alcohol (EVA) resin, chlorinated polyethylene, chlorinated EVA resin, petroleum resin, etc. Can be mentioned. Solvents used in the release layer or topcoat layer include aromatic hydrocarbons such as toluene and xylene; n aliphatic or alicyclic hydrocarbons such as monohexane and cyclohexane; ethyl acetate, propyl acetate, etc.
- aromatic hydrocarbons such as toluene and xylene
- n aliphatic or alicyclic hydrocarbons such as monohexane and cyclohexane
- ethyl acetate, propyl acetate etc.
- Esters ; alcohols such as methanol, ethanol, isopropyl alcohol; ketones such as acetone and methyl ethyl ketone; alkylene glycol mono alcohols such as ethylene glycol monoethyl ether and propylene glycol monomethyl ether Kill ether or the like is preferably used.
- the metal vapor-deposited film is immersed in a solvent that dissolves the release layer and the topcoat layer and stirred to separate the metal vapor-deposited film. Further, the peeled metal vapor-deposited film is stirred in a solvent to form a metal thin film strip having a size in the plane direction of about 5 to 25 x m, filtered and dried.
- the solvent used for peeling is not particularly limited as long as it dissolves the peeling layer and the topcoat layer.
- a metal thin film strip can be obtained by the same method as described above. When using metal foil, immerse it in a solvent and pulverize it to a predetermined size with a stirrer.
- the metal thin film strip is preferably surface-treated in order to enhance dispersibility in the ink.
- Surface treatment agents include organic fatty acids such as stearic acid, oleic acid and palmitic acid; isocyanates such as methylsilyl isocyanate; cellulose such as nitrocellulose, cellulose acetate propionate, cellulose acetate butyrate and ethyl cellulose Derivatives are mentioned, and are adsorbed on the surface of the metal thin film strip by a known and conventional method.
- binder resin used in the high gloss ink those conventionally used for conventional gravure ink, flexo ink, screen ink, paint, and the like can be used.
- specific examples include polymer resins such as acrylic resins for paints, butyl chloride resins, vinylidene chloride resins, salt-but-butyl acetate resins, ethylene-acetate resin, polyolefin resins, chlorinated olefin resins, and ethylene-acrylic resins.
- a polyurethane resin, a polyamide resin, a urea resin, an epoxy resin, a polyester resin, a petroleum-based resin, a cellulose derivative resin, etc. are preferably used.
- those obtained by chemically bonding polar groups such as rubonic acid group, phosphoric acid group, sulfonic acid group, amino group, quaternary ammonium base to these resins may be used or used in combination.
- the high-brightness ink has no defoaming, settling prevention, pigment dispersion, fluidity modification, anti-blocking, antistatic, antioxidation, light stability, as long as it does not impair the design and spreadability.
- Various additives used in conventional gravure inks, flexo inks, screen inks, paints, etc. are added for the purpose of properties, UV absorption, internal crosslinking, etc. It doesn't matter. Examples of such additives include coloring pigments, dyes, waxes, plasticizers, leveling agents, surfactants, dispersants, antifoaming agents, chelating agents, and polyisocyanates. it can.
- the solvent used in the high-brightness ink it is possible to use a known conventional solvent used in conventional gravure ink, flexo ink, screen ink, paint or the like.
- aromatic hydrocarbons such as toluene and xylene; aliphatic or alicyclic hydrocarbons such as n-hexane and cyclohexane; esters such as ethyl acetate and propyl acetate; methanol, ethanol and isopropyl
- alcohols such as alcohol; ketones such as acetone and methyl ethyl ketone; alkylene glycol alkyl ethers such as ethylene glycol monoethyl ether and propylene glycol monomethyl ether.
- the pigment and other additives are finely divided to submicron by kneading using a roll mill, ball mill, bead mill, or sand mill.
- the metal thin film strip to be blended in order to develop a metallic luster is preferably 5 to 25 / im. There is a risk that the metallic luster will be extremely lowered. Therefore, it is desirable to prepare the ink by simply mixing the above blending ingredients without preparing the high-gloss ink.
- the metal thin film strip is preferably surface-treated as described above.
- the laminated sheet when a laminated sheet having a configuration in which a decorative layer is sandwiched between thermoplastic resin layers is used, the laminated sheet has a desired shape without impairing the excellent design of the laminated sheet. It is preferable because it can be molded.
- thermoplastic resin layer (A-1), a decorative layer (B), and a thermoplastic resin layer (A_2) serving as a supporting base material are laminated in this order.
- Laminated sheets are preferred.
- the transparent or translucent thermoplastic resin layer (A-1) side is the surface layer.
- the decorative layer (B) having a high design property can be visualized through the transparent or translucent thermoplastic resin layer (A-1).
- One or more decorative protective layers, ink layers, adhesive layers and the like may be provided between the transparent or translucent thermoplastic resin layer (A_1) and the decorative layer (B).
- one or more surface protective layers (topcoat layers) may be provided on the side that becomes the surface layer during molding.
- thermoplastic resin layer (A-2) serving as the support substrate is the layer closest to the injection molding resin side of the obtained molded article, it has a heat-fusibility with the injection resin. It is preferable.
- the thermoplastic resin layer (A-2) serving as a supporting substrate has a role of protecting the decorative layer and assisting the strength and rigidity of the laminated sheet or the molded article to be obtained.
- Tg (AM) glass transition temperature
- thermoplastic resin layer (A-1) that can be used for the thermoforming sheet
- a film that is malleable by heating preferably in the form of a film
- the thermoplastic resin film is preferably a transparent or translucent single layer or multilayer film, and may contain a colorant.
- match mold molding since a molding process is performed by heat, a film mainly composed of a thermoplastic resin whose Tg is in the range of 30 to 300 ° C is more preferable, and Tg is 50 to 250 ° C. is there.
- thermoplastic resin examples include polyolefin resins such as polyethylene and polypropylene, polyester resins such as polyethylene terephthalate and polybutylene terephthalate, acrylic resins such as polymethyl methacrylate and polyethylene methacrylate, and ionomer resins.
- Polyamides such as polystyrene, polyacrylic nitrile, acrylic nitrile styrene resin, methyl methacrylate-styrene resin, nylon Fluorine such as oil, ethylene monoacetate resin, ethylene monoacrylate resin, ethylene ethyl acrylate resin, ethylene-butyl alcohol resin, chlorine resin such as poly salt butyl and polyvinylidene chloride, fluorine such as polyfluoride bur and polyvinylidene fluoride Resins, polycarbonate resins, cyclic polyolefin resins, modified polyethylene ether resins, methylpentene resins, cellulose resins and the like are preferably used.
- thermoplastic resins one or two selected from the group of acrylic resin, polyester resin, polycarbonate resin, and cyclic polyolefin resin is excellent because of the excellent thermoformability and sharpness of the decorative layer.
- a film having the above as a main component is preferred.
- two or more of the above exemplified resins may be mixed or multilayered for use.
- the various resins shown as examples used as the thermoplastic resin film may be modified with rubber within a range that does not impair transparency.
- the method of making the rubber-modified product but a method of copolymerizing by adding a rubber component monomer such as butadiene at the time of polymerization of various resins, and the resin and synthetic rubber or thermoplastic elastomer are heat-melted. The method of blending is mentioned.
- the thermoplastic resin film may contain various additives commonly used for film applications such as antioxidants, ultraviolet absorbers, and lubricants within a range that does not impair the transparency.
- thermoplastic resin film is not particularly limited, and it may be formed into a film by a conventional method. Further, the thermoplastic resin film may be stretched in a uniaxial direction or a biaxial direction as long as it does not impair the extensibility during thermoforming. good.
- the thickness of the thermoplastic resin film is not particularly limited. However, since the decorative protective layer (described later) and the decorative layer are spread layers such as ink, the coating property and thermoformability are good.
- the range is preferably 2000 ⁇ , more preferably f, 50 to 500 zm.
- thermoplastic resin layer (A-2) as support substrate (Thermoplastic resin layer (A-2) as support substrate)
- the thermoplastic resin layer (A-2) used as a supporting substrate for thermoforming sheets is mainly composed of a thermoplastic resin having a Tg in the range of 30 to 300 ° C for mat mold molding. The more preferred Tg that the film is preferred is 50-250 ° C.
- the thermoplastic resin Examples include acrylonitrile / butadiene Z styrene (ABS) resin, alitrononitrile.
- AES resin (meth) acrylic ester Z styrene (MS) resin, styrene / butadiene Z styrene (SBS) resin, styrene / isoprene Z butadiene / styrene (SIBS) resin, polyethylene (PE) resin and polypropylene (PP) Resin, general purpose resin such as vinyl chloride (PVC) resin, and olefin elastomer (TP ⁇ ), chlorinated butyl elastomer (TPVC), styrene elastomer (SBC), urethane elastomer (TPU) ), Thermoplastic elastomers ( ⁇ ) such as polyester elastomers ( ⁇ ), and polyamide elastomers ( ⁇ ).
- thermoplastic resin layer (A-2) serving as the support substrate is not particularly limited, but is preferably 10 / im to 3000 / im, for example.
- thermoplastic resin layer (A-2) As support substrate
- the laminated sheet for thermoforming becomes a three-dimensional shaped body by thermoforming.
- the thermoplastic resin layer (A-2) and thermoplastic resin film layer (A-1) used as the support base have different molding shrinkage rates, the molded body will be deformed, which is good. It is difficult to maintain a precise shape.
- an inorganic filler is added to the resin of the thermoplastic resin layer (A-2) serving as the supporting substrate, the molding shrinkage can be controlled with great strength, and the supporting substrate resin layer and the thermoplastic resin can be controlled. Since the difference in molding shrinkage of the thermoplastic resin between the film layer and the film layer can be reduced, deformation during and after molding can be prevented.
- the type of inorganic filler that can be used in the present invention is not particularly limited, and examples thereof include talc, calcium carbonate, clay, diatomaceous earth, my strength, magnesium silicate, and silica.
- the amount of the inorganic filler added to the thermoplastic resin layer (A-2) serving as the support substrate is determined by the mass of the layer (A-2) relative to the resin from the viewpoint of the balance between moldability and molding shrinkage. In percentage 5 to 60% by mass is preferable.
- the particle size of the inorganic filler is not particularly limited, but if the particle size is too large, the surface of the layer (A-2) becomes uneven, and in the case of a decorative sheet having a decorative layer, the decorative sharpness is impaired. There is a risk of being. For this reason, since the layer (A-2), which is the base of the decorative layer, is required to be smooth, the average particle size of the inorganic filler added to the layer (A-2) is preferably 8 zm or less. 4 zm The following is more preferable. In particular, in the case of a decorative sheet having a mirror-like metallic luster, 2 zm or less is preferable.
- thermoplastic resin layer (A-2) As supporting substrate
- thermoplastic resin layer (A-2) serving as a supporting base material because the underlying color concealability of the molded article is improved.
- the colorant used here is not particularly limited, and conventional inorganic pigments, organic pigments, dyes, and the like used for coloring general thermoplastic resins can be used in accordance with the intended design.
- inorganic faces such as titanium oxide, titanium yellow, iron oxide, complex oxide pigments, ultramarine, cobalt blue, chromium oxide, bismuth vanadate, bonbon black, zinc oxide, calcium carbonate, barium sulfate, silica, talc, etc.
- Azo pigments phthalocyanine pigments, quinacridone pigments, dioxazine pigments, anthraquinone pigments, isoindolinone pigments, isoindoline pigments, perylene pigments, perinone pigments, quinophthalone pigments, thioindigo pigments Organic pigments such as diketopyrrolopyrrole pigments; metal complex pigments and the like.
- the dye it is preferable to use one or two or more kinds selected mainly from genoleps of oil-soluble dyes.
- the amount of the colorant added to the thermoplastic resin layer (A-2) serving as the support base varies depending on the type of the colorant, the thickness and color tone of the target thermoforming sheet, etc.
- the mass percentage with respect to the resin constituting the layer (A-2) is preferably in the range of 0.:! To 20% by mass. Preferably, it is in the range of 0.5 to 15% by mass. If the addition amount of the colorant exceeds 20% by mass with respect to the resin, the impact strength decreases, and if the addition amount of the colorant is less than 0.1% by mass, the hue and background color are sufficiently concealed. It's a trend.
- thermoplastic resin layer (A-2) serving as the supporting substrate has a plasticizer, an antioxidant, an ultraviolet absorber, an antistatic agent, a flame retardant, and the like, as long as its impact strength and moldability are not impaired.
- Sliding Additives such as additives may be added. These additives may be used alone or in combination of two or more.
- One or more decorative protective layers are provided between the thermoplastic resin film layer (A-1) and the decorative layer (B) for the purpose of improving heat resistance, solvent resistance, design properties, weather resistance, etc. May be.
- the decorative layer (B) is made of a highly glossy ink, it is desirable to provide the following decorative protective layer as the ink protective layer.
- the type of resin that can be used for the decorative protective layer is not particularly limited as long as it does not impair the spreadability of the thermoforming sheet, but it is easy to adjust the crosslinking density, weather resistance, and the thermoplastic resin film layer (A— Acrylic resins are preferred from the standpoint of adhesion to 1).
- UV curing, EB curing, hydroxyl group-containing copolymer / isocyanate curing, silanol / water curing, epoxy / amine curing, etc. can be used.
- hydroxyl group-containing copolymer / isocyanate curing is preferred from the viewpoints of easy adjustment of the crosslinking density, weather resistance, reaction rate, presence or absence of reaction byproducts, production cost, and the like.
- a coloring agent may be added to the decorative protective layer to form a colored layer.
- the amount of colorant added varies depending on the type of colorant, the desired color tone, the thickness of the decorative protective layer, etc., but the total light transmittance of the decorative protective layer is not to conceal the decorative layer (B). In particular, it is preferably 20% or more, and more preferably the total light transmittance is 40% or more.
- a pigment is preferable.
- the pigment used here is not particularly limited, and known and commonly used pigments such as colored pigments, metallic pigments, interference color pigments, fluorescent pigments, extender pigments, and antifungal pigments can be used.
- Examples of the coloring pigment include quinacridone pigments such as quinacridone red, azo pigments such as pigment red, and organic pigments such as phthalocyanine pigments such as phthalocyanine blue, phthalocyanine green, and perylene red; titanium oxide and carbon black Inorganic pigments such as Examples of metallic pigments include aluminum powder, nickel powder, copper powder, brass powder, and chromium powder. Examples of the interference color pigment include pearl luster pearl my flour and pearl luster colored pearl my flour.
- Fluorescent pigments include quinacridone pigments, anthraquinone pigments, perylene pigments, Linone pigment, diketopyrrolopyrrole pigment, isoindolinone pigment, condensed azo pigment, benzimidazolone pigment, monoazo pigment, insoluble azo pigment, naphthol pigment, flavanthrone pigment, anthrapyrimidine Organic pigments such as nickel pigments, quinophthalone pigments, pyranthrone pigments, pyrazolone pigments, thioindigo pigments, anthanthrone pigments, dioxazine pigments, phthalocyanine pigments, indanthrone pigments; nickel dioxin yellow and copper pigments Metal complexes such as zomethine yellow; metal oxides such as titanium oxide, iron oxide and zinc oxide; metal salts such as barium sulfate and calcium carbonate; inorganic pigments such as carbon black, aluminum and mica.
- thermoplastic resin layer (A-2) serving as a supporting substrate
- lamination can be performed by a dry lamination method, a wet lamination method, a hot melt lamination method, or the like using a conventional solvent-type adhesive.
- the adhesive constituting the adhesive layer is a conventional phenol resin-based adhesive, resorcinol resin-based adhesive, phenol-resorinosinol resin-based adhesive, epoxy resin-based adhesive, urea resin-based adhesive.
- Thermosetting resin adhesives such as polyurethane adhesives and polyaromatic adhesives; Reactive adhesives using ethylene unsaturated carboxylic acid copolymers, etc .; acetate acetate resin, acrylic resin, ethylene acetate acetate resin
- Thermoplastic resin adhesives such as polybulal alcohol, polybulucetal, chlorinated resin, nylon and cyanoacrylate resin; black-prene adhesive, nitrile rubber adhesive, SBR adhesive, natural rubber Examples thereof include rubber adhesives such as adhesives.
- an acrylic urethane adhesive is preferable because it has good adhesion between an acrylic resin and a polypropylene resin and has good elongation followability in vacuum forming and match mold forming.
- the adhesive coating method is one for gravure coater, gravure reverse coater, flexo coater. Blanket coater, ronore coater, knife coater, air knife coater, kissta, " ⁇ Su ⁇ 1 ⁇ -- ⁇ . ⁇ Ta" ⁇ ; Pimma 1 les 1 ⁇ Sco " ⁇ 1 ⁇ , coating method such as micro reverse coater etc. can be used.
- a range of 0.:! To 30 g / m 2 is preferable for sufficient adhesion and good drying properties. Particularly preferred is 2 to 10 g / m 2 . If the applied amount of the adhesive is too small, the adhesive strength is weakened, and if the applied amount of the adhesive is too large, the drying property tends to decrease.
- the thickness of the adhesive layer is preferably in a range force S of 0.! To 30 ⁇ , more preferably :! to 20 xm, particularly preferably 2 to: 10 zm.
- the adhesive surface of the thermoplastic resin layer (A-2) serving as the support substrate is subjected to plasma treatment, corona treatment, flame treatment, Surface treatment such as electron beam irradiation treatment, roughening treatment, ozone treatment, etc .; dry plating treatment such as vacuum deposition, sputtering, ion plating, etc. may be performed.
- a pressure-sensitive adhesive layer may be provided instead of the adhesive layer.
- acrylic adhesive, rubber adhesive, polyalkyl silicon adhesive, urethane adhesive, polyester adhesive, and the like are preferably used.
- the sheet for thermoforming used in the present invention has performances such as designability, abrasion resistance, scratch resistance, weather resistance, stain resistance, water resistance, chemical resistance, and heat resistance on the surface side during molding.
- one or more transparent, translucent or colored clear topcoat layers can be provided as a surface protective layer.
- a lacquer type, a crosslinking type with isocyanate or epoxy, a UV crosslinking type or an EB crosslinking type is preferably used as long as the spreadability of the thermoforming sheet is not inhibited.
- a method for producing a laminated sheet and a match mold forming method are shown below.
- the acrylic polyol resin “6KW — 032E” (trade name, manufactured by Dainippon Ink and Chemicals, solid content 38% ( Solubility 1J: Ethyl acetate), Hydroxyl value 30KOHmgZg)
- polyisocyanate containing an isocyanurate ring “BURNOC K DN-981 J (trade name, large Made by Nippon Ink Chemical Co., Ltd., solid content 75% (solvent: ethyl acetate), functional group number 3, NCO concentration 14% 8 parts were mixed (100 parts in total) to prepare a decorative protective layer solution (primer) .
- thermoplastic resin film layer (A-1) with the decorative layer (B) and the thermoplastic resin layer (A-2) as the supporting base
- aromatic polyester polyol resin “LX-703VLJ” (Trade name, manufactured by Dainippon Ink & Chemicals, Inc.) 15 parts
- aliphatic polyisocyanate “KR_90” (trade name, manufactured by Dainippon Ink & Chemicals, Inc.) as a curing agent
- ethyl acetate as a diluent 18
- the parts were mixed (34 parts in total) to prepare a polyester urethane adhesive.
- thermoplastic resin layer (A_2) used as the supporting substrate is composed of the first layer (C-1) consisting mainly of propylene-ethylene random copolymer “FS3611” (trade name, manufactured by Sumitomo Chemical Co., Ltd.) and propylene.
- first layer (C-1) consisting mainly of propylene-ethylene random copolymer “FS3611” (trade name, manufactured by Sumitomo Chemical Co., Ltd.) and propylene.
- a two-layer, two-layer sheet in which the second layer (C_2) composed mainly of one butene random copolymer “SP7834” (trade name, manufactured by Sumitomo Chemical Co., Ltd.) was used was used.
- the raw material resins for the above two layers (C 1) and layer (C 2) were 210 ° C respectively.
- the sheet was cooled with a metal roll adjusted to 40 ° C. to obtain a sheet for a supporting base resin layer having a thickness of 0.30 mm.
- the laminate (A-2) consisting of the layer (C-1) and the layer (C-2) force showed no maximum value in the DMA measurement at a tan ⁇ force of 0 ° C or more.
- the rubber-modified PMMA film (A-1) was coated with the solution for the decorative protective layer (A-1ZB intermediate layer) using a microgravure coater and dried to a thickness of 2. ⁇ ⁇ m. Aging treatment was performed at 50 ° C for 3 days. Next, the high-brightness ink was applied and dried as a decorative layer (B) on the decorative protective layer using a gravure coater to a dry film thickness of 2. ⁇ m.
- thermoplastic resin layer (A_ 2) sheet (layer (C 1) containing propylene ethylene random copolymer as the main component) as the support substrate After applying corona treatment so as to be several 40 dyne / cm, the adhesive (B / A-2 intermediate layer) was applied and dried to a dry film thickness of 5 ⁇ using a micro gravure coater, 50. Glue together the surface of the rubber-modified PMMA film with the high-brightness ink. After aging treatment with C for 3 days, a laminated sheet for molding (S_l) was obtained. The 20 ° light intensity value (measurement angle 20 °) of the sheet (S_l) was 1050%.
- the 20 ° gloss value was measured in accordance with JI S Z8741 using “Micro_TRI_gloss” manufactured by BYK Gardner (the same applies to the following examples and comparative examples).
- Horizontal surface 11a and box 12 are rectangular with a circumference of 183 x 204 mm (area 373 cm 2 ) (outside of convex part l ib is 113 x 158 mm), top surface 11c is a rectangle with 51 x 66 mm, horizontal surface 11a to top surface 11c
- the slope of the slope l ib is 35, 55, 60, 70 °, and the joint between the top surface 11c and the slope l ib is 0.5, 1, 1, 5, 3mmR, and the slope l ib
- the hard aluminum alloy “Alumino HARD” (trade name) manufactured by Daido Amister Co., Ltd.
- the vertical machining center “NV5000J (product name)” manufactured by Mori Seiki Co., Ltd. are used. It was made using.
- the mass of the entire concave mold including the movable frame clamp and air cylinder and the entire convex mold were both approximately 25 kg (both weighed approximately 25 kgf).
- a small vacuum forming machine made by Hermis FE38PH was used for the match molding in this example. Attach the concave and concave movable frame clamps to the plug movable device (upper side) and the convex and convex movable frame clamps to the mold movable device (lower side). Carried out.
- thermoplastic resin film layer (A-1) side of the laminated sheet (S-1) is up.
- a match mold molded body was obtained by the steps (1) to (9).
- the heater temperature was 370 ° C.
- the distance between the sheet and the heater was 130 mm
- the heating time was 12 seconds
- the sheet temperature at the start of molding was 115 ° C.
- the sheet temperature near the upper part of the core was measured from the lower side (the thermoplastic resin layer (A_2) side serving as the supporting base material).
- the maximum temperature when the sheet was heated with a heater was taken as the molding temperature.
- the concave mold temperature was 95 ° C and the convex mold temperature was 75 ° C.
- a concave movable frame clamp use a frame clamp (Fig. 5) without flanges to reduce the pressure of the four air cylinders (50mm ⁇ ) that move the frame clamp. Lkgf / cm 2 ⁇ ] 0.
- IMPa ⁇ Thrust: approx. 80 kgf ⁇ approx. 800 N ⁇
- all four rising air cylinders (50 ⁇ ⁇ ) rise pressure 2 kgf / cm 2 0.2 MPa ⁇
- Thrust approx. 160kg f ⁇ approx.
- the lowering pressure of the concave movable air cylinder (104mm ⁇ ) and the rising pressure of the convex movable air cylinder (H 2mm ⁇ ) are 5kgf / cm 2 0.5 MPa ⁇ ( Thrust: About 425 kgf ⁇ about 4250 N ⁇ and about 492 kgf ⁇ about 4920 N ⁇ ), and the molding method A (Fig. 1) is used in which the sheet fixed by a movable frame clamp after heating is pressed against the concave mold first.
- R reproducibility was measured for the 3 mmR portion of the four-sided corner portion of the top surface of the molded body.
- the molding feasibility evaluation was ⁇
- the mold reproducibility evaluation was ⁇
- the 20 ° gloss value of the 110% development ratio was 850%
- the gloss retention was 81%.
- the gloss evaluation at a development rate of 110% was ⁇ .
- the 20 ° gloss value of the 150% development ratio was 750%
- the gloss retention was 71%
- the gloss evaluation of the 150% development ratio was ⁇ .
- a molded body (M-1a) was obtained in the same manner as in Example 1 except that a black grid pattern with a 1 mm interval was printed in advance on the decorative layer (B) side of the thermoplastic film layer (A-1). It was. At a deployment rate of 110%, almost no distortion of the grid pattern was observed. At a deployment rate of 150%, the grid pattern itself was deformed, but there was almost no distortion of the shoreline.
- the clamping force for fixing the sheet with the frame clamp is about 800 N (stress is about 95 kPa), and the mold closing force between the concave and convex molds is about 2.9 kN (stress is about 85 kPa (horizontal plane 21a was a rectangle of 175 x 196 mm (area: 343 cm 2 ))
- the molding feasibility evaluation was ⁇
- the mold reproducibility evaluation was ⁇
- 110% developed The 20 ° gloss value of the part was 800%
- the gloss retention was 76%
- the gloss evaluation of the 110% developed part was ⁇ .
- the 20 ° gloss value of the 150% developed part was 650%, the gloss retention was 62%, and the gloss evaluation of the 150% developed part was ⁇ .
- a molded body (M — 2a) was obtained in the same manner as in Example 2 except that a black grid pattern with an interval of 1 mm was previously printed on the decorative layer (B) side of the thermoplastic film layer (A-1). Although the distortion of the grid pattern was hardly observed at the deployment rate of 110%, the shoreline appeared to be slightly distorted at the deployment rate of 150%.
- the thermoplastic resin layer (A-2) serving as the support substrate is made of transparent ABS resin (methyl methacrylate-acrylic).
- Nitrile-butadiene-styrene copolymer, trade name “SXH-290”, manufactured by Nippon A & E Co., Ltd., Tg 115 ° C)
- Force 65mm ⁇ Single-screw extruder formed using only a single screw extruder A layered sheet for forming (S-3) was obtained in the same manner as in Example 1 except that the adhesive coating side of the laminating method was changed to the high gloss ink coated surface.
- the 20 ° gloss value of the sheet (S-3) was 950%.
- a molded body (M-3) was obtained in the same manner as in Example 1 except that a concave mold designed to have a clearance of 200 / m was used.
- the evaluation of moldability was ⁇
- the mold reproducibility evaluation was ⁇
- the 20 ° gloss value of the 110% developed part was 800. /.
- the gloss retention is 84% and 110. /.
- the gloss evaluation of the developed part was ⁇ .
- the 20 ° gloss value of the 150% developed part was 600%
- the gloss retention was 63%
- the gloss evaluation of the 150% developed part was ⁇ .
- Example 1 except that the primer and the high gloss ink were not used, and a 0.04 zm aluminum thin film was previously laminated on the thermoplastic resin film layer (A-1) as a decorative layer (B) by vacuum deposition.
- a laminated sheet for molding (S-4) was obtained.
- the 20 ° gloss value of the sheet (S-4) was 1450%.
- the molded body (M-4) was obtained in the same manner as in Example 1.
- the molding propriety evaluation was 0, and the mold reproducibility evaluation was ⁇
- the 20 ° gloss value of the 110% developed part was 1350%, the gloss retention was 93%, and the gloss evaluation of the 110% developed part was ⁇ .
- the 20 ° gloss value of the 150% developed part was 650%, the gloss retention was 45%, and the gloss evaluation of the 150% developed part was ⁇ .
- the gravure printing ink “UNIVIA NT” (Daiichi) is used as the decorative layer (B) in advance on the decorative layer (B) side of the thermoplastic resin film layer (A-1). Except for printing a black grid pattern with lmm spacing on the first plate and a white solid pattern on the second and third plates by gravure printing using this ink chemical industry).
- a laminated sheet for molding (S-5) was obtained.
- a molded body (M-5) was obtained in the same manner as in Example 1.
- a molded body (M_6) was obtained in the same manner as in Example 1 except that the sheet temperature at the start of molding was 100 ° C.
- the evaluation of moldability was ⁇
- the mold reproducibility evaluation was ⁇
- the 20 ° gloss value of the 110% developed part was 1000. /.
- the gloss retention is 95% and 110.
- the glossiness of the / o opening was ⁇ .
- the 20 ° gloss value of the 150% developed part was 850%
- the gloss retention was 81%
- the gloss evaluation of the 150% developed part was ⁇ .
- a molded body (M_7) was obtained in the same manner as in Example 1 except that the sheet temperature at the start of molding was 130 ° C.
- the evaluation of moldability was ⁇
- the mold reproducibility evaluation was ⁇
- the 20 ° gloss value of the 110% developed part was 650. /.
- the gloss retention is 62% and 110. /.
- the gloss evaluation of the developed part was ⁇ .
- the 20 ° gloss value of 150% developed part is 600%
- gloss The retention rate was 57%
- the gloss evaluation of the 150% developed part was ⁇ .
- a comparative molded body (M_) was obtained in the same manner as in Example 1 except that the molding temperature was 140 ° C.
- the molding feasibility evaluation was ⁇
- the mold reproducibility evaluation was ⁇
- the 110% developed part 20 ° gloss value was 400%
- the gloss retention was It was 38%
- the glossiness evaluation of 110% developed part was X.
- the 20 ° gloss value of the 150% developed part was 250%
- the gloss retention was 24%
- the gloss evaluation of the 150% developed part was X.
- the air vent hole remains at the joint between the top surface and the slope of the molded body (M —: ⁇ ), and the pressure marks when the sheet is sandwiched between the concave and convex shapes remain on a part of the top surface.
- a comparative molded body (M-1) was prepared in the same manner as in Comparative Example 1 except that a black grid pattern with 1 mm spacing was printed in advance on the decorative layer (B) side of the thermoplastic film layer (A-1). Obtained. Although the distortion of the shoreline was hardly observed at the deployment rate of 110%, the grid pattern was slightly deformed, and a clear shoreline distortion was observed at the deployment rate of 150%.
- Example 2 The same sheet as in Example 1 was vacuum-formed only with a convex shape without using a movable frame clamp.
- the molding temperature was set to 140 ° C. to obtain a comparative molded body-).
- the comparative molded body (M-2 ') was evaluated in the same manner as in Example 1.
- the ratio was 29%, and the gloss evaluation of the 110% developed part was X.
- the 20 ° gloss value of the 150% developed part was 200%, the gloss retention was 19%, and the gloss evaluation of the 150% developed part was X.
- a comparative molded body (M-2) was prepared in the same manner as in Comparative Example 2 except that a black grid pattern with 1 mm spacing was printed on the decorative layer (B) side of the thermoplastic film layer (A-1). Obtained. In the 110% development rate, the grid pattern was deformed along with the shoreline distortion, and in the 150% development rate, clearly uneven shoreline distortion was observed.
- Example 3 For the same sheet as in Example 1, match mold molding was performed using a concave mold and a convex mold without using a movable frame clamp. In the same manner as in Example 1, the molding temperature was 115 ° C. to obtain a comparative molded body (M-3 ′). The comparative molded body (M-3 ') was evaluated in the same manner as in Example 1. As a result, X was evaluated for moldability, ⁇ was reproducible for mold reproducibility, 20 ° gloss value was 110%, and the gloss value was 800%. The retention rate was 76%, and the gloss rating for the 110% development rate was ⁇ .
- the 20 ° gloss value at a development rate of 150% was 500%
- the gloss retention was 48%
- the gloss evaluation at a development rate of 150% was ⁇ .
- a part of the sheet was released from the clamp of the molding machine, and chilled marks (cooling marks) due to contact between the sheet and the concave mold occurred on all the slopes of the molded body.
- Example 1 For the same sheet as in Example 1, remove the movable frame clamp of the present invention from the air cylinder and operate only 4 rods (diameter 20 mm) of the air cylinder to perform match mold molding under the same molding conditions as in Example 1. As a result, a comparative molded body (M— ⁇ ) was obtained. As a result of evaluating the comparative molded body (M-) in the same manner as in Example 1, the molding feasibility evaluation was X, the mold reproducibility evaluation was ⁇ , the expansion rate was 110%, the 20 ° gloss value was 800%, and the gloss retention rate was It was 76%, and the glossiness evaluation at a development rate of 110% was ⁇ .
- the 20 ° gloss value at a development rate of 150% was 500%
- the gloss retention rate was 48%
- the gloss evaluation at a development rate of 150% was ⁇ .
- part of the sheet was released from the clamp of the molding machine, and chilled marks (cooling marks) due to contact between the sheet and the concave mold occurred on all the slopes of the molded body.
- Example 1 For the same sheet as in Example 1, remove the short sides of the movable frame clamps 14 and 24 so that only the two sides of the sheet can be fixed, and perform mold molding under the same molding conditions as in Example 1.
- a comparative molded body (M-5 ′) was obtained.
- the comparative molded body (M-5 ') was evaluated in the same manner as in Example 1.
- X was evaluated for moldability
- ⁇ was evaluated for mold reproducibility
- 20 ° gloss value was 110%
- the gloss retention was 800%.
- the rate was 76%
- the gloss rating for the 110% development rate was ⁇ .
- the 20 ° gloss value of the 150% development ratio was 550%
- the gloss retention ratio was 52%
- the gloss evaluation of the 150% development ratio was ⁇ .
- clan Sheet tearing occurred in parts that were not pressed, and chilled marks (cooling marks) were generated on the two slopes where the sheet clamp did not come out during molding due to contact between the sheet and the concave mold.
- a comparative molded body (M-6 ′) was obtained in the same manner as in Example 5 except that the molding temperature was 140 ° C.
- the evaluation of molding feasibility was “ ⁇ ” and the mold reproducibility evaluation was “ ⁇ ”.
- almost no distortion of the shoreline was observed at the 110% expansion ratio, but the grid pattern was slightly deformed, and a clear distortion of the shoreline was observed at the 150% expansion ratio.
- the development rate was 150%, the base was seen through, and a difference in whiteness from the development rate of 110% was recognized.
- a chilled mark (cooling mark) was generated on the part of the molded body ( ⁇ -6 ') near the top surface of the inclined surface due to contact between the sheet and the convex mold.
- Tables 1 and 2 summarize the main points and evaluation results of the implementation conditions of the above examples and comparative examples.
- Example 5 a molded article having a good appearance with little change in strength and color pattern in which the metallic luster layer was not used as the decorative layer was obtained.
- Comparative Example 1 by using a movable frame clamp, good mold reproducibility without wrinkles in the molded body was obtained, but the gloss retention was poor due to the relatively high molding temperature. became.
- Comparative Examples 4 and 5 when match mold molding was performed using a movable clamp that was not a frame shape, the force S was able to extend the sheet slackness after heating to some extent, and the sheet was pulled into the mold. As the effect of preventing was insufficient, molding wrinkles occurred as in Comparative Example 3. Further, for the same reason as in Comparative Example 3, the gloss retention at the 150% developed portion was inferior.
- Example la, 2a and Comparative Example la, 2a in the case of a decorative sheet having a printed pattern as a decorative layer, deformation of the printed pattern can be suppressed by performing match mold molding at a relatively low temperature.
- Example 5 Comparative Example 6 in which no metallic luster layer was used.
- the present invention is particularly useful for the production of molded products that are used in applications such as automobile-related members, construction-related members, and household electrical appliances, have excellent decorative sharpness, and do not require outer coating.
- it is useful as a molding method and molding apparatus for a laminated sheet for molding having specular metallic luster.
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Abstract
Description
Claims
Priority Applications (2)
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US11/914,101 US20090039556A1 (en) | 2005-05-10 | 2006-05-10 | Thermoforming method for thermoforming sheet and thermoforming apparatus |
EP06746217A EP1880828A1 (en) | 2005-05-10 | 2006-05-10 | Process for forming thermoformable sheet and forming machine |
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JP2005-137495 | 2005-05-10 | ||
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US (1) | US20090039556A1 (ja) |
EP (1) | EP1880828A1 (ja) |
KR (1) | KR20070118302A (ja) |
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WO (1) | WO2006121079A1 (ja) |
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CN109437524A (zh) * | 2018-12-17 | 2019-03-08 | 苏州胜禹材料科技股份有限公司 | 不等厚玻璃3d热弯机及3d玻璃成型方法 |
GB2580685B (en) * | 2019-01-24 | 2021-04-28 | Softform Ltd | A method and tool for manufacturing a container from a thermoplastic material |
KR20220060582A (ko) * | 2020-11-04 | 2022-05-12 | 삼성디스플레이 주식회사 | 윈도우 성형 장치 및 이를 이용한 윈도우 성형 방법 |
CN112917789B (zh) * | 2021-01-27 | 2022-08-30 | 业成科技(成都)有限公司 | 热压成型制程方法及其热压装置 |
KR20240060056A (ko) * | 2022-10-28 | 2024-05-08 | 주식회사 엘지화학 | 성형체 |
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- 2006-05-10 US US11/914,101 patent/US20090039556A1/en not_active Abandoned
- 2006-05-10 EP EP06746217A patent/EP1880828A1/en not_active Withdrawn
- 2006-05-10 WO PCT/JP2006/309403 patent/WO2006121079A1/ja active Application Filing
- 2006-05-10 CN CNA2006800157410A patent/CN101171118A/zh active Pending
- 2006-05-10 KR KR1020077025896A patent/KR20070118302A/ko active IP Right Grant
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WO2009026063A1 (en) * | 2007-08-21 | 2009-02-26 | 3M Innovative Properties Company | Custom thermoformed decoration |
WO2012115103A1 (ja) * | 2011-02-21 | 2012-08-30 | タキロン株式会社 | 骨接合プレート成形具及び骨接合プレート成形方法 |
Also Published As
Publication number | Publication date |
---|---|
EP1880828A1 (en) | 2008-01-23 |
CN101171118A (zh) | 2008-04-30 |
KR20070118302A (ko) | 2007-12-14 |
US20090039556A1 (en) | 2009-02-12 |
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