JPH11348103A - Decorative sheet, blow-molding with decorative sheet and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide blow moldings with a decorative sheet free from a trapped air. SOLUTION: In the method for manufacturing blow-moldings with a decorative sheet by which it is possible to dispose the decorative sheet 1 in a mold for blow-molding and form the decorative sheet 1 on the surface of moldings simultaneously with a blow-molding process, the decorative sheet 1 is used which has a microspace formed layer 4 as an uppermost layer on the side formed integrally with a blow molding resin. The typical microspace formed layer 4 is one which has microshort fibers implanted. For example, an adhesive is applied to the surface of the sheet 1 to form an adhesive layer and the microshort fibers are sealed by sticking the tips of the fibers in the adhesive layer under a high voltage electrostatic field (electrostatic filling method).

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative sheet that does not generate air pockets during blow molding, a blow-molded article with a decorative sheet using the decorative sheet, and a method of manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, hollow blow-molded articles such as food containers, cosmetic containers, and chemical containers have contents displayed thereon for the purpose of increasing the commercial value of the products or incentivizing consumers to purchase. Decorative sheets are being provided,
The decorative sheet 1 to be provided on the inner surface of the cavity of the blow molding die 5 is held by means such as vacuum suction 10 (FIG. 4).
), The thermoplastic resin extruded as a parison 6 via a die 9 is sandwiched by the mold 5 (see FIG. 5), and compressed air 11 or the like is blown into the bag-shaped parison 6 to inflate the mold 5. The decorative sheet 1 is formed on the surface of the molded product 12 while being in close contact with the inner surface of the cavity to form the product.
(See FIG. 6).

In recent years, the objects to be blow-molded have been expanded to containers other than those described above, and the size and shape of the objects have been increasing. For example, it is desired that a spoiler 13 (see FIG. 7) of an automobile, which changes the flow of air around the vehicle body during traveling, be manufactured by blow molding.

[0004]

However, if the area of the decorative sheet to be inserted into the mold during blow molding is large, air between the surface of the inflated parison 6 and the adhesive surface of the decorative sheet 1 is discharged well. It becomes difficult. In other words, parison 6
In a state in which the surface and the surface to which the decorative sheet 1 is attached have not yet been bonded in a certain portion with air left therebetween, the bonding has already been completed in the surrounding portion, and the blow-molded article with the decorative sheet has been completed. In some cases, air pockets 14 were generated everywhere (see FIG. 8). This air pocket 14
Is presumed to hinder the smooth shrinkage of the molded product 12 itself or the smooth following of the decorative sheet 1 when the blow molded product shrinks due to cooling. ing.

As a result, in the case where the decorative sheet 1 is integrated with the entire upper half surface of a large hollow molded product such as the spoiler 13 of an automobile, the decorative sheet 1 must be manufactured without using blow molding. Specifically, the molded article is divided into upper and lower thin parts, and the upper half part 15 is prepared by providing the decorative sheet 1 on the surface of the molded article at the same time as the injection molding of the molten resin. This is a method in which the production efficiency is extremely low and the cost is high, in which the hollow part is combined with the lower half part 16 injection-molded in the above (see FIG. 9).

Also, when the shape of the blow-molded product is complicated, the air between the surface of the parison 6 and the adhering surface of the decorative sheet 1 is difficult to be discharged well, and similarly, the air pocket 14 may be generated.

Accordingly, an object of the present invention is to solve the above problems and to provide a blow-molded article with a decorative sheet having no air pockets.

[0008]

In order to achieve the above object, a decorative sheet according to the present invention comprises a decorative sheet having at least a design layer provided on a base sheet, the side of the decorative sheet being integrated with the blow-molded resin. Was configured such that a fine space forming layer was provided as the uppermost layer of the above.

In the above structure, the fine space forming layer is formed by flocking.

In the above structure, the fine space forming layer is formed by laminating a woven or nonwoven fabric.

In the above structure, the fine space forming layer is formed of a foam layer.

The blow-molded article with a decorative sheet according to the present invention is constructed such that each of the decorative sheets is integrated with the surface of the molded article by a fine space forming layer in the blow-molded article with a decorative sheet. .

The method for producing a blow-molded article with a decorative sheet according to the present invention comprises placing the decorative sheet in a mold for blow molding and providing the decorative sheet on the surface of the molded article simultaneously with the blow molding. In the method for producing a blow molded article, each of the above decorative sheets was used, and the decorative sheet was configured to be integrated with the surface of the molded article by the fine space forming layer.

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The decorative sheet of the present invention and a method of manufacturing a blow molded article with the decorative sheet using the same will be described in detail with reference to the drawings. FIG. 1 is a sectional view showing one embodiment of a basic layer configuration of the decorative sheet of the present invention, and FIG.
FIG. 3 is a partially enlarged cross-sectional view showing one embodiment of the manufacturing process of the blow molded article with a decorative sheet of the present invention, FIG. 3 is a cross-sectional view showing another embodiment of the decorative sheet of the present invention, and FIGS. It is sectional drawing which shows one Example of the manufacturing process of the blow molded article with a decorative sheet. In the drawing, 1 is a decorative sheet, 2 is a base sheet, 3 is a design layer, 4 is a fine space forming layer, 5 is a mold, 6 is a parison, 7
Denotes air, 8 denotes a backing sheet, 9 denotes a die, 10 denotes vacuum suction, 11 denotes compressed air, and 12 denotes a molded product.

First, the decorative sheet shown in FIG. 1 will be described.

Examples of the base sheet 2 include crystalline polypropylene, crystalline propylene-ethylene copolymer,
Polyolefins such as crystalline polybutene-1, crystalline poly-4-methylbenten-1, low, medium or high density polyethylene; aromatic vinyl polymers such as polystyrene and styrene-butadiene copolymer; polyvinyl chloride, chloride Vinyl halide polymers such as vinylidene resin; nitrile polymers such as acrylonitrile-styrene copolymer, acrylonitrile-styrene-butadiene copolymer; polyamides such as nylon 6, nylon 6, 6, para or meta-xylylene adivamide ;polyethylene terephthalate,
Polyesters such as polytetramethylene terephthalate; various polycarbonates; resin sheets such as thermoplastic resins such as polyacetals such as polyoxymethylene; metal foils such as aluminum foil and copper foil; synthetic paper; or composites of the above sheets and so on. In addition, if it is a base sheet material of the normal decorative sheet 1 used for blow molding, it can be used without being limited to the above-mentioned example.

The design layer 3 is usually formed on the base sheet 2 as a printing layer. When the base sheet 2 is made of an opaque material, the forming place is limited to the side opposite to the side where the base sheet 2 is bonded to the blow molded article, but when the base sheet 2 is made of a transparent material, the side where the base sheet 2 is bonded to the blow molded article and the opposite side At least one of them. As the material of the printing layer, a resin such as a polyvinyl resin, a polyamide resin, a polyester resin, a polyacryl resin, a polyurethane resin, a polyvinyl acetal resin, a polyester urethane resin, a cellulose ester resin, and an alkyd resin is used as a binder. It is preferable to use a coloring ink containing a pigment or dye of an appropriate color as a coloring agent. As a method for forming the printing layer, a normal printing method such as an offset printing method, a gravure printing method, a screen printing method, and a coating method such as a gravure coating method, a roll coating method, and a comma coating method may be used. In particular, an offset printing method or a gravure printing method is suitable for performing multicolor printing and gradation expression.

The design layer 3 may be composed of a metal thin film layer or a combination of a printing layer and a metal thin film layer. The metal thin film layer is for expressing metallic luster as a design layer, and is formed by a vacuum deposition method, a sputtering method, an ion plating method, a plating method, or the like. In this case, metals such as aluminum, nickel, gold, platinum, chromium, iron, copper, tin, indium, silver, titanium, lead, and zinc, and alloys or compounds thereof are used according to a desired metallic gloss color. As an example of forming a partial metal thin film layer, after forming a solvent-soluble resin layer in a portion that does not require a metal thin film layer, a metal thin film is entirely formed thereon, and solvent cleaning is performed. There is a method of removing an unnecessary metal thin film together with the solvent-soluble resin layer. The solvent often used in this case is water or an aqueous solution. As another example, there is a method in which a metal thin film is formed on the entire surface, a resist layer is formed on a portion where the metal thin film is to be left, and the resist layer is removed by etching with an acid or an alkali. . When the metal thin film layer is provided, a front anchor layer or a rear anchor layer may be provided in order to improve the adhesion between the other formation layer and the metal thin film layer.
As the material of the front anchor layer and the rear anchor layer, two-component cured urethane resin, thermosetting urethane resin, melamine resin, cellulose ester resin, chlorine-containing rubber resin, chlorine-containing vinyl resin, polyacrylic resin, It is preferable to use an epoxy resin, a vinyl copolymer resin resin, or the like. Examples of a method for forming the front anchor layer and the rear anchor layer include a coating method such as a gravure coating method, a roll coating method, and a comma coating method, and a printing method such as a gravure coating method and a screen printing method.

The fine space forming layer 4 is provided as the uppermost layer on the side integrated with the blow molding resin. As the fine space forming layer 4, there is a material obtained by implanting fine short fibers. For example, apply an adhesive on the sheet to form an adhesive layer,
The tip of the short fiber is pierced and fixed to the adhesive layer by a high-voltage electrostatic field (electrostatic flocking method). In addition, the short microfibers are temporarily attached to another release sheet, and the tip of the short microfibers is pierced into the resin sheet by overlapping with a resin sheet such as polyolefin or acrylonitrile-styrene-butadiene copolymer in a softened state, After cooling the resin sheet, only the release sheet is peeled off to transfer the fine short fibers to the resin sheet surface, and the obtained sheet can be laminated with the base sheet 2 provided with the design layer 3. In addition, the method of flocking of short microfibers (also referred to as flocking) is used for interior decoration parts of automobiles, carpets, wallpaper, etc. for the purpose of surface decoration, and a known method is applied to the fine space forming layer 4. It is possible. The material of the short microfibers is preferably selected from the same material as the resin of the parison 6 in order to increase the adhesion to the molded product. For example, if the resin of the parison 6 is a polypropylene resin, the flocking fiber is also a polyolefin resin. Of course, even if different materials are used, the resin of the parison 6 can be entangled with the flocking fiber to obtain sufficient adhesion.

The fine space forming layer 4 may be formed by laminating a woven or nonwoven fabric.

Further, the fine space forming layer 4 may be formed of a foam layer. Examples of the method for forming the foamed layer include known foaming agents such as azodicarbamide, PP oxybis (benzenesulfonyl) hydrazide, azobisisobutylnitrile, NN'-dimethyl-NNN'-dinitrosoterephthalamide, After applying a resin containing diazoaminobenzene, phthalate, or the like, the resin is foamed by heating or the like to form continuous pores.

By providing the fine space forming layer 4, when the decorative sheet is provided on the surface of the molded article at the same time as the blow molding in the mold 5, the surface of the expanded parison 6 and the decorative sheet 1 are bonded. The air between the surface and the air is well discharged. That is, the parison 6 surface and the decorative sheet 1
Although the adhesion surface is in close contact with the surface portion of the fine space forming layer 4, the parison 6 does not enter until the fine space inside the fine space forming layer 4 is filled. Therefore,
In a state where the parison 6 surface and the decorative sheet 1 bonding surface have not yet bonded to each other in a certain portion, leaving air therebetween.
Even if the bonding has already been completed in the surrounding area, if the parison 6 in the unbonded part is further pressed against the bonding surface of the decorative sheet 1 by the pressure from behind, the air 7 that is about to be left will pass through the minute space. It is then discharged (see FIG. 2).

Further, a backing sheet 8 may be laminated between the fine space forming layer 4 and the base sheet 2 in order to prevent wrinkles or tears due to heat or molding pressure during blow molding (see FIG. 3).

Next, a method of manufacturing the blow molded article with a decorative sheet of the present invention will be described.

First, the mold 5 is a pair of molds capable of closing the mold, and is provided with a die 9 for feeding the parison 6 into a space formed when the mold is closed. The die 9 has a function of forming the pipe-shaped parison 6 heated to the forming temperature between the blow-molding dies 5 in the open state, and the lower portion is fused to form a bag by closing the mold 5. It has a function of blowing a pressurized gas such as compressed air into the parison 6 from a blowing hole to expand the parison 6. The mold 5 is for closing the lower part of the parison 6 by closing the mold.

Further, as a resin material of the blow molded product,
For example, high density polyethylene, low density polyethylene,
Polypropylene, polyvinyl chloride, polyester, AB
S and the like.

The blow molding die 5 and the decorative sheet 1 described above.
First, the decorative sheet 1 is held on the inner surface of the cavity of the mold 5. As a holding method, a method of sucking the decorative sheet 1 on the inner surface of the mold by vacuum suction 10 using a reduced-pressure suction device (see FIG. 4), a method of sticking the sheet by static electricity, a cavity of the mold 5 There is a method of fixing a part of the decorative sheet 1 in the outer peripheral portion with a pin or the like.

Next, the decorative sheet 1 is provided on the surface of the molded article at the same time as the blow molding. In other words, plasticization in the heating cylinder,
The thermoplastic resin extruded as the parison 6 is sandwiched between the dies 5 through a die 9 by any method such as screw transfer or piston extrusion. At the time of extrusion, the parison 6 hangs down to a predetermined length by its own weight at the extrusion speed. Before parison 6 is not cooled, mold 5
The lower part of the pipe-shaped parison 6 is cut and fused by a cutter at the bottom of the parison to make the parison 6 into a bag shape (see FIG. 5). Simultaneously or thereafter, compressed air 11 is blown into the bag-shaped parison 6 from the die 9 to expand the parison 6, and the mold 5
To obtain a molded product (see FIG. 6). At this time, the adhesive surface of the decorative sheet 1 comes into contact with the parison 6 and is heated to the molding temperature of the parison 6 to be in a temporarily molten state and adhere to the surface of the molded product. Next, after the mold is opened, the molded article 12 is taken out, and a blow molded article with a decorative sheet having the decorative sheet 1 adhered to the surface is obtained.

In the blow-molded article with the decorative sheet obtained as described above, the air between the surface of the parison 6 and the bonding surface of the decorative sheet 1 is discharged through the fine space during the blow molding. Therefore, a smooth surface free of air pockets is obtained.

The description of the blow molding in the method for producing a blow molded article with a decorative sheet is directed to direct blow molding, but the present invention is not limited to this, and sheet blow molding, injection blow molding,
It also includes other blow molding such as stretch blow molding.

[0031]

The decorative sheet, the blow-molded article with the decorative sheet and the method of manufacturing the same according to the present invention have the above-described structure and operation, and therefore have the following effects.

That is, in the present invention, the fine space forming layer is provided as the uppermost layer on the side of the decorative sheet integrated with the blow molding resin. Therefore, in the process of manufacturing a blow-molded article with a decorative sheet using this sheet, the air between the parison surface and the decorative sheet bonding surface is discharged through a minute space, so that a large or complicated shape is formed. Even with the blow-molded article with a decorative sheet, a smooth appearance can be obtained without air pockets.

In addition, since the decorative sheet can be integrated with the blow molding of a large-sized hollow molded product at the same time as the blow molding, there is no need for the work of assembling the molded product into parts as in the past, so that the production efficiency is high and the cost is reduced. Can be.

[Brief description of the drawings]

FIG. 1 is a sectional view showing one embodiment of a basic layer configuration of a decorative sheet of the present invention.

FIG. 2 is a partially enlarged cross-sectional view showing one embodiment of a manufacturing process of the blow molded article with a decorative sheet of the present invention.

FIG. 3 is a sectional view showing another embodiment of the decorative sheet of the present invention.

FIG. 4 is a cross-sectional view showing one embodiment of a manufacturing process of a blow molded product with a decorative sheet.

FIG. 5 is a cross-sectional view showing one embodiment of a manufacturing process of a blow molded product with a decorative sheet.

FIG. 6 is a cross-sectional view showing one embodiment of a manufacturing process of a blow molded article with a decorative sheet.

FIG. 7 is a perspective view showing one embodiment of a large blow molded product.

FIG. 8 is a partially enlarged cross-sectional view showing one embodiment of a manufacturing process of a conventional blow molded article with a decorative sheet.

FIG. 9 is a cross-sectional view showing one embodiment of a large-sized hollow molded product with a decorative sheet without using blow molding.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Decorative sheet 2 Base sheet 3 Pattern layer 4 Fine space forming layer 5 Die 6 Parison 7 Air 8 Backing sheet 9 Die 10 Vacuum suction 11 Compressed air 12 Molded product 13 Spoiler 14 Air pool 15 Upper half part 16 Lower half parts

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[Procedure amendment]

[Submission date] June 10, 1999

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] 0004

[Correction method] Change

[Correction contents]

[0004]

However, if the area of the decorative sheet to be inserted into the mold during blow molding is large, air between the surface of the inflated parison 6 and the adhesive surface of the decorative sheet 1 is discharged well. It becomes difficult. In other words, parison 6
In a state where the surface and the bonding surface of the decorative sheet 1 are not bonded to each other in a certain portion with air left therebetween, the bonding has already been completed in the surrounding portion, so that the blow molded product with the decorative sheet is provided. In some cases, air pockets 14 were generated everywhere (see FIG. 8). This air pocket 1
4 is a molded product 12 when the blow molded product shrinks by cooling.
It is presumed that the smooth contraction of itself or the smooth following of the decorative sheet 1 is hindered, and in fact, a smooth appearance cannot be obtained at the occurrence portion.

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code FI // B29K 105: 20 B29L 9:00 22:00

Claims (6)

[Claims] 1. A decorative sheet having at least a design layer provided on a base sheet, wherein a fine space forming layer is provided as an uppermost layer on the side integrated with the blow-molded resin. Sheet. 2. The decorative sheet according to claim 1, wherein the fine space forming layer is formed by flocking. 3. The decorative sheet according to claim 1, wherein the fine space forming layer is formed by laminating a woven or nonwoven fabric. 4. The decorative sheet according to claim 1, wherein the fine space forming layer comprises a foam layer. 5. A blow-molded article with a decorative sheet, wherein the decorative sheet according to claim 1 is integrated with the surface of the molded article by a fine space forming layer. Goods. 6. A method of manufacturing a blow-molded article with a decorative sheet, wherein the decorative sheet is placed in a blow-molding die and the decorative sheet is provided on the surface of the molded article at the same time as the blow molding. A method for producing a blow-molded article with a decorative sheet, characterized in that the decorative sheet is integrated with the surface of the molded article by the fine space forming layer.