JPS60244902A - Plastic anti-glare mirror and its manufacturing method - Google Patents

Abstract

PURPOSE:To improve durability of a plastic antidazzle mirror and to provide easily functions such as resistance to scratching thereto by laminating mirror- surfaced and half-mirror-surfaced plastic films or sheet and resin layer. CONSTITUTION:A polycarbonate resin film 5 which is formed partially with a mirror coat 11 on one side, a polycarbonate resin film 5' which is formed partly with a half mirror coat 12 on one side and a functional film 13 such as hard coat film on the opposite side and a resin layer 6 formed by injection molding of a molten polycarbonate resin are laminated and united and are securely and thermally welded to each other by a welding part 7.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a novel plastic anti-glare mirror and a method for manufacturing the same.
It is possible to provide plastic anti-glare mirrors that are easily imparted with safety, scratch resistance, anti-fog properties, anti-static properties, anti-reflection properties, and the like.

[Conventional technology and its problems]

Conventionally, mirrors are made by depositing metal on one side of inorganic glass or plastic to form a mirror, then applying a coating to protect the mirror metal to form a plate crystal, and then converting it into metal, wood, resin, etc. It is manufactured by being integrated into the frame, handle, etc. by gluing it.

Inorganic glass has disadvantages such as being heavy, breaking, limited shapes and colors, and low productivity, so in recent years,
Synthetic resin materials are becoming widely used.

When a synthetic resin material is used, it has disadvantages such as being more easily scratched than inorganic glass, and it is usually necessary to apply a hard coat to impart scratch resistance.

Plastic mirrors are molded either by injection molding or by hot oiling of an extrusion plate or casting plate. When using injection molding, it is necessary to use a highly fluid molding material, and since highly fluid molding materials generally have poor impact resistance and solvent resistance, they are difficult to use when forming functional films such as hard coats. There are drawbacks such as cracks and scratches and physical property deterioration after coating with a functional film. Furthermore, since the anti-glare mirror of the present invention has a prism shape with non-parallel surfaces, it is difficult to form the internal part and the thin part in a well-balanced manner, resulting in poor productivity. If the plate is damaged by heat and oil, its shape is restricted, making it unsuitable for use as a normal anti-glare mirror, and it also has the disadvantage of being prone to optical distortion.

Further, conventional mirrors and plastic mirrors require a protective coating to protect the metal part of the mirror, which has the disadvantage of requiring many steps.

[Means for solving problems]

The present invention provides a plastic mirror and a method for manufacturing the same that improves or overcomes the drawbacks of conventional methods.

That is, the present invention provides a lamination of a thermoplastic film or sheet partially mirrored on one side, a thermoplastic film or sheet partially half-mirrored one side, and a resin layer formed by injection molding. It is a plastic anti-glare mirror in which the frame and the mounting portion where the mirror surface and the half mirror surface are non-parallel are integrally molded. In a preferred embodiment, the opposite surface of the half mirror portion is coated with a hard coat film. , a thermoplastic film or sheet coated with one or more types of mechanical films selected from antifogging films, antistatic films, antireflection films, etc.

Also, such plastic anti-glare mirrors include (1) a thermoplastic plastic film or sheet partially mirrored on one side as well as one side;

A step of punching out a partially half-mirrored thermoplastic plastic film or sheet into the same shape as the mirror to create a mirror-shaped punched piece; c) The punched piece corresponds to a portion of the mirror of the mirror molding mold. (3) The mold is closed, and molten resin is injected at high pressure by injection molding means to laminate and integrally mold the resin layer, frame, and mounting parts. and (4) removing the molded product from the mold. In a preferred embodiment, a thermoplastic plastic film or sheet partially mirrored on one side. and a step of punching out a thermoplastic plastic film or sheet whose one side is partially half-mirrored into the same shape as the mirror to create a mirror-shaped punched piece, and inserting the punched piece into the mirror part of a mirror molding mold. This process consists of simultaneously performing a step of mounting a part of the cavity corresponding to the mold with the partially mirrored surface on the inside at the same time as the step of closing the mold.

First, in order to facilitate understanding of the present invention, the present invention will be explained using drawings.

FIG. 2 is an example of an overall view of a plastic anti-glare mirror molded according to the present invention, and FIG.
It is a sectional view at -A'.

In Figure 2, the resin injected through the sprue 2, runner 3, and gate 4 forms a film whose inner surface is a half mirror and whose outer surface is coated with a functional film such as a hard coat film, and a film whose inner surface is mirror coated. The non-half mirror or non-mirrored portion of the outer periphery of the mirror is firmly integrated by heat fusion, and the mounting portion of the mirror is formed in a cylindrical shape on the side surface. In addition, in FIG. 1, a polycarbonate resin film 5 is partially coated with a mirror coat 11 on one side, a polycarbonate resin film 5 is partially coated with a half mirror coat 12 on one side, and a functional film 13 such as a hard coat film is coated on the opposite side. The film 5' and a resin layer 6 formed by injection molding of molten polycarbonate resin are laminated and integrated, and are firmly heat-sealed by a welding part 7.

Here, when fixing a polycanibonate resin film or sheet 5.5" coated with a functional film such as a half-mirror film, mirror film, or hard coat film on one side to the mold cavity, do not use static electricity or vacuum. This can be easily carried out using suction force or other conventionally known methods.

The thermoplastic plastic film or sheet having a functional film such as a half-mirror film, a mirror film, and a hard coat film on one side of the present invention is made of a thermoplastic plastic such as a polycarbonate resin, a polycarbonate resin, and a polybutylene terephthalate resin composition. material, polymethyl methacrylate (PMMA), acrylonitrile-
Typical thickness of transparent plastics such as styrene copolymer (AS resin) and polystyrene, 100-1.00
0μ, preferably 200 to 500μ film or sheet by a conventionally known method, for example, in the case of a half-mirror film or mirror film, by vapor deposition of aluminum or other metal, or in the case of a node coating, an epoxy resin system, an acrylic resin. In the case of an anti-fog film, a water-soluble resin coating agent is coated with a node coating agent such as a resin, amino resin, or polysiloxane, and then cured by heat or ultraviolet rays. Then, by curing by means such as heat or ultraviolet rays, an antistatic film and an antireflection film are similarly formed by vapor deposition of a conventionally known antistatic paint, antireflection paint, antistatic layer, or antireflection layer. . Moreover, these functional membranes can also be made into composite membranes having two or more types of functions at the same time.

Examples of thermoplastic plastics used in injection molding include those similar to the pluslacs used for functional films such as the half-mirror film, mirror film, and hard coat film.

Here, the plus racks used for films or sheets with a functional film such as a half-mirror film, mirror film, and hard coat film formed on one side and the thermoplastic plastics used for injection molding are usually of the same type. is preferable from the viewpoint of thermal adhesiveness and optical uniformity, and the melt viscosity of the plus rank used for the film or sheet is higher than the melt viscosity of the thermoplastic used for small injection molding, that is, it has a higher molecular weight. It is preferable to use a film or sheet from the viewpoint of preventing the film or sheet from losing its shape due to the molten resin produced by injection molding. In the case of polycarbonate resin, films or sheets with a hard coat film or anti-fogging film formed on one side and a half-mirror coating on the other side, and films or sheets with a molecular weight of 25,000 or more coated with a mirror coating on one side are injection molded. molecular weight 15
,000 to 25,000 is preferably used.

It is also possible to use different polymers for these non-plastic plastic films or sheets and for injection molding, and in this case, a polymer that promotes thermal fusion with the thermoplastic transparent resin to be injection molded. For the purpose of preventing the film from melting and losing its shape due to the resin used for injection molding, a primer coat - for example, one whose main component is a higher molecular weight substance of the same type as the molding resin. It is best to apply a transparent paint such as heat or ultraviolet curable paint to the half-mirror coat or mirror coat side, which is the opposite side of the hard coat or anti-fog coat.
Furthermore, a primer coat is not particularly required for the half-mirror-coated surface or the mirror-coated surface for adhesion to the injection molded resin layer, but if durability is particularly required due to usage conditions or other reasons, It is also a preferred embodiment to use a transparent primer coat for adhesion as desired.

In addition, plastic films or sheets coated with a functional film such as half-mirror coat, mirror part-1, and hard coat film on one side, or plastics for injection molding, may contain dyes, pigments, ultraviolet absorbers, and infrared absorbers. It is also possible to impart special performance by adding agents, compounds having photochromic properties, etc.

〔Example〕 ・Hereinafter, it will be explained using examples.

Example-1 Extruded polycarbonate film with a molecular weight of 30,000 and a thickness of 200μ (500in+
An acrylic primer was applied to one side of the sample (mm+) by the wire barcode method and dried. Next, a silicone top coat was applied onto the primer by a wire barcode method and cured at 130°C for 1 hour. Then, on the opposite side of this film, a metal half-mirror film was formed by sputtering in a conventional manner on a portion corresponding to a portion of the mirror having the desired mirror design shape.

In addition, the extrusion molded product has a molecular weight of 30,000 and a thickness of 200μ.
polycarbonate film (500”+u x 60
A metal mirror film was formed on one side of the mirror (0 m) by sputtering in a conventional manner on a portion corresponding to a part of the mirror having a desired mirror design shape. The hard coat film, the partial half-mirror film-forming film, and the partial mirror film-forming film obtained above were cut out into the shape of the plastic anti-glare mirror shown in FIG. installed in the cavity. Next, a polycarbonate resin having a molecular weight of 23,000 was injection molded. The resulting plastic anti-glare mirror with attached parts is completely heat-sealed to the molded resin and the resin of the half mirror part and the untreated part of the outer periphery of the mirror part, and the half mirror film and the mirror film part are encapsulated. The appearance was in good condition and no abnormalities were observed.

〔Effect of the invention〕

As described above, the present invention provides a highly economical plastic that is durable, lightweight, safe, and easily endowed with scratch resistance, antifogging properties, antistatic properties, antireflection properties, etc. It is possible to provide anti-glare mirrors.

In addition, in a preferred embodiment of the method for manufacturing the plastic anti-glare mirror of the present invention, (1) it is lightweight because it is molded from polycarbonate resin;
Excellent impact resistance and high safety.

■Polycarbonate resin film or sheet partially coated with a half-mirror coat on one side and hard coat film or anti-fog film on the other side, and polycarbonate resin film or sheet partially coated with a mirror coat on one side in an injection mold. Since the molten polycarbonate resin layer is heat-sealed and integrated with the molten polycarbonate resin layer, plastic mirrors with the desired surface characteristics can be obtained without going through any special mirror treatment or painting process, resulting in excellent productivity and post-processing such as painting. Eliminates the occurrence of defects that tend to occur during the process.

■It is extremely easy to selectively use half-mirror films, mirror films, and special functional films, and it is also easy to selectively use molding resins, so it is possible to use molding resins that are not possible with post-processing (painting, sputtering, etc.). Plastic anti-glare mirrors are easily obtained.

(2) Since the mold is equipped with a half-mirror film, mirror film, or special functional film, it is easy to mold with no visual defects and no optical distortion.

-It has the following characteristics.

[Brief explanation of drawings]

FIG. 2 is a perspective view of the plastic anti-glare mirror of the present invention, and FIG. 1 is a sectional view taken along line A-A in FIG. , 4: Gate 5: Plastic film with partial mirror film 5° 2 sides Partial half mirror 1 Plastic film with functional film on the opposite side, 6: Injection molded resin layer, 7: Fusion part 11: Mirror film, 12: Half mirror Membrane, 13: Indicates a functional membrane. Patent applicant: Mitsubishi Gas Chemical Co., Ltd. Representative: Kazuyoshi Nagano

Claims (1)

[Claims] 1. A thermoplastic film or sheet with one side partially mirrored, a thermoplastic film or sheet with one side partially mirrored, and a resin layer formed by injection molding. The plastic anti-glare mirror 2 has a frame and mounting part that are integrally molded, and the mirror surface and half mirror surface are non-parallel, and the opposite surface of the half mirror part is a node coating film,
Anti-fog films, antistatic films, anti-reflection films, etc. A plastic anti-glare mirror 3 according to claim 1, which is made of a thermoplastic film or sheet coated with one or more functional films selected from A plastic film or sheet and a thermoplastic film or sheet with one side partially half-mirrored are composed of a polycarbonate resin with a molecular weight of 25,000 or more, and the resin layer, frame, and attachment are formed by injection molding. part with a molecular weight of 15,000 to 25,000
The plastic anti-glare mirror 4 according to claim 1 or 2, which is made of polycarbonate resin (
11 Punching a thermoplastic plastic film or sheet with one side partially mirrored and a thermoplastic plastic film or sheet with one side partially mirrored into the same shape as the mirror to create a mirror-shaped punched piece. (2) inserting the punched piece into a part of the cavity corresponding to a part of the mirror of the mold for molding the mirror; (3) closing the mold and injecting molten resin at high pressure by injection molding means to laminated and integrally mold the resin layer portion, frame and mounting portion; (4) Manufacturing method of plasti-7 anti-glare mirror including the step of taking out the molded product from the mold 59 Thermoplastic plastic film or sheet with one side partially mirrored and one side partially half mirrored The step of punching out the thermoplastic plastic film or sheet into the same shape as the mirror to create a mirror-shaped punched piece, and partially mirroring the punched piece into a part of the cavity corresponding to the mirror part of the mirror molding mold. Claim 4, which comprises simultaneously carrying out the step of mounting with the surface facing inside and the step of closing the mold.
Manufacturing method of plastic anti-glare mirror described in section