JP6050681B2 - Manufacturing method of molded products - Google Patents

Description

  The present invention relates to a method for manufacturing a molded article.

Molded products (decorative materials) whose surfaces are decorated are used for interior materials, furniture, furniture, kitchen doors, storage doors, and the like of automobiles.
As a method for producing a decorative material, for example, there is a method of spraying a thermosetting paint on the surface of a molding member such as plastic or plywood. However, many processes are required for painting, and heating at a high temperature is required.

  There is also a method of manufacturing a decorative material by attaching a decorative sheet (film) to the surface of a molding member. For example, when producing a decorative material provided with a hard coat layer having scratch resistance on the surface, if a decorative sheet provided with a hard coat layer in advance is used, the hard coat layer is hard and has a low elongation rate. Cracks occur without being able to follow the product shape change. Therefore, after a decorative sheet is molded and pasted along the surface of the substrate, an ultraviolet curable hard coat agent is applied by a spray coating method or the like, and then a ultraviolet coat is applied to form a hard coat layer. It is common.

  On the other hand, as a method for producing outdoor molded articles such as automobile bodies and exterior parts, a decorative film in which a thermoplastic resin layer, an uncured ultraviolet curable hard coat layer, and a release film layer are laminated is used. Placed on the male mold of the injection mold so that the thermoplastic resin layer of the decorative film is in contact with the injection molded resin, and the molten resin is press-fitted into the gap between the male mold and the decorative film. After that, a method for producing a molded article in which a decorative film layer is formed on the surface by irradiating ultraviolet rays to cure the hard coat layer and then peeling off the release film has been proposed (Patent Document 1). reference).

Japanese Patent No. 4627099

In the method of curing by irradiating ultraviolet rays after spraying an ultraviolet curable hard coat agent, the cost increases due to an increase in the number of steps. Moreover, in the case of spray coating, there are many material losses, and it is necessary to consider the influence on the environment.
Moreover, when manufacturing a molding by injection molding like patent document 1, it is necessary to heat injection molding resin at high temperature, and used base materials (member for shaping | molding) other than resin, such as a wood-type member. It is not suitable for the production of cosmetics.

  The present invention provides a method for producing a molded product that can also be used for a molding member other than a resin, such as a wood-based member, and that can produce a high-quality molded product having high surface hardness and smoothness at a low temperature. For the purpose.

In order to achieve the above object, the following invention is provided.
<1> preparing a laminated sheet in which a base material layer, an ultraviolet curable hard coat uncured layer, and a protective layer that transmits ultraviolet light and is peelable are laminated in this order;
An adhesive layer is provided between the base material layer side of the laminated sheet and the molding member, and the molding member is formed by a molding method in which the laminated sheet is adhered to the surface of the molding member using a pressure difference of atmospheric pressure. Forming along the surface and adhering via the adhesive layer;
Forming a hard coat layer obtained by irradiating the hard coat uncured layer of the laminated sheet adhered to the molding member with ultraviolet rays to cure the hard coat uncured layer;
Peeling the protective layer from the hard coat layer;
The manufacturing method of the molded article which has this.
<2> The laminated sheet is laminated on the first base material layer and the first base material layer as the base material layer, and has a second base material layer having a higher hardness than the first base material layer. The method for producing a molded article according to <1>, wherein the hard coat uncured layer is laminated on the opposite surface of the second substrate layer on which the first substrate layer is laminated.
<3><1> or <2> in which the 30% modulus at 70 ° C. of the base material layer is vertical 3.2 ± 0.3 N / cm and horizontal 2.7 ± 0.3 N / cm. The manufacturing method of the molded article of description.

  According to the present invention, there can be used a molding member other than a resin, such as a wood-based member, and a method for producing a molded product that can produce a high-quality molded product having high surface hardness and smoothness at a low temperature. Provided.

It is a figure which shows the main processes in the manufacturing method of the molded article which concerns on this invention. It is a schematic sectional drawing which shows an example of the laminated constitution of the lamination sheet used by this invention. It is the schematic which shows an example of the membrane shaping | molding apparatus which can be used when membrane-molding by this invention. It is the schematic which shows the state shape | molded by the membrane shaping | molding apparatus shown in FIG.

  As a result of intensive studies, the present inventors have used a laminated sheet including a hard coat layer before ultraviolet irradiation (a layer before hard coat UV irradiation, hereinafter referred to as “ultraviolet curable hard coat uncured layer”) to form a membrane. In addition to resin, the laminated sheet is molded and adhered along the surface of the molding member by a molding method in which the pressure difference of atmospheric pressure such as TOM molding, vacuum molding, etc. is used to adhere to the surface of the molding member. It was found that a high-quality molded product having a high surface hardness and smoothness can be produced at a low temperature.

  That is, the method for producing a molded product according to the present invention prepares a laminated sheet in which a base material layer, an ultraviolet curable hard coat uncured layer, and a protective layer that transmits ultraviolet rays and is peelable are laminated in this order. An adhesive layer is provided between the step (laminated sheet preparation step) and the base material layer side of the laminated sheet and the molding member, and the laminated sheet is brought into close contact with the surface of the molding member using a pressure difference of atmospheric pressure A step (molding step) of forming along the surface of the molding member by the molding method to be adhered and bonding via the adhesive layer, and ultraviolet rays on the hard coat uncured layer of the laminated sheet adhered to the molding member A step of forming a hard coat layer by irradiating and curing the uncured hard coat layer (ultraviolet irradiation step), and a step of peeling the protective layer from the hard coat layer (peeling step). Constructed.

FIG. 1 shows an example of a manufacturing process of a molded product according to the present invention. FIG. 2 is a diagram schematically showing an example of the layer structure of the laminated sheet used in the present invention. FIG. 3 schematically shows an example of an apparatus used for forming a membrane according to the present invention.
Hereinafter, each step will be specifically described.

<Laminated sheet preparation process>
First, a laminated sheet is prepared in which a base material layer, an ultraviolet curable hard coat uncured layer, and a protective layer that transmits ultraviolet light and can be peeled are laminated in this order (FIG. 1A).

(Laminated sheet)
The laminated sheet 10 shown in FIG. 2 includes a primer layer 22, a base material layer 20 having a two-layer structure, an ultraviolet curable hard coat uncured layer 16, and a protective layer 18 that transmits ultraviolet light and can be peeled off. They are stacked in this order.

-Base material layer-
The base material layer 20 is a layer that supports the hard coat layer 16 and the protective layer 18, is deformed along the surface of the molding member 42, and can be in close contact with the adhesive layer (not shown).

  As a material which comprises the base material layer 20, the thermoplastic resin which has a moldability, a softness | flexibility, and a drawability is preferable, and an acrylic resin is more preferable. Specifically, for example, a polymer or copolymer of methacrylic acid or methacrylic acid ester represented by polymethyl methacrylate (PMMA), a copolymer of alkyl methacrylate, alkyl acrylate and styrene, etc. From the viewpoint of safety, a copolymer of alkyl methacrylate, alkyl acrylate and styrene and a mixture of methyl methacrylate and methyl acrylate copolymer is preferable, and acrylic rubber is blended to give flexibility. Is also preferable.

  The base material layer 20 may contain various additives, and examples thereof include a plasticizer, a lubricant, and a processing aid.

  The base material layer 20 may have a single-layer structure, but preferably has a two-layer structure. A base material layer 20 of the laminated sheet 10 shown in FIG. 2 includes a first base material layer 12 and a second base material layer 14 having a higher hardness than the first base material layer 12.

  There is no restriction | limiting in particular in the film forming method of the base material layer 20, What is necessary is just to apply a well-known sheet forming method. Of these, the calendar method is preferable in terms of ease of production and easy maintenance of the apparatus. When the base material layer 20 is formed by a calendar method, for example, the base material layer 20 may be formed under conditions of 180 ° C. to 220 ° C. using an apparatus such as a rolling roll manufactured by Nippon Roll Co., Ltd.

-First substrate layer-
The first base layer 12 is preferably made of a soft and stretchable material in consideration of moldability. Examples of the material constituting the first base layer 12 include methyl methacrylate, methyl acrylate copolymer, a blend of methyl acrylate copolymer and acrylic rubber, and the like. For example, a film formed by a calendar method can be used.

  The thickness of the first base material layer 12 is preferably 250 μm ± 100 μm, and more preferably 250 μm to 300 μm.

-Second base material layer-
The second base material layer 14 is located on the side where the hard coat layer is provided, and is composed of a layer having a higher hardness than the first base material layer 12. The hardness in the present invention is based on the pencil hardness.
For example, in the laminated sheet in which the hard coat layer is directly provided on the flexible first base material layer 12, the final hardness (after peeling the protective layer) as the laminated sheet may be insufficient. By providing the second base material layer 14 having a higher hardness than the first base material layer 12 on the side where the hard coat layer is provided, the hardness of the entire base material layer 20 can be increased.

  The second base material layer 14 is preferably composed of a resin film that has a hardness higher than that of the first base material layer 12 and does not hinder elongation during molding. The hardness of the second base material layer 14 may be about H in pencil hardness (JIS K-5400 pencil scratch test) from the viewpoint of maintaining moldability without inhibiting the flexibility and elongation of the whole base material layer. preferable.

  The thickness of the second base material layer 14 is preferably less than the thickness of the first base material layer 12 from the viewpoint of maintaining the moldability without inhibiting the flexibility and elongation of the base material layer 20 as a whole. Specifically, it is more preferably 75 μm ± 50 μm, and particularly preferably 50 μm to 100 μm.

Specifically, a resin film such as PMMA (polymethyl methacrylate) or vinyl chloride can be suitably used as the second base material layer 14.
The base material layer 20 can be produced by laminating the second base material layer 14 on the first base material layer 12 before applying the hard coating agent.

The substrate layer 20 preferably has a 30% modulus at 70 ° C. of 3.2 ± 0.3 N / cm and a width of 2.7 ± 0.3 N / cm. The modulus value is a hardness measured according to JIS K-6301, and is specifically a value measured as follows.
That is, a 25 mm wide strip in accordance with JIS K-6301 is punched out, a tensile test is performed at a pulling speed of 50 mm / min and 70 ° C., and a modulus at 30% elongation is measured. As a method of adjusting the hardness of the base material layer 20, when it is desired to make it soft, the second base material layer 14 is made thin, or when the first base material layer 12 is made thick and hard, the second base layer 20 is used. The material layer 14 may be thickened or the first base material layer 12 may be thinned.

  In addition, when comprising the base material layer 20 by a single layer, it is preferable that the thickness of a base material layer is the range of 200 micrometers-450 micrometers, and it is more preferable that it is the range of 250 micrometers-400 micrometers.

-Hard coat uncured layer-
The hard coat uncured layer 16 is formed, for example, by applying an ultraviolet curable hard coat agent on the base material layer 20 (second base material layer 14).

  The hard coat agent is selected from materials that are cured by ultraviolet irradiation and function as a hard coat layer having scratch resistance. For example, those containing urethane acrylate, an acrylic monomer, and a radical photopolymerization initiator are suitable.

  The method of applying the hard coat agent to the base material layer 20 is not particularly limited. For example, since the loss of the hard coat agent is large in the case of spray coating, the paint containing the hard coat agent is applied to the coater method on the base material layer 20. It is preferable to apply and dry. In addition, what is necessary is just to apply | coat the coating material containing a hard-coat agent to the 2nd base material layer 14 side with high hardness, when the base material layer 20 is a 2 layer structure, as shown in FIG. From the viewpoint of thickness uniformity, surface smoothness, and the like, the direct reverse coater method is preferred, and it is desirable to dry while applying air after coating.

  The thickness of the hard coat uncured layer 16 depends on the use of the molded product to be manufactured, etc., but after being cured by ultraviolet irradiation, from the viewpoint of ensuring scratch resistance and smoothness as the hard coat layer, It is preferable that it is 5-50 micrometers in thickness, for example, and it is more preferable that it is 10-30 micrometers.

  The hard-coating uncured layer 16 is preferably hardened after curing, with no scratches with a sapphire needle 30 g, or with a pencil hardness (JIS K-5400 Pencil Scratch Test) H with no scratches.

-Protective layer-
The protective layer 18 protects the hard-coating uncured layer 16 before curing, and after forming the laminated sheet along the surface of the molding member 42, a layer that transmits ultraviolet rays when the hard-coating uncured layer 16 is cured. It is.
The protective layer 18 can be provided by, for example, laminating a protective film that transmits ultraviolet rays and is peelable on the hard coat uncured layer 16.

When a laminated sheet having a UV curable hard coat uncured layer is formed, the surface is easily affected by the specularity of the protective film surface and the uneven elongation. The protective film (protective layer) 18 preferably has specularity from the viewpoint of ensuring the surface smoothness of the molded product at the time of UV irradiation and peeling, in addition to UV transparency and releasability.
Further, the protective film 18 is preferably easy to stretch from the viewpoint of preventing the occurrence of uneven elongation (such as wrinkles) during molding.

As the protective film 18, a polyethylene (PE) film, a polypropylene (PP) film, a polyethylene terephthalate (PET) film, and the like can be used. From the viewpoint of moldability at low temperatures, a PE film and a PP film are preferable. A low density polyethylene (LDPE) clear film is particularly preferred.
The protective film 18 preferably has a mirror state on at least the side in contact with the hard coat uncured layer 16 in order to prevent wrinkles and the like from being generated in the hard coat layer.

  From the viewpoint of protecting the laminated sheet 10 from, for example, roll-to-roll and protecting it from foreign matter adhered when stored in a roll state, the protective film 18 is preferably thick. Specifically, the thickness of the protective film 18 is preferably 100 to 200 μm.

-Primer layer-
The primer layer 22 is a layer provided as necessary in order to improve the adhesion between the laminated sheet 10 and the molding member 42. The material that improves the adhesion between the laminated sheet and the molding member 42 together with the adhesive applied to the surface of the molding member 42 is the surface opposite to the hard coat uncured layer 16 of the base material layer 20, that is, the base. When the material layer 20 has a two-layer structure, the primer layer 22 may be formed by coating on the first base material layer 12 side. Specifically, before applying the hard coat agent to the base material layer 20, the primer layer 22 is formed by gravure-coating urethane-based paint on the surface to be bonded to the molding member 42 and drying with hot air. Can do.

  In addition, although it is preferable to apply the primer layer 22 to the base material layer (base material sheet) 20 before forming the hard coat uncured layer 16 as described above, the base material layer 20 (second base material) is provided. After sequentially laminating the hard coat uncured layer 16 and the protective layer 18 on the layer 14), the primer layer 22 may be provided on the opposite surface (first substrate layer) of the substrate layer 20.

  Although the thickness of the primer layer 22 is not limited, Usually, it is 1-5 micrometers, Preferably it is 2-3 micrometers.

-Other layers-
The laminated sheet 10 based on the present invention may have other layers. For example, a colored layer containing a colorant or the like can be provided in order to impart decorativeness. In addition, for example, the base material layer 20 or the hard coat layer 16 may be made to contain a colorant without using a separate color layer, and may also serve as the color layer.

Examples of the colorant include pearl particles, metal powders such as aluminum powder, and pigments. Among these, pigments are generally used.
Examples of the pigment that can be used in the present invention include carbon black and titanium dioxide. For example, when carbon black is used, it is preferably used as a mixture in which carbon black, an ester dispersant, and an acrylic resin are mixed in advance.
When colorants such as pearl particles, aluminum powder, and pigments are used, their average particle size is generally preferably in the range of 0.5 μm to 100 μm, more preferably in the range of 3 μm to 50 μm. It is.

<Molding process>
By the molding method in which an adhesive layer is provided between the base material layer 20 side of the laminated sheet 10 and the molding member 42, the laminated sheet 10 is brought into close contact with the surface of the molding member 42 using a pressure difference of atmospheric pressure. Molding is performed along the surface of the molding member 42 and bonded through the adhesive layer (FIG. 1B).

(Member for molding)
The molding member 42 is a molding member having a shape, size, weight and the like corresponding to a target molded product, and the laminated sheet 10 is molded along the surface thereof and bonded through an adhesive layer. .
The material, shape, size, and the like of the molding member 42 may be selected in consideration of the application, purpose, design, cost, etc. of the molded product to be manufactured. As the molding member 42, for example, a wood-based member (MDF) such as wood plywood, wood fiber board, and particle board can be preferably used. However, a resin molding member, a metal molding member such as aluminum, a molding member such as glass or ceramic It can also be used.

(Adhesive layer)
The adhesive layer (not shown) is usually formed by applying an adhesive to the surface of the molding member 42 before molding the laminated sheet 10 along the surface of the molding member 42.
There is no restriction | limiting in particular as an adhesive agent, According to the kind etc. of the shaping | molding member 42, it selects suitably. For example, (1) two-component curable polyester adhesive, (2) two-component curable urethane adhesive, and (3) two-component curable acrylic pressure-sensitive adhesive are preferably used.
The adhesive used for forming the adhesive layer is also available as a commercial product. For example, the Oliveline series [Toyo Ink Co., Ltd.], Welder Adhesive No. 3660 [two-component curable polyurethane adhesive: No Tape Industry Co., Ltd.], Daikarak 7250NT [two-component curable polyester adhesive: Daido Kasei Kogyo Co., Ltd.] and the like are suitable.

The thickness of the adhesive layer is preferably in the range of 20 μm to 50 μm in terms of dry film thickness.
The method for forming the adhesive layer on the surface of the molding member 42 is not particularly limited, and a known method such as a coating method using a spray, a coater, or a transfer method can be employed. What is necessary is just to select according to a shape etc.

  The adhesive layer may be provided by being laminated on the laminated sheet 10 side, that is, the primer layer 22 of the laminated sheet 10, or the base material layer 20 (first base material layer 12 without providing the primer layer on the laminated sheet 10). ) May be provided with an adhesive layer.

(Molding method in which the pressure difference of the atmospheric pressure is used to adhere to the surface of the molding member)
After forming the adhesive layer on the surface of the molding member 42 and providing an adhesive layer, the surface of the molding member 42 is formed by a molding method in which the laminated sheet 10 is brought into close contact with the surface of the molding member 42 using a pressure difference of atmospheric pressure. And are bonded through the adhesive layer.
In the present invention, “a molding method in which the pressure difference of the atmospheric pressure is used to closely contact the surface of the molding member” refers to two spaces partitioned by the laminated sheet 10 when the laminated sheet 10 is disposed on the molding member 42. This means a method of forming the laminated sheet 10 in close contact with the surface of the molding member 42 by providing a pressure difference so that the pressure on the molding member 42 side becomes relatively low. Specifically, membrane molding , TOM molding, vacuum molding and the like.

(Membrane molding)
Membrane molding is applied to a three-dimensional woody material (MDF: Medium Density Fiberboard), which is a molding member, with an adhesive applied in advance, covered with a decorative sheet, heated to near the softening point of the decorative sheet, and then further decorated Cover the sheet with a stretchable silicone rubber sheet, evacuate it from the wood-based member side, and then blow compressed air from the silicone rubber side as necessary to make the decorative sheet a three-dimensional member (molding member) This is a method of forming in conformity with the shape.

A membrane molding apparatus 30 shown in FIG. 3 includes a stage 34 in which an MDF (molding member) 42 is installed, a silicone rubber sheet 38, an infrared heater 40, and the like in a chamber 32. The stage 34 is provided with a through hole 36 for evacuation.
For example, a polyurethane emulsion is applied as an adhesive to the surface of the molding member 42 to provide an adhesive layer (not shown), and the laminated sheet 10 is disposed so as to cover the surface of the molding member 42.

  Next, the laminated sheet 10 is heated by the infrared heater 40 and evacuated through the through hole 36 provided in the stage 34. The laminated sheet 10 is softened by heating, and the laminated sheet 10 is pressed along the surface of the molding member 42 by the silicone rubber sheet 38 as shown in FIG. Thereby, the laminated sheet 10 is molded along the surface of the molding member 42 and adhered to the surface of the molding member 42. In addition, what is necessary is just to perform the heating of the lamination sheet 10 so that skin temperature may be about 60 to 70 degreeC, for example, and it can shape | mold at low temperature.

In the present invention, not only membrane molding, but other molding methods using a pressure difference of atmospheric pressure such as TOM molding and vacuum molding may be performed.
TOM (Three dimension Overlay Method) Molding is a process in which the molded body (molding member) and decorative sheet (laminated sheet) pre-molded with resin, etc. are evacuated in a vacuum environment, heated, molded, and pressurized. It is a method of decorating a molded product through. Even in the TOM molding, an injection process at a high temperature is unnecessary, and a target decorative molded product can be manufactured at a low temperature.

<Ultraviolet irradiation process>
After the molding, the molding member 42 to which the laminated sheet 10 is adhered is taken out from the chamber 32 of the membrane molding apparatus 30, and the hard coat uncured layer 16 of the laminated sheet 10 adhered to the molding member 42 is irradiated with ultraviolet rays for hard coating. A hard coat layer obtained by curing the uncured layer 16 is formed (FIG. 1C).
By irradiating ultraviolet rays from the protective layer 18 side, the ultraviolet rays pass through the protective layer 18 and the hard coat uncured layer 16 can be cured.

  The light source for irradiating ultraviolet rays is not particularly limited as long as it can irradiate ultraviolet light in a wavelength region for curing the hard coat uncured layer 16 after molding, and an LED light source, a high-pressure mercury lamp, a black light, or the like can be adopted. it can.

<Peeling process>
After the hard coat uncured layer 16 is turned into a hard coat layer by ultraviolet irradiation, the protective layer 18 is peeled off (FIG. 1D).

Through the above steps, a molded product in which a hard coat layer is provided on the outermost surface of the molding member 42 can be manufactured.
According to the present invention, a molding member other than a resin such as a wood-based member can be used, and the hardness and smoothness of the surface can be reduced without going through a process of heating at a high temperature that melts the resin as in injection molding. High quality molded products can be manufactured at low temperatures.

  The method for producing a molded product of the present invention can be applied to the production of various products that require scratch resistance, decorativeness, and the like. For example, interior materials and exterior materials of automobiles, railway vehicles, aircraft, joinery, furniture It can be suitably used in various fields such as kitchen doors and storage doors.

  EXAMPLES Hereinafter, although an Example is given and this invention is demonstrated concretely, this invention is not restrict | limited to these.

<Example 1>
(Production of laminated sheet)
-Production of base film-
Using an acrylic resin (Mitsubishi Rayon Co., Ltd.) 100 parts by mass and a processing aid (Metabrene: made by Mitsubishi Rayon Co., Ltd.) 5 parts by mass, a 300 μm thick acrylic film (first base material layer) is formed by a calendar method. did.
Thereafter, a PMMA film having a thickness of 75 μm (manufactured by Mitsubishi Rayon Co., Ltd.) was laminated as the second base material layer on the acrylic film (first base material layer) to prepare a base film having a two-layer structure.

About the obtained base film, 70 degreeC and 30% modulus were measured as follows.
A 25 mm wide strip in accordance with JIS K-6301 is punched out, a tensile test is performed at a pulling speed of 50 mm / min and 70 ° C., and a modulus at 30% elongation is measured.
As a result of the above measurement, the 30% modulus of the base film was vertical 3.1 N / cm and horizontal 2.5 N / cm.

-Formation of primer layer-
A urethane-based paint was gravure-coated on the first substrate layer side of the substrate film and dried with hot air to form a primer layer having a thickness of 3 μm.

-Formation of uncured hard coat layer-
Next, a UV curable paint (solvent: methyl isobutyl ketone) containing urethane acrylate, an acrylic monomer and a radical photopolymerization initiator is applied to the PMMA film surface (second base material layer side) of the base film with a direct reverse coater. Coated and dried. Thereby, a hard coat uncured layer was formed.

-Formation of protective layer-
The hard coat uncured layer was dried and a polyethylene film for surface protection (trade name: Convenience Pure Soft, manufactured by Okamoto Co., Ltd.) having a thickness of 150 μm was laminated as a protective film for protecting the hard coat uncured layer.
Thereby, the laminated sheet 1 which has a primer layer in the 1st base material layer side of the base material layer, and was laminated | stacked with the hard-coat uncured layer and the protective film on the 2nd base material layer side was obtained.

(Membrane molding)
A polyurethane emulsion (trade name: No. 4281, manufactured by No-Tape Industries Co., Ltd.) is applied as an adhesive to the surface of the MDF, and the membrane is so that the primer layer side of the laminated sheet 1 is bonded to the MDF via the adhesive. Molding was performed. The molding temperature was set to 65 ° C., and the molding time was set to 3 minutes.

After forming the membrane, the laminated sheet 1 adhered to the MDF was irradiated with ultraviolet rays (UV) to cure the hard coat uncured layer to obtain a hard coat layer.
After curing by UV irradiation, the laminated protective film was peeled off.

  The appearance of the molded product 1 obtained as described above was free from problems such as wrinkles, and a high-quality molded product was obtained.

<Example 2>
(Production of laminated sheet)
A laminated sheet 2 was produced in the same manner as in Example 1 except that the following single-layer acrylic (300 μm) film was used as the base film.
The substrate film was measured at 70 ° C. and 30% modulus, and it was found to be 2.2 N / cm in length and 1.7 N / cm in width.

(Membrane molding)
A molded product 2 was produced by membrane molding in the same manner as in Example 1 except that the laminated sheet 2 was used.

  The appearance of the molded product 2 obtained as described above is free from wrinkles and other problems, but the appearance defect (glue duck) that picks up the uneven thickness of the adhesive during molding was worse than that of Example 1. Furthermore, the physical properties with surface scratches were somewhat inferior to those of Example 1.

DESCRIPTION OF SYMBOLS 10 Laminated sheet 12 1st base material layer 14 2nd base material layer 16 Hard coat layer 16 Hard coat uncured layer 18 Protective film (protective layer)
20 Base material layer 22 Primer layer 30 Membrane molding device 32 Chamber 34 Stage 36 Through hole 38 Silicone rubber sheet 40 Infrared heater 42 Molding member

Claims (2)

Preparing a laminated sheet in which a base material layer, an ultraviolet curable hard coat uncured layer, and a protective layer that transmits ultraviolet light and is peelable are laminated in this order;
An adhesive layer is provided between the base material layer side of the laminated sheet and the molding member, and the molding member is formed by a molding method in which the laminated sheet is adhered to the surface of the molding member using a pressure difference of atmospheric pressure. Forming along the surface and adhering via the adhesive layer;
Forming a hard coat layer obtained by irradiating the hard coat uncured layer of the laminated sheet adhered to the molding member with ultraviolet rays to cure the hard coat uncured layer;
Peeling the protective layer from the hard coat layer;
Have a, the laminated sheet includes, as the base layer, and the first acrylic resin film, the provided first been laminated acrylic resin film, wherein the first hardness than the acrylic resin film A second acrylic resin film having a high thickness and a thin thickness, and the hard coat uncoated surface is opposite to the second acrylic resin film on which the first acrylic resin film is laminated. A method for producing a molded product in which a cured layer is laminated . 2. The method for producing a molded article according to claim 1, wherein a 30% modulus at 70 ° C. of the base material layer is 3.2 ± 0.3 N / cm in length and 2.7 ± 0.3 N / cm in width. .

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