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WO2014203917A1 - Film, procédé de moulage de film, moule, moulage comprenant le film et procédé de moulage s'y rapportant - Google Patents

Film, procédé de moulage de film, moule, moulage comprenant le film et procédé de moulage s'y rapportant Download PDF

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Publication number
WO2014203917A1
WO2014203917A1 PCT/JP2014/066099 JP2014066099W WO2014203917A1 WO 2014203917 A1 WO2014203917 A1 WO 2014203917A1 JP 2014066099 W JP2014066099 W JP 2014066099W WO 2014203917 A1 WO2014203917 A1 WO 2014203917A1
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WO
WIPO (PCT)
Prior art keywords
film
mold
molding
convex portion
hard coat
Prior art date
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PCT/JP2014/066099
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English (en)
Japanese (ja)
Inventor
田原　久志
鈴木　克則
昭郎 大久保
Original Assignee
三菱瓦斯化学株式会社
Ｍｇｃフィルシート株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 三菱瓦斯化学株式会社, Ｍｇｃフィルシート株式会社 filed Critical 三菱瓦斯化学株式会社
Priority to CN201480034476.5A priority Critical patent/CN105392612B/zh
Priority to KR1020167000233A priority patent/KR102196604B1/ko
Priority to JP2015522949A priority patent/JP6525871B2/ja
Publication of WO2014203917A1 publication Critical patent/WO2014203917A1/fr

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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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • 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
    • B29C51/04—Combined thermoforming and prestretching, e.g. biaxial stretching
    • 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
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/30—Moulds

Definitions

  • the present invention relates to a film, a molding method for thermoforming the film into a desired three-dimensional shape, a molding die, and a three-dimensional shaped article (molded article) using the film.
  • the present invention relates to a hard coat sheet or the like. It is used suitably for manufacture of the decorative molded product containing this.
  • Decorated molded products painted molded products
  • in-mold molded products are attracting attention from the aspects of productivity, design and functionality.
  • Examples of applicable objects include exterior parts of mobile phones, automobile-related parts, medical equipment, electronics products, home appliances, building materials, containers such as detergents and cosmetics, and toys.
  • Patent Document 1 discloses a resin molded product having a good appearance such as a mirror surface and a diaphragm surface, without forming a film layer or coating on the surface, and with a large size that can withstand high pressure as in an injection molding method.
  • a supporting member that supports the mold member in a state in which a space is secured between the mold member and the molding surface having the molding surface, and the molding surface has a Vicat softening temperature (T) ° C. or higher of the sheet-like resin to be molded.
  • the opening 2 can be made into a square shape, a fitting member with a decorative frame or the like can be simplified, and a special operation such as extending the cooling time to prevent warping.
  • T Vicat softening temperature
  • the opening periphery green in the mold Are formed so that each side swells outwardly, and the degree of the swell is formed so that each side of the opening circumference is linear due to deformation accompanying material cooling after molding.
  • a pressure forming mold characterized by being defined is disclosed.
  • the rising height is increased (generally less than 4 mm) even in a substantially vertical shape.
  • the scratching property of the resin surface is not improved so much, there is a problem that the hard coat is scratched at the time of use despite the cost.
  • the inventors of the present invention have focused on the fact that cracks that are concentrated in the vicinity of the bottom surface are generated by a mechanism during shaping. That is, it is a problem that the part finally extended becomes local elongation.
  • the part finally extended becomes local elongation.
  • When shaping only with pressurized air only the base of the bottom surface is stretched locally, while when pressing with a mold without using pressurized air when shaping, the area near the top surface is stretched locally. It was found that cracks occurred.
  • air or the like is involved because the mold and the top of the sheet that require strict quality especially for the appearance of the design are in contact, or the mold surface is transferred to the sheet when the mold is not polished. It was found that the appearance deteriorated.
  • the purpose of the present application is to provide a mold, a molding method, and the like that keep the shaped sheet appearance good, for example, so as not to generate cracks even when a hard coat having scratch resistance is used.
  • An object of the present invention is to provide a film or sheet and a molded article including them, in which the height of the shape rises and the curvature on the top surface side can be reduced, and design restrictions are minimized.
  • the present invention is particularly preferably used in molding a hard coat sheet or the like in which cracks are easily generated.
  • the present invention is as follows.
  • a hard coat having 10 or less scratches on the surface of the film before molding in the scratch resistance test (according to ASTM D 2486-79, using a pork brush at a load of 450 g for 200 reciprocations).
  • the film is provided with at least a layer, and is formed on the outer side of the convex portion with respect to the first region (thick portion) of the film disposed on the convex portion of the lower mold for molding used at the time of molding.
  • the film is characterized in that the elongation ratio of the second region (edge) of the film is 100% or less.
  • a lower mold having a convex part;
  • An upper die provided with a pressing member located outside the convex portion at the time of mold clamping;
  • the film is molded by a molding method including a secondary shaping step for secondary shaping of the film at least outside the convex portion of the lower mold clamped by the pressure of the gas introduced from the upper mold side.
  • a lower mold having a convex part provided with a concave part for forming a hole and / or a concave part in the molded product;
  • An upper die provided with a pressing member located outside the convex portion at the time of mold clamping;
  • the film is molded by a molding method including a secondary shaping step for secondary shaping of the film at least outside the convex portion of the lower mold clamped by the pressure of the gas introduced from the upper mold side.
  • the elongation ratio of the second region (end portion) of the film formed on the outer side of the convex portion with respect to the first region (thick portion) of the film disposed on the convex portion at the time of molding is 100. % Or less, the film according to (2) or (3).
  • the film according to (2) or (3) above which is a hard coat film having a hard coat layer.
  • a molded article comprising the film according to any one of (1) to (6) above.
  • a lower mold having a convex part An upper die provided with a pressing member located outside the convex portion at the time of mold clamping;
  • a film forming method comprising: a secondary shaping step of secondary shaping of the film at least outside the convex portion of the lower mold clamped by the pressure of the gas introduced from the upper mold side is there.
  • a lower mold having a convex part provided with a concave part for forming a hole and / or a concave part in the molded product,
  • An upper die provided with a pressing member located outside the convex portion at the time of mold clamping;
  • a film forming method comprising: a secondary shaping step of secondary shaping of the film at least outside the convex portion of the lower mold clamped by the pressure of the gas introduced from the upper mold side is there.
  • the film formed by the method according to (8) or (9) above is a hard coat film printed on the surface opposite to the hard coat layer, A processing step of processing the hard coat film so as to correspond to the shape of the injection mold cavity; An insert step of forming a film base by inserting a hard coat film so that the hard coat surface is in contact with the cavity in the cavity of the injection mold; A molding method for molding a molded product, comprising: a molding step of molding the molded product by integrating the film base material and the injection molding material by injection molding.
  • Molding including a lower mold having a convex part, an upper mold provided with a pressing member positioned outside the convex part at the time of mold clamping, and a fixing frame for fixing the film between the upper mold and the lower mold It is a metal mold.
  • the pressing member operates via an air cylinder or a hydraulic cylinder, and the tip cross-sectional shape of the pressing member that presses the film is chamfered and / or rounded, and the primary shaping step and the secondary shaping
  • a film or sheet in particular, a sheet having a hard coat, and a design application shape range such as a shaped article and an in-mold molded article thereof, and a film or sheet in which no crack is generated, Further, a three-dimensional shaped product (molded product) and the like can be provided.
  • the thickness of the film or sheet used in the present invention is preferably 0.05 to 1.2 mm, and it is preferable to have a hard coat layer as the surface layer.
  • the height of the molded product obtained in the present application depends on the hard coat elongation performance, but occurs in the scratch resistance test (according to ASTM D 2486-79, using a pig hair brush and 200 reciprocations at a load of 450 g).
  • ASTM D 2486-79 using a pig hair brush and 200 reciprocations at a load of 450 g.
  • Using a practical hard coat with scratches of 10 or less scratches it is possible to manufacture molded products having a vertical vertical wall height of 4 mm or more and a maximum height of 15 mm, which is not currently available. Become.
  • the hard coat (layer) preferably has 5 or less scratches, more preferably, in the scratch resistance test (according to ASTM D 2486-79, using a pork brush at 200 cycles with a load of 450 g). Is 3 or less.
  • the film or sheet examples include (1) a transparent sheet using a transparent plastic material, and (2) a resin layer having impact resistance and moderate heat resistance as a base layer, and a hard resin layer on one or both sides thereof. (3) A sheet or a multilayer sheet in which a hard coat layer is formed on one or both sides of the sheet (1) or (2).
  • Transparent plastic materials used for the film or sheet include aromatic polycarbonate, amorphous polyolefin (typical example: alicyclic polyolefin), poly (meth) acrylate, polysulfone, acetylcellulose, polystyrene, amorphous polyester ( Representative examples: cycloaliphatic polyester), transparent polyamide, polyethylene terephthalate resin, and the like, and transparent resins made of these compositions.
  • resins used for optics are preferred, and are aromatic polycarbonate, (meth) acrylic resin, styrene- (meth) acrylate copolymer resin, hydrogenated styrene- (meth) acrylate copolymer resin (of styrene component). Examples include hydrogenated benzene rings to partially alicyclic rings), transparent polyamides, and compositions of aromatic polycarbonates and amorphous polyesters (typical examples: alicyclic polyesters).
  • Aromatic polycarbonate includes 2,2-bis (4-hydroxyphenyl) alkane and 2,2- (4-hydroxy-3) in terms of impact resistance, strength, heat resistance, durability, and bending workability.
  • 5-Dihalogenophenyl A polymer produced by a known method using a bisphenol compound typified by alkane is preferable, and the polymer skeleton includes a structural unit derived from a fatty acid diol or a structural unit having an ester bond.
  • an aromatic polycarbonate produced using 2,2-bis (4-hydroxyphenyl) propane is preferred.
  • An amorphous polyester resin used as a composition with an aromatic polycarbonate includes, for example, a dicarboxylic acid component typified by 1,4-cyclohexanedicarboxylic acid and a diol component typified by 1,4-cyclohexanedimethanol.
  • a dicarboxylic acid component typified by 1,4-cyclohexanedicarboxylic acid
  • diol component typified by 1,4-cyclohexanedimethanol.
  • other small components may be esterified or transesterified, and then a polymerization catalyst may be added as appropriate, and the reaction vessel may be gradually depressurized to obtain a polycondensation reaction. .
  • alicyclic dicarboxylic acids or ester-forming derivatives thereof include 1,2-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, 1,4-cyclohexanedicarboxylic acid, 1,4-decahydronaphthalene dicarboxylic acid. And acid, 1,5-decahydronaphthalenedicarboxylic acid, 2,6-decahydronaphthalenedicarboxylic acid, 2,7-decahydronaphthalenedicarboxylic acid, and ester-forming derivatives thereof.
  • polyamide resin used in the present invention examples include those known as optically transparent polyamide resins.
  • the heat distortion temperature which is one index of heat resistance, is in the range of, for example, 100 to 170 ° C.
  • aromatic polyamide resin examples thereof include alicyclic polyamide resins, aliphatic polyamide resins, and copolymers thereof.
  • the alicyclic polyamide resin is preferable from the balance of mechanical strength, chemical resistance, transparency, etc., but two or more polyamide resins may be combined.
  • polyamide resin examples include, but are not limited to, GLILAMIDTRFE5577, XE3805 (manufactured by EMS), NOVAMIDX21 (manufactured by Mitsubishi Engineering Plastics), and Toyobo Nylon T-714E (manufactured by Toyobo).
  • (Meth) acrylic resin is polymethyl methacrylate (PMMA), homopolymers of various (meth) acrylic esters represented by methyl methacrylate (MMA), or PMMA or MMA and one or more other monomers. A copolymer obtained by mixing a plurality of these resins may also be used. Among these, (meth) acrylates having a cyclic alkyl structure excellent in low birefringence, low hygroscopicity, and heat resistance are preferable. Examples of the (meth) acrylic resin as described above include, but are not limited to, Acripet (manufactured by Mitsubishi Rayon), Delpet (manufactured by Asahi Kasei Chemicals), and Parapet (manufactured by Kuraray).
  • Acripet manufactured by Mitsubishi Rayon
  • Delpet manufactured by Asahi Kasei Chemicals
  • Parapet manufactured by Kuraray
  • the base material layer of (2) is a layer for maintaining basic physical properties, and as a resin to be used, an aromatic polycarbonate, a composition of an aromatic polycarbonate and an amorphous polyester resin is used because of its high impact resistance. It is given as a representative example.
  • the hard resin layer formed on one or both surfaces of the base material layer includes (meth) acrylic resin, styrene- (meth) acrylate copolymer resin, hydrogenated styrene- (meth) acrylate copolymer resin (styrene component benzene).
  • Aromatic polycarbonate resins copolymerized with 2,2- (4-hydroxy-3-methylphenyl) alkane, aromatics compatible with aromatic polycarbonate resins, etc.
  • Examples include a composition of a (meth) acrylic resin and an aromatic polycarbonate resin copolymerized with a (meth) acrylic monomer containing a ring, and a (meth) acrylic resin and a hydrogenated styrene- (meth) acrylate copolymer resin ( Those obtained by hydrogenating the benzene ring of the styrene component to partially alicyclic) are preferred. These are usually used as a composition containing an ultraviolet absorber because of improved weather resistance.
  • the film or sheet is usually produced by an extrusion method or a coextrusion method, and the thickness is preferably selected as appropriate from a range of 0.05 mm to 1.2 mm.
  • the thickness of the hard resin layer formed on one side or both sides of the base sheet is less than half the thickness of the multilayer sheet, and is preferably selected from 0.03 mm to 0.1 mm. If it is too thin, the hardness such as pencil hardness will be low, and if it is too thick, the effect of increasing the hardness will be lost, and the characteristic deterioration of the base sheet will increase, which is not preferable. Then, in the extrusion step or after the extrusion, a hard coat process is performed.
  • thermoforming a material excellent in wear resistance and fingerprint resistance (fingerprint wiping property) is preferable, but since it is essential to give a desired three-dimensional shape by thermoforming, the desired thermoformability is achieved. It is preferable to select one with a hard coat shown.
  • the hard coat layer a compound that forms a known cross-linked film such as acrylic, silicon, melamine, urethane, and epoxy can be used.
  • the curing method a known method such as ultraviolet curing, thermal curing, electron beam curing or the like can be used. Among these, a surface that can be made to have a pencil hardness of H or higher is preferable for the surface to be the surface side, and an acrylic type and a urethane acrylate type are preferable from the viewpoint of the balance with the heat formability.
  • the hard coat layer may be applied by an ordinary method, such as a coating method such as a roll coating method, a dipping method, or a transfer method.
  • a crosslinkable polymerizable compound having at least two (meth) acryloyloxy groups meaning acryloyloxy group and / or methacryloyloxy group, hereinafter the same
  • the residue that binds the acryloyloxy group is a hydrocarbon or a derivative thereof, and the molecule can include an ether bond, a thioether bond, an ester bond, an amide bond, a urethane bond, and the like.
  • a long chain component having a molecular weight of 1,000 to several thousand can be appropriately included as a component imparting heat formability.
  • the multilayer sheet used in the present invention usually has a design print layer on the back surface.
  • the multilayer sheet used in the present invention preferably has a hard coat layer on the back surface from the viewpoint of handleability, suitability for printing on the back surface and metallization.
  • the back side has a hard coat layer / printing layer on a base resin, and an injection molding resin is placed on the hard coat layer / printing layer, and is heat-sealed. From this point, if there is a printing layer in the part that needs to be stretched, select the printing ink that adheres firmly to the hard coat layer, has the property of stretching moderately, and is also heat-sealed with the molding resin to be used It is preferable to do. In addition, even when the hard coat treatment is not performed on one side, it can be used without any problem.
  • a mold described later is used. Specifically, it is a method for producing a three-dimensional shaped product by molding a film so as to have a predetermined three-dimensional shape using a molding die, preferably a pressure molding die, and is fixed to a fixed frame.
  • the heated sheet is heated (heating process), the mold is clamped simultaneously with the fixed frame, the movable ring is advanced, and the film or sheet is primarily shaped to the bottom of the lower mold (primary shaping process), and then from the pressurized air introduction hole
  • a secondary shaping step in which the film or sheet is completely shaped into a core shape or a concave shape during molding by the pressure of the introduced pressurized air.
  • the conventional manufacturing process is as follows. (I) Hold the sheet with the sheet holder. (Ii) The sheet is moved to the heating zone together with the sheet holder and heated by infrared rays from above to soften the sheet at a temperature higher than its Tg.
  • a sheet holder is fitted between the upper mold and the lower mold, and mold clamping is performed to prepare for sheet molding, and at the same time, pressurized air is introduced.
  • the sheet is fixed from the part in contact with the surface of the mold core by pressurized air (below Tg of the resin), and the non-contact part rapidly expands and contacts and is fixed to the surface of the mold core.
  • the shaped product conforms to the surface shape of the core or the recess. Only the sheet in the vicinity of the bottom surface that was the final non-contact portion is locally stretched.
  • V After discharging pressurized air, etc., take out the shaped product.
  • the film forming method of the present invention differs from the manufacturing steps (i) to (v) in the following points.
  • ⁇ The heated sheet fixed to the holder (fixed frame) at the time of mold clamping is folded by the movable ring at an angle between the mold core and the ring so as to correspond to the rising part or recess of the mold ( At this time, the sheet is shaped until it is substantially unstretched. (Temporary shaping) Then, by introducing gas, preferably compressed air, the sheet is shaped while being pressed against the mold core. At this time, the sheet is gradually shaped along the mold core shape (including the concave portion), and the lower portion of the rising portion is finally stretched most.
  • the following effects are recognized. That is, ⁇ Because the bottom of the film was in contact with the mold core (including the recess) until the compressed air was introduced, the cooling did not proceed, so even the lower part of the rising part of the shaped sheet Shape shaping is possible until the bottom shape is 1 mmR or less. -Since the amount and area stretched by secondary shaping are less than usual, the thickness is uniform throughout, so the hard coat is also stretched uniformly. ⁇ PET film, which cannot be shaped by pressure forming, can be shaped with a ring using hydraulic pressure.
  • the manufacturing method of the three-dimensional shaped article of the present invention uses the above-described novel pressure forming mold and uses the conventional conditions except that the pressure of the pressurized air is within a range that can be said to be low. can do.
  • the infrared heating may be a conventional normal near infrared heater or a far infrared heater.
  • region (thick part) of the film arrange
  • the elongation of (edge) is 100% or less, preferably 50% or less, more preferably 40% or less.
  • a local elongation (paragraph) [0005]) can be suppressed.
  • the elongation percentage is calculated as follows.
  • a film or sheet heat-formed into a desired shape according to the present invention for example, a multilayer sheet is mounted on a mold for injection molding, and a molding resin material is injection molded to form a molded product. Can be manufactured. It is essential that the resin molding material is heat-sealed with the heat-formed multilayer sheet. Although it may heat-seal well as it is, as described above, the back side of the multilayer sheet is usually provided with a design by printing, and also serves as a protective layer for heat-seal with the injection molding resin as appropriate. Those having a primer layer formed thereon can be used. Specific examples of molded products that can be manufactured using the film of the present invention include mobile phone exterior parts, automobile-related parts, medical equipment, electronics products, home appliances, building materials, containers for detergents and cosmetics, toys, etc. Is mentioned.
  • the difference in dimension between the inner diameter of the mold pressing member and the outer diameter of the convex portion is (film thickness before molding (mm) ⁇ 2) +1 mm to 4 mm, more preferably 1.5 mm to 4 mm. .
  • FIG. 1 is a schematic view showing an embodiment of a pressure forming mold according to the present invention.
  • a pressure-air forming mold 40 shown in FIG. 1 includes an upper mold 10 having a pressurized air introduction hole 12, a lower mold 20 having a mold core 22, and a film or sheet 32.
  • the movable ring 15 is housed in the upper mold 10 before molding, including a fixed frame 30 fitted by the lower mold 20.
  • the movable ring 15 advances to a position where the film heated at the time of primary shaping hits the bottom of the recess 23 provided in the lower mold 20 or the core 22 and stops, and then the pressure of the pressurized air introduced from the pressurized air introduction hole 12 is stopped.
  • an operation mechanism that retracts to a position before molding.
  • a hydraulic cylinder is used as the operating mechanism, but the present invention is not limited to this.
  • FIG. 2 is a schematic plan view showing the same configuration as that of the compressed air molding die shown in FIG. 1 and showing a primary shape formed by the movable ring 15.
  • FIG. 3 is a schematic diagram showing a state in which pressurized air is introduced from the pressurized air introduction hole 12 and primary shaping is performed.
  • a pressure forming mold (hereinafter referred to as a main mold) 40 of the present invention includes an upper mold 10, a lower mold 20, and a fixed frame 30.
  • the lower die 20 has a mold core 22 (convex portion) including a rising portion 24 substantially perpendicular to the bottom surface 20S.
  • a recess 23 is formed on the bottom surface 20 ⁇ / b> S of the lower mold 20 and between the mold core 22 and the fixed frame 30.
  • the upper mold 10 has a movable ring 15 (pressing member). The movable ring 15 can be moved back and forth in the vertical direction as indicated by an arrow A, and surrounds the outer periphery of the mold core 22 during primary shaping (see FIG.
  • the movable ring 15 has a chamfered or rounded cross-sectional shape of the ring front end surface 15T so that the sheet is not damaged when the sheet is pushed.
  • the chamfering shape and chamfering amount are in the range of 0.5 to 2 mmC, and the round shape is in the range of 0.5 to 2 mmR.
  • the pressure is not particularly specified, but preferably, the pressure of the pressurized air is set to a maximum set pressure of 5 MPa or less, so that the mold thickness may be thin and the shaped sheet is less likely to remain distorted.
  • a more preferable set maximum pressure is 1 to 2 MPa.
  • the rising part 24 and the recessed part 23 of the mold core 22 may have a round shape or a substantially vertical wall rising. From the standpoint of local elongation of the sheet, the latter is overwhelmingly large in local elongation, so that it is a difficult shape in terms of preventing hard coat cracks. Therefore, the rising portion 24 and the recess 23 are preferably chamfered.
  • the curvature of the molded sheet is about 2 mmR in the conventional mold, whereas the mold itself is stretched uniformly and thinly when the mold of the present invention is used. In addition, the curvature can be 1 mmR or less.
  • the sheet or film 32 fixed to the fixed frame 30 is heated to a predetermined temperature and softened (heating step).
  • the movable ring 15 advances toward the lower surface 20S, thereby pressing the heated sheet or film 32 to form the top surface shape and the recess 23 of the mold core 22, and the bottom surface 20S of the lower mold 20.
  • the movable ring 15 is installed on the upper mold 10 in connection with an air cylinder and a hydraulic cylinder, and controls the speed and the like by a flow meter (none of which is shown) attached to the pressure forming machine.
  • control is performed by a program sequence of the pressure forming machine.
  • mold clamping is performed when the sheet reaches a predetermined heating time or a predetermined temperature, and then the movable ring 15 is advanced.
  • the movable ring 15 is retracted to a predetermined position of the upper mold 10 immediately after the end of applying the compressed air or by the end of the exhaust process. If the movable ring 15 moves backward to the mold opening (release) step, there is a risk of scratches on the rising surface of the molded product, which is not preferable.
  • the timing time for introducing the compressed air is within one second.
  • the film is heated to a shapeable temperature (Tg or higher) and the time from the primary shaping to the secondary shaping is not within 1 second, the film is cooled (Tg or less), and is shaped by the secondary shaping. It becomes impossible to form. As soon as the timing of introducing the pressurized air is earlier, the secondary shaping becomes better. However, if the primary shaping is not completed, a molded product having a desired height cannot be obtained. As described above, the timing can also be adjusted by setting the speed of the movable ring 15 (hydraulic cylinder speed) to be faster with the flow meter.
  • the distance between the fixed frame 30 and the mold core 22 it is desirable to provide a distance that is at least twice the height of the rising portion 24. More preferably, it is 3 to 4 times. If the distance between the fixed frame 30 and the mold core 22 is less than twice the height of the rising portion 24, the sheet between them is actually pushed through the movable ring 15. Becomes too large locally, and even if the height of the mold core 22 is low, the sheet 32 is easily torn, and if it is a hard coat product, cracks are likely to occur.
  • the difference DL between the inner diameter of the movable ring 15 and the outer diameter of the mold core 22 is set as a range of +1 mm to 4 mm with respect to (sheet thickness (mm) ⁇ 2) (see FIG. 2; the sheet is not shown). ) That is, the distance DL 1 between the rising portion 24 of the mold core 22 and the movable ring 15 in one direction, for example, the direction indicated by the arrow B in FIG. 2 (corresponding to the direction perpendicular to the paper surface in FIG. 1) is A value obtained by adding a distance of 0.5 mm to 2 mm to the sheet thickness.
  • the distance DL 1 between the core 22 and the movable ring 15 is 1 mm (the gap excluding the sheet thickness 0.5 mm from the distance DL 1 is 0.5 mm) to 2.5 mm. (The gap excluding the sheet thickness of 0.5 mm from the distance DL 1 is 2 mm).
  • the difference in dimension DL between the inner diameter of the movable ring 15 and the outer diameter of the mold core 22 is defined as 2 mm to 5 mm obtained by adding 1 mm to 4 mm to 0.5 mm ⁇ 2 that is the thickness of the sheet, that is, 1 mm.
  • the dimensional relationship between the outer diameter of the recess provided in the mold core 22 and the inner diameter of the movable ring is the above-described numerical value.
  • the sheet is shaped in a form close to a two-dimensional bending process, without extending the rising portion 24, so that the primary shaping can be performed with substantially uniform elongation.
  • a gap of less than 0.5 mm on one side DL 1 or DL 2 is less than 0.5 mm
  • the sheet or film 32 is stretched while being dragged with the ring when pushed by the movable ring 15, and is pulled locally.
  • hard coat cracks are likely to occur particularly on the top surface side, and the precision in producing the mold is increased, and the mold cost is also increased.
  • the shapes of the core 22 and the movable ring 15, and the recesses 23 provided in the core 22 and the movable ring 15 are preferably substantially similar. What is necessary is just to set in the range of the dimension mentioned above, and even if the core 22 is a rectangle, the movable ring 15 may be a rounded rectangle or a substantially elliptical shape. Moreover, a round may enter in only the four corners of the core 22, or a 45 degree angle may be attached. When the dimension range of the gap is exceeded, the above-described defect may occur.
  • the heated sheet or film 32 is pressed by advancing the movable ring from the state shown in FIG. 1, the heated sheet fixed to the fixed frame is fixed to the fixed frame 30, the upper mold 10, and the lower mold. Clamp at the same time as 20 (see FIG. 3). In this way, the film or sheet 32 is moved to the bottom surface 20S of the lower mold 20 to perform primary shaping (primary shaping step).
  • pressurized air is introduced from the pressurized air introduction hole 12 of the upper mold 10 as indicated by an arrow C (see FIG. 4).
  • secondary shaping is performed in which the film or sheet 32 is completely shaped so as to correspond to the shapes of the core 22 and the recess 23 at the time of molding (secondary shaping step).
  • the pressurized air is efficiently introduced to the surface of the sheet or film 32.
  • a pressure forming machine (manufactured by NK Enterprise) was used as a molding machine.
  • a hydraulic drive device (manufactured by Yuken Kogyo Co., Ltd.) is attached to the molding machine so as to be linked in sequence.
  • Aluminum was used as the material of the pressure forming mold 40 (see FIG. 1 and the like) of the present invention.
  • the mold core 22 provided in the lower mold 20 has a shape having a square 50 mm square (4 corner curvature R; 2 mmR) as viewed from above, a ⁇ 20, 5 mm recess in the center, and a top surface curvature of 2 mmR.
  • the one having a substantially vertical rising surface 24 having a height of 12 mm was used.
  • the movable ring 15 As the movable ring 15 attached to the upper mold 10, a ring similar in shape to the outer periphery of the mold core 22 and the recess 23 was used. Note that the movable ring 15 is retracted before molding and is in a predetermined position of the upper mold 10.
  • the movable ring 15 has a chamfered shape with a thickness of 2 mm and a tip of 0.5 mmC as an outer shape and a concave ring, is attached to an upper mold, and is connected to a hydraulic drive device and hydraulic piping.
  • Example 1 A sheet of coextruded acrylic resin layer formed with an acrylic resin layer on the surface of a 140mm square aromatic polycarbonate resin base material layer, and a hard coat on the acrylic resin layer (MRF08U 0.5 manufactured by Mitsubishi Gas Chemical Co., Ltd.) mm (hard coat elongation: 40%, scratch resistance test (according to ASTM D 2486-79, using a pig hair brush and 200 strokes at a load of 450 g) has a scratch resistance of 5 or less.
  • the design of the printed layer IMB006 binder laminated on INQ-HF (white) manufactured by Teikoku Ink Co., Ltd.) on the PC surface (back surface) of the hard coat) was used.
  • the fixed frame 30 for fixing the sheet is a fixed frame having a window so that a 100 mm square sheet can be formed.
  • the distance between the fixed frame 30 and the mold core 22 was 50 mm.
  • Set the sheet on the sheet fixing frame convey the sheet to the heating zone, heat it with an IR heater (400 ° C setting), and confirm that it reaches 190 ° C with an infrared radiation thermometer, then see Fig. 1 Move to the indicated clamping zone and clamp.
  • the hydraulic drive device was immediately driven to advance the ring until it hits the lower mold and the bottom of the recess. After the end of the advancement, 0.5 seconds later, pressurized air set at a maximum pressure of 2 MPa was introduced into the mold 40.
  • the lower part of the rising part 24 and the lower part of the concave part on the top surface of the core 22 had R of 0.8 mm or less.
  • R 0.8 mm or less.
  • no cracks were generated in the hard coat layer, despite the height of the outer peripheral height of 12 mm and the recess of 5 mm. Subsequently, unnecessary parts were punched out with a press die to obtain a formed molded product.
  • Example 2 The molded product obtained in Example 1 was inserted into a 2 mm thick injection mold having a 51 mm square cavity and a recess ⁇ 20 on the surface, and an injection molding machine (J110AD manufactured by Nippon Steel) , Using a PC (Iupilon H3000 manufactured by Mitsubishi Engineering Plastics Co., Ltd.) with a resin temperature of 300 ° C, a mold temperature of 80 ° C, and an injection pressure of 100 MPa. A molded product was obtained. Since the molded product punched out in Example 1 had a small bottom edge, it could be inserted neatly into the mold, and no problems were caused by injection molding. In Example 2, an injection molded product decorated with a hard coat was obtained.
  • Example 3 Using the mold used in Example 1, the height of the mold core was changed to 5 mm.
  • a PET sheet having a hard coat extending 140 mm square (Toughtop THS 0.18 mm manufactured by Toray Industries, Inc. (hard coat elongation rate: 20%, scratch resistance test (according to ASTM D 2486-79, pig hair brush (Practical hard coat with scratch resistance of 5 or less) under a load of 450g at a load of 450g)) on the back side of the hard coat) (on INQ-HF (white) made by Teikoku Ink Co., Ltd.)
  • the IMB006 binder was laminated). The relationship of clearance is as follows.
  • Example 1 (Comparative Example 1) Using the mold used in Example 1, pressure forming was carried out under the same conditions and conditions as in Example 1 without operating the movable ring 15. The shaped product was poorly shaped on the bottom surface, and when the shape of the sheet on the bottom surface was measured, it was about 2 mmR. Further, regarding the MRF08U sheet (see Example 1), cracks occurred in the vicinity of the bottom surface part, probably because the vicinity of the bottom surface was locally extended. Although injection molding was carried out as in Example 2, since the crack was generated in the hard coat, the appearance of the molded product was ugly.
  • the film of the present invention and the molding method thereof are suitably used for the production of a decorative sheet molded product or an in-mold molded product, and include mobile phone exterior parts, automobile-related parts, medical machinery, electronic products, and home appliances. It can be used in the fields of building materials, containers for detergents and cosmetics, and toys.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

L'invention porte sur un film, pour lequel, en plus de la conservation d'un aspect favorable, l'apparition de craquelures a été empêchée de façon fiable, et sur un procédé de moulage, etc. pour de tels films. Le film, pour lequel, en plus de la conservation d'un aspect favorable, l'apparition de craquelures a été empêchée de façon fiable, et le procédé de moulage, etc. s'y rapportant ont été réalisés par : fermeture de la coquille supérieure et de la coquille inférieure d'un moule de moulage, un film étant fixé entre la coquille supérieure et la coquille inférieure et chauffé, et pressage du film à l'aide d'un élément de pressage de coquille supérieure sur l'extérieur d'une section en saillie de la coquille inférieure pour un premier formage; et ensuite la mise en œuvre d'un second formage du film au moins sur l'extérieur de la section en saillie de la coquille inférieure à l'aide de la pression d'un gaz introduit à partir du côté de la coquille supérieure.
PCT/JP2014/066099 2013-06-20 2014-06-18 Film, procédé de moulage de film, moule, moulage comprenant le film et procédé de moulage s'y rapportant WO2014203917A1 (fr)

Priority Applications (3)

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CN201480034476.5A CN105392612B (zh) 2013-06-20 2014-06-18 膜和用于对膜进行成型的成型方法、模具、以及包括膜的成型品及其成型方法
KR1020167000233A KR102196604B1 (ko) 2013-06-20 2014-06-18 필름과 필름을 성형하기 위한 성형 방법, 금형, 및 필름을 포함하는 성형품과 그의 성형 방법
JP2015522949A JP6525871B2 (ja) 2013-06-20 2014-06-18 フィルムとフィルムを成形するための成形方法、金型、およびフィルムを含む成形品とその成形方法

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JP2013129850 2013-06-20
JP2013-129850 2013-06-20

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WO2014203917A1 true WO2014203917A1 (fr) 2014-12-24

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WO2021193809A1 (fr) * 2020-03-26 2021-09-30 三菱瓦斯化学株式会社 Article obtenu par moulage d'insertion de film et procédé de fabrication d'un article moulé par insertion de film

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CN109664459A (zh) * 2019-02-18 2019-04-23 东莞市艾尔玛科技有限公司 一种解决高凸形模仁转写箔皱褶的结构及其操作方法
CN111097653B (zh) * 2019-11-20 2021-06-08 浙江环龙新材料科技有限公司 一种医用敷料tpu薄膜加工装置
CN112157901B (zh) * 2020-09-07 2025-03-25 上海磐云科技有限公司 一种气囊保压覆膜装置
KR20220039919A (ko) * 2020-09-21 2022-03-30 삼성디스플레이 주식회사 커버 윈도우, 이의 제조 방법, 및 이를 포함하는 표시 장치
KR102824759B1 (ko) * 2023-02-10 2025-06-25 주식회사 태동테크 탄성체를 활용한 필름 제조 방법 및 시스템

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WO2021193809A1 (fr) * 2020-03-26 2021-09-30 三菱瓦斯化学株式会社 Article obtenu par moulage d'insertion de film et procédé de fabrication d'un article moulé par insertion de film

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JP6525871B2 (ja) 2019-06-05
KR102196604B1 (ko) 2020-12-30
JPWO2014203917A1 (ja) 2017-02-23
KR20160021806A (ko) 2016-02-26
TWI626146B (zh) 2018-06-11
CN105392612A (zh) 2016-03-09
TW201513992A (zh) 2015-04-16
CN105392612B (zh) 2018-09-21

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