Resin molded article and method for producing resin molded article

Abstract

The resin molded body is provided with: a translucent resin layer; and a bright material contained in the resin layer, the bright material having: a metal layer formed of a metal material; a coloring layer containing a coloring agent and covering the metal layer; and an exposed portion in which the metal layer is exposed from the colored layer.

Description

Technical Field

[0001] The present disclosure relates to a resin molded body and a method for producing the resin molded body. Background Art

[0002] Conventionally, a resin molded body having a transparent layer stacked on a resin layer containing a pigment and a glittering material is known (for example, see Patent Document 1). In addition, a resin molded body having a resin layer in which a glittering material such as aluminum powder is blended with a resin material containing a colorant is also known (for example, see Patent Document 2). In this way, by containing a glittering material in the resin layer, a resin molded body having a glittering feeling is realized.

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent Application Publication No. 2014-168916

[0006] Patent Document 2: Japanese Patent Application Publication No. 2004-83608 Summary of the invention

[0007] Technical problem to be solved by the invention

[0008] The resin molded article of Patent Document 1 has a good glossiness by stacking a transparent layer on a resin layer containing a glossy material. On the other hand, the resin molded article of Patent Document 1 requires a process of stacking a transparent layer on a resin layer. In addition, the resin molded articles of Patent Document 1 and Patent Document 2 have a problem of poor glossiness due to uneven distribution of a colorant.

[0009] The present disclosure aims to provide a resin molded body having good glossiness without providing a transparent layer.

[0010] Technical solutions for solving technical problems

[0011] The resin molded body of the present disclosure comprises: a light-transmitting resin layer; and a glittering material contained in the resin layer. The glittering material comprises: a metal layer formed of a metal material; a coloring layer containing a colorant and covering the metal layer; and an exposed portion where the metal layer is exposed from the coloring layer.

[0012] In addition, the manufacturing method of the resin molded body involved in the present disclosure includes: a process of preparing a metal layer formed by a metal material; a process of covering the metal layer with a coloring layer containing a colorant; a process of cutting the metal layer and the coloring layer along a direction intersecting the surface of the metal layer covered by the coloring layer to produce a bright material; and a process of mixing the bright material into a light-transmitting resin material and using the resin material to mold a resin layer.

[0013] Effects of the Invention

[0014] According to the resin molded body, since the resin layer has light transmittance, light penetrating the resin layer is reflected to the exposed portion of the glittering material and the colored layer. Thus, the resin molded body can present an appearance with good glittering feeling without providing a transparent layer.

[0015] In addition, according to the method for producing a resin molded body, there is no step of forming a transparent layer on the resin layer, so that a resin molded body having a good glossiness can be produced at low cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a cross-sectional view of a resin molded body.

[0017] Figure 2 This is a diagram showing an example of a resin molded body mounted on a vehicle.

[0018] Figure 3 It is a cross-sectional view of a bright material.

[0019] Figure 4 It is a figure which shows the manufacturing apparatus of the resin molded body.

[0020] Figure 5 FIG. 1 is a diagram showing a method for producing a resin molded body.

[0021] Figure 6 FIG. 2 is a diagram showing a method for producing a resin molded body.

[0022] Figure 7 It is a cross-sectional view of a resin molded body in another embodiment. DETAILED DESCRIPTION

[0023] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings.

[0024] like Figure 1 As shown, the resin molded body 1 includes a resin layer 2 and a plurality of bright materials 4 contained in the resin layer 2. Figure 2 As shown, in this embodiment, the resin molded body 1 is used for a decorative portion C1 of the edge of a cup holder used in the interior of a car. In addition, the resin molded body 1 is used for a decorative portion C2 of a door trim or a decorative portion of an exterior of a car (not shown), etc. Since the resin molded body 1 is used for such a part that can be seen by the user, it is required to have a high appearance design. Therefore, the resin molded body 1 is required to have a glossy feeling with no color unevenness and good color rendering.

[0025] like Figure 1As shown, the resin layer 2 is a layer of the main material that becomes the material forming the resin molded body 1. In the present embodiment, the resin molded body 1 is formed by injection molding the resin material forming the resin layer 2. In the present embodiment, the resin material forming the resin layer 2 is a thermoplastic resin. Thermoplastic resins are, for example, polypropylene, polyethylene, ABS resin, acrylic resin, PC (polycarbonate) resin, etc. In addition, the resin material forming the resin layer 2 can be selected from thermoplastic resins or alloy materials of thermoplastic resins. For example, thermoplastic resins are polyamide, polyethylene terephthalate, modified polyphenylene ether, etc. In addition, the resin material forming the resin layer 2 can also be a resin material in which fibrous or flaky fillers are mixed in a thermoplastic resin. In short, the resin layer 2 can be formed of any resin material as long as it is a thermoplastic resin.

[0026] The resin layer 2 has light transmittance. Specifically, the resin layer 2 is formed by not containing a colorant in the above-mentioned resin material, so that it has light transmittance. The resin layer 2 is preferably colorless and transparent. The resin layer 2 may be slightly colored by the color of the resin material itself.

[0027] Next, the bright material 4 is described. The bright material 4 is in the form of a plate or a sheet. The length of the long side of the bright material 4 in the in-plane direction is 10 μm to 200 μm. More preferably, the length of the long side of the bright material 4 is 50 μm to 150 μm. It should be noted that the length of the short side in the in-plane direction is equal to the length of the long side.

[0028] like Figure 3 As shown, the bright material 4 has a metal layer 6 formed of a metal material and a coloring layer 8 containing a colorant and covering the metal layer 6. The metal layer 6 is a layer formed of a metal material in a thin film. For example, the metal material can be selected from aluminum, chromium, gold, silver, platinum, nickel, etc. In this embodiment, the metal layer 6 is a metal thin film formed by physical vapor deposition or chemical vapor deposition of the above-mentioned metal material. The thickness of the metal layer 6 formed by such vapor deposition is 1nm~1000nm. More preferably, the thickness of the metal layer 6 is 2nm~100nm.

[0029] The coloring layer 8 is a coating layer covering the metal layer 6. In this embodiment, the coloring layer 8 includes a first coloring layer covering the surface 6a of the thin film forming the metal layer 6 and a second coloring layer covering the back surface 6b of the metal layer 6. It should be noted that in this embodiment, Figure 3The upper side of the metal layer 6 is the surface 6a, and the lower side is the back side 6b. In the metal layer 6, the lower side may be the surface 6a, and the upper side may be the back side 6b. The coloring layer 8 is formed by a coloring layer forming material containing a colorant such as a dye, a pigment, or a pigment. The coloring layer 8 is more preferably formed by a coloring layer forming material containing a pigment that is more UV-resistant than a dye. The coloring layer forming material can be any general paint or coating layer forming material containing such a pigment. The thickness of the coloring layer 8 is 1 μm to 30 μm. More preferably, the thickness of the coloring layer 8 is 5 μm to 10 μm. That is, the coloring layer 8 is thicker than the metal layer 6.

[0030] The bright material 4 further includes an exposed portion 10. The exposed portion 10 is a portion where the metal layer 6 is exposed from the colored layer 8. In the present embodiment, the bright material 4 includes the exposed portion 10 at the end portion in the long side direction or the short side direction of the bright material 4, that is, at the end portion in the in-plane direction. The exposed portion 10 is formed by exposing both ends of the metal layer 6 sandwiched by the colored layer 8.

[0031] Next, a method for producing the resin molded body 1 will be described.

[0032] like Figure 4 As shown, the resin molded body 1 is manufactured by a manufacturing device 21. The manufacturing device 21 includes: a first drum 24 for delivering a wound film 22; a first coating roller 26 for coating a coloring layer forming material on the film 22; a vapor deposition device 28 for vapor-depositing a metal material on the coloring layer 8 to form a metal layer 6; a second coating roller 30 for coating a coloring layer forming material on the metal layer 6; and a second drum 32 for winding the film 22.

[0033] like Figure 5 As shown in (A), first, from the first roller 24 (refer to Figure 4 ) The film 22 is fed out. The film 22 is a film formed of a resin material in a thin film shape. The resin material is, for example, polyethylene terephthalate, polycarbonate, polypropylene, etc. Next, as Figure 5 As shown in (B), the colored layer 8 is formed on the film 22 sent out from the first roller 24. The colored layer 8 is applied by the first coating roller 26 (see Figure 4 ) is formed by coating a coloring layer forming material.

[0034] Then, if Figure 5 As shown in (C), the film 22 on which the colored layer 8 is formed passes through the vapor deposition device 28 (see Figure 4 ). The evaporation device 28 heats the metal material to vaporize or sublime it, so that the metal material adheres to the coloring layer 8. Thus, a metal thin film is further formed on the film 22 on which the coloring layer 8 is formed. As a result, a metal layer 6 is further formed on the film 22 on which the coloring layer 8 is formed.

[0035] Then, if Figure 5 As shown in (D), the second coating roller 30 (refer to Figure 4 ) is applied onto the metal layer 6 to form a coloring layer 8. In this way, the coloring layer 8 is formed on the metal layer 6. In this embodiment, the coloring layer 8 is located on the back side 6b of the metal layer 6. The coloring layer forming material applied by the second coating roller 30 may also be the same as the coloring layer forming material applied by the first coating roller 26 (see Figure 4 ) is the same as the coloring layer forming material applied by the second coating roller 30. In addition, the coloring layer forming material applied by the second coating roller 30 may be different from the coloring layer forming material applied by the first coating roller 26. The film-coated sheet 12 thus formed is wound around the second roller 32 (refer to Figure 4 )superior.

[0036] Then, if Figure 5 As shown in (E), the film 22 is peeled off from the film-bearing sheet 12. Thus, the Figure 5 The sheet-shaped bright material shown in (F) is the sheet 14. The coloring layer forming material may also flow to the end of the metal layer 6 during the manufacturing process and cover the hidden metal layer 6. That is, the end of the sheet 14 may also be covered by the coloring layer forming material (refer to Figure 5 (F) The right end of the sheet 14). In addition, at the end of the sheet 14, the colored layer 8 may protrude from the metal layer 6 (see the left end of the sheet 14).

[0037] Then, if Figure 6 As shown, a sheet 14 is cut to produce a bright material 4. The sheet 14 is cut in a direction intersecting the surface 6a or the back surface 6b of the thin film metal layer 6 covered by the colored layer 8. The size of the cut sheet 14 is as described above. An exposed portion 10 where the metal layer 6 is exposed from the colored layer 8 is formed on the cut surface of the sheet 14. It should be noted that in this embodiment, the four ends of the sheet 14 are cut off before cutting. As a result, the metal layer 6 is exposed from the colored layer 8. Therefore, the exposed portion 10 is formed at both ends of the long side direction L of all the bright materials 4. However, the process of cutting off the ends of the sheet 14 is not necessary.

[0038] Next, the bright material 4 manufactured as described above is mixed with a resin material having light transmittance. Thus, the resin layer 2 is molded. It should be noted that a colored layer 8 coated with a different color may be mixed with the resin material as the bright material 4. In the present embodiment, the bright material 4 is mixed with the above-mentioned resin material. Then, the resin material mixed with the bright material 4 is injected into an injection molding mold and injected. In this way, the resin molded body 1 is manufactured.

[0039] In the resin layer 2 of the resin molded body 1 thus manufactured, there is no colorant separated from the bright material 4, or even if there is, it is very small. Therefore, the resin layer 2 has light transmittance. As a result, the resin molded body 1 does not have the colorant unevenly distributed on the surface of the resin layer 2 as in the case where the resin layer 2 contains the colorant. Therefore, the resin molded body 1 can allow light incident from the outside to pass through the inside of the resin layer 2.

[0040] Specifically, if Figure 1 As shown by the imaginary line in the middle, the light incident on the resin layer 2 travels through the resin layer 2 and is reflected by the colored layer 8. In this embodiment, the resin molded body 1 is injection molded in a state where the bright material 4 is mixed in the resin material. Therefore, the bright material 4 is dispersed and arranged inside the resin layer 2. As a result, the light is reflected in the portion close to the surface where the light is incident (see Figure 1 D1) or the far part ( Figure 1 Therefore, the resin molded body 1 can obtain better color rendering, that is, a sense of depth.

[0041] In addition, part of the light incident on the resin layer 2 is reflected by the exposed portion 10. Thus, the resin molded body 1 can present a good appearance having not only the depth of color but also a glossy feeling.

[0042] Furthermore, in the resin molded body 1, the resin layer 2 forming the pattern of the resin molded body 1 develops color. That is, the resin molded body 1 does not need to form a transparent layer on the resin layer 2 in order to achieve good color development. Thus, the resin molded body 1 can be manufactured at a lower cost.

[0043] As described above, according to the present disclosure, it is possible to provide a resin molded body 1 that exhibits an appearance having a good glossy feel without overlapping a transparent layer on the resin layer 2 .

[0044] <Other embodiments>

[0045] As mentioned above, although embodiment of this disclosure was described, this disclosure is not limited to the said embodiment, Various changes are possible within the range which does not deviate from the summary of invention.

[0046] For example, in the above-mentioned embodiment, the resin molded body 1 is described as a part for automobiles, but the present disclosure is not limited thereto. The resin molded body 1 may be a resin part for other than automobiles.

[0047] In addition, in the above-mentioned embodiment, the example in which the exposed portion 10 is provided at both ends in the long side direction L is used for description, but the present disclosure is not limited thereto. Figure 7 As shown in (A), the exposed portion 10 may be provided by cutting away a portion of the colored layer 8 to expose a portion of the surface 6a of the metal layer 6. Figure 7 As shown in (B), the entire back surface 6b of the metal layer 6 may be exposed to provide the exposed portion 10. In short, the exposed portion 10 may be in any form as long as a part of the metal layer 6 is exposed from the colored layer 8.

[0048] In addition, the coloring layer 8 may have different colors on the back surface 6b and the front surface 6a. In this way, the resin molded body 1 can obtain a further sense of depth due to the difference in hue in addition to the sense of depth produced by the reflection of light at random positions.

[0049] Description of Reference Numerals

[0050] 1: resin molded body; 2: resin layer; 4: bright material; 6: metal layer; 6a: surface; 6b: back surface; 8: coloring layer; 10: exposed portion; 12: sheet; C1, C2: decorative portion; L: long side direction; S: short side direction.

Claims

1. A resin molded body comprising: a light-transmitting resin layer; and The bright material contained in the resin layer, The bright material has: a metal layer formed of a metal material; a coloring layer containing a colorant and covering the metal layer; and An exposed portion where the metal layer is exposed from the colored layer.

2. The resin molded article according to claim 1, wherein The exposed portion is provided at an end portion of the metal layer formed in a thin film shape.

3. The resin molded article according to claim 1 or 2, wherein The metal layer has a front surface and a back surface, The coloring layer includes a first coloring layer covering the front surface and a second coloring layer covering the back surface.

4. A method for producing a resin molded body, comprising: A step of preparing a metal layer formed of a metal material; A step of covering the metal layer with a colored layer containing a colorant; The step of cutting the metal layer and the coloring layer in a direction intersecting the surface of the metal layer covered by the coloring layer to produce a bright material; as well as A step of mixing the bright material into a light-transmitting resin material and molding a resin layer using the resin material.

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