High-plasticity INS film and its applications

Abstract

This invention discloses a high-plasticity IN NS film and its applications. The high-plasticity IN NS film of this invention comprises, from top to bottom, the following layers stacked sequentially: a tactile layer, a matte layer, a PMMA film layer, an ink layer, an adhesive layer, and an ABS substrate layer. The matte layer is formed by printing and coating with a dual-curing coating resin A. The components of dual-curing coating resin A include, by weight, 80-120 parts of polyurethane acrylate prepolymer, 3-5 parts of photoinitiator, 1-1.5 parts of leveling agent, 0.3-0.7 parts of defoamer, and 3-7 parts of matte agent. The tactile layer is formed by printing and coating with a dual-curing coating resin B. The components of dual-curing coating resin B include, by weight, 80-120 parts of polyurethane acrylate prepolymer, 3-5 parts of photoinitiator, 1-1.5 parts of leveling agent, 0.3-0.7 parts of defoamer, and 5-10 parts of tactile agent. This invention solves the problem that after high-temperature stretching and thermoforming, the I NS film is prone to cracking at the corner where it wraps with the plastic parts, resulting in a low yield of injection molded parts.

Description

Technical Field

[0001] This invention relates to the field of functional membrane technology, and in particular to a high-plasticity INS membrane and its applications. Background Technology

[0002] Plastic is a major component of interior decoration, but its original texture is not popular with the public. Manufacturers use various surface treatment processes to improve the original feel of plastic. Among them, INS (Insulated Panel) technology is a commonly used plastic surface treatment process.

[0003] INS, or Film Insert Molding, utilizes thermoforming or high-pressure molding to stretch a pre-printed film material three times, then cut inserts according to the product shape, and finally accurately place these inserts into the injection mold cavity for injection molding. However, most existing INS molds face the challenge of cracking at the corners where the film meets the plastic part after high-temperature stretching thermoforming, resulting in a low yield rate of injection molded parts. Summary of the Invention

[0004] To solve the above-mentioned technical problems, the present invention provides a high-plasticity INS film and its application, which avoids the problem that the INS film is prone to cracking at the corner of the plastic part after high-temperature stretching and thermoforming, resulting in a low yield of injection molded parts.

[0005] The technical solution of this invention is:

[0006] A highly plastic INS film, characterized in that it comprises layers stacked sequentially from top to bottom:

[0007] Matte layer, PMMA film layer, ink layer, adhesive layer and ABS substrate layer;

[0008] The matte layer is formed by printing and coating with a dual-curing coating resin A; the amount of each component added in the dual-curing coating resin A includes, by weight, 80-120 parts of polyurethane acrylate prepolymer, 3-5 parts of photoinitiator, 1-1.5 parts of leveling agent, 0.3-0.7 parts of defoamer and 3-7 parts of matte agent.

[0009] Furthermore, a tactile layer is also provided on the matte layer, which is formed by printing and coating with dual-curing coating resin B;

[0010] The amount of each component added in the dual-curing coating resin B includes, by weight, 80-120 parts of polyurethane acrylate prepolymer, 3-5 parts of photoinitiator, 1-1.5 parts of leveling agent, 0.3-0.7 parts of defoamer, and 5-10 parts of tactile agent.

[0011] Furthermore, the photoinitiator is one or more of 2-hydroxy-2-methyl-1-phenyl-1-propanone and 1-hydroxycyclohexylphenyl ketone.

[0012] Furthermore, the leveling agent is an organosilicone acrylate.

[0013] Furthermore, the defoamer is a polyether siloxane copolymer.

[0014] Furthermore, the tactile agent is one or more of polyethylene terephthalate micro powder and polymethyl methacrylate micro powder.

[0015] Furthermore, the matting agent is one or more of silicon dioxide and titanium dioxide.

[0016] Furthermore, the polyurethane acrylate prepolymer is formed by reacting polyether diol and a bifunctional isocyanate compound to form an isocyanate-terminated first polyurethane prepolymer, then reacting the first polyurethane prepolymer with an epoxy alcohol compound to form an epoxy-terminated second modified polyurethane prepolymer, and finally reacting the second modified polyurethane prepolymer with an acrylic compound and ending it with unsaturated bonds.

[0017] Furthermore, the polyether diol is polyethylene glycol.

[0018] Furthermore, the difunctional isocyanate compound is hexamethylene diisocyanate (HDI).

[0019] Furthermore, the epoxy alcohol compound is glycidol.

[0020] Furthermore, the acrylic compound is methacrylic acid.

[0021] Furthermore, the molecular weight of the polyurethane acrylate prepolymer is Mn = 8000-12000.

[0022] The high-plasticity INS film of the present invention can be applied to the surface treatment process of plastic products.

[0023] Specifically, the high-plasticity INS film is first stretched three times, cut, and placed into a mold. Then, the plastic product is injected into the mold. After demolding, the product is cured under ultraviolet light in a UV curing oven at an intensity of 600 mJ / cm². 2 The illumination time is 4-10 seconds.

[0024] The beneficial technical effects of this invention are:

[0025] The present invention provides a high plasticity INS film, which includes, from top to bottom, the following layers stacked in sequence: a matte layer, a tactile layer, a PMMA film layer, an ink layer, an adhesive layer, and an ABS substrate layer.

[0026] The matte layer is formed by printing and coating with dual-curing resin A, and the tactile layer is formed by printing and coating with dual-curing resin B. Since both dual-curing resin A and dual-curing resin B contain polyurethane acrylate prepolymer and photoinitiator, the matte layer and tactile layer of the INS film of this invention are formed in two steps. The first step is that during the preparation of the INS film, the polyurethane acrylate prepolymer in the matte layer and the tactile layer undergoes preliminary thermal film formation, so that the two coatings each have certain mechanical properties and good tensile properties. After that, the INS film is applied to the plastic surface treatment process by high-temperature thermoforming injection molding. Thus, compared with the INS film of the prior art, the INS of this invention effectively avoids the problem of easy cracking at the corner of the plastic part after high-temperature stretching and thermoforming. After the INS film is demolded from the plastic part, the INS film on the plastic part undergoes a second curing film formation under UV light, that is, light curing film formation, which further improves the overall performance of the matte layer and the tactile layer and ensures the strength of the plastic part. Attached Figure Description

[0027] Figure 1 This is a finished product image of the INS film applied to a plastic surface in Example 1;

[0028] Figure 2 This is a picture of the finished product of INS film applied to a plastic surface, which is a comparative example 1. Detailed Implementation

[0029] In order to better understand the technical means of the present invention and to implement it in accordance with the contents of the specification, the specific embodiments of the present invention will be further described in detail below with reference to the accompanying drawings and examples. The following examples are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0030] All reagents used in this invention are commercially available, including 2-hydroxy-2-methyl-1-phenyl-1-propanone (1173), organosilicon acrylate (TEGO Rad2700), polyether siloxane copolymer (TEGO Airex902W), silica (Evonik, OK520), polymethyl methacrylate micro powder (15nm), hydroxyl acrylic resin (Changxing, 6233), and polyethylene glycol with a molecular weight Mn = 1000.

[0031] Example 1

[0032] like Figure 1 As shown, the present invention provides a high plasticity INS film, comprising, from top to bottom, the following layers stacked sequentially: a tactile layer, a matte layer, a PMMA film layer, an ink layer, an adhesive layer, and an ABS substrate layer.

[0033] The tactile layer is printed and coated with dual-curing coating resin B, the matte layer is printed and coated with dual-curing coating resin A, the PMMA film layer is made of PMMA material, the adhesive layer is an adhesive coating layer used to connect the PMMA film layer and the ABS substrate layer together, and the adhesive layer used in this invention is a polyurethane adhesive material; the ABS substrate layer is made of ABS material and is used to fuse with the component material during injection molding.

[0034] The aforementioned dual-curing coating resin A comprises, by weight, 100 parts of polyurethane acrylate prepolymer, 5 parts of photoinitiator 2-hydroxy-2-methyl-1-phenyl-1-propanone, 1 part of leveling agent silicone acrylate, 0.5 parts of defoamer polyether siloxane copolymer, and 5 parts of matting agent silica, which are mixed and stirred evenly to obtain the final product.

[0035] The above-mentioned dual-curing coating resin B comprises, by weight, 100 parts of polyurethane acrylate prepolymer, 5 parts of photoinitiator 2-hydroxy-2-methyl-1-phenyl-1-propanone, 1 part of leveling agent organosilicone acrylate, 0.5 parts of defoamer polyether siloxane copolymer, and 5 parts of tactile agent polymethyl methacrylate micro powder, which are mixed and stirred evenly.

[0036] The preparation process of the above-mentioned polyurethane acrylate prepolymer is as follows:

[0037] Polyethylene glycol was dehydrated under vacuum until the moisture content was below 0.05%. The polyethylene glycol was then added to butyl acetate, stirred, and heated to 70-75°C. While stirring, HDI and dibenzothiophene (DBT) catalyst were added dropwise over 30 minutes. After the addition was complete, the temperature was raised to 80-85°C and the reaction was maintained for 3 hours. The NCO value was measured; once it reached 50% of the theoretical value, the first isocyanate-terminated polyurethane prepolymer was obtained. The temperature was lowered to 40-45°C, and glycidol was added dropwise. The reaction was then carried out at 70-75°C until the NCO value reached 0, yielding the second epoxy-terminated modified polyurethane prepolymer. MAA (methacrylic acid) and hydroquinone (polymerization inhibitor) were added dropwise, and the reaction was continued for 2 hours. The reaction was terminated when the titration acid value was less than 6 mg KOH / g. This yielded a methacrylate-terminated polyurethane acrylate prepolymer. The molar ratio of HDI to polyethylene glycol is 2:1, the molar ratio of the first polyurethane prepolymer to glycidol is 1:1, the molar ratio of the epoxy group to MAA in the second modified polyurethane prepolymer is 1:1, and the molecular weight of the polyurethane acrylate prepolymer is Mn = 8000-12000.

[0038] Furthermore, the solid content of the polyurethane acrylate prepolymer was tested, and it was diluted with an organic solvent to a suitable coating thickness for application. In this invention, the solid content of the polyurethane acrylate prepolymer was 25%, and the organic solvent used for dilution, by volume ratio, was methyl ethyl ketone: ethyl acetate: butyl acetate = 3:3:4.

[0039] The preparation process of the INS membrane of this invention is as follows:

[0040] S1, using an automatic precision gravure printing machine, the pattern and ink are printed on the underside of the PMMA film to form an ink layer;

[0041] S2, using a rolling frame, dual-curing coating resin B is printed onto the upper side of the PMMA film to form a matte layer; using a rolling frame, dual-curing coating resin A is printed onto the upper side of the matte layer to form a tactile layer, and then baked in an oven at 120°C for 2 minutes to allow the matte layer and tactile layer to be surface-dried and preliminarily thermally formed. The two coatings have certain mechanical properties, thus forming the basic film material 1.

[0042] S3, using a high-precision coating and laminating machine, the ABS substrate layer is unwound through its first unwinding, and polyurethane adhesive is applied to the upper side of the ABS substrate layer by roller coating to form an adhesive layer. Then, the polyurethane adhesive is dried in an oven at 80°C to form the basic film material 1.

[0043] S4, the above-mentioned base film material is unwound by the second unwinding of the high-precision coating and laminating machine, and the base film material 1 and base film material 2 are laminated together by the composite pressure roller at 100°C and 0.3Pa to produce the finished roll INS film of Example 1.

[0044] In this invention, the thickness of the matte layer is approximately 6 μm, the thickness of the tactile layer is approximately 8 μm, the thickness of the PMMA film layer is approximately 100 μm, and the thickness of the ABS substrate layer is approximately 400 μm.

[0045] The INS film of the present invention is applied in the surface treatment process of plastic products, and its specific application steps are as follows:

[0046] First, the INS film of this invention is stretched three times, cut, and placed in a molding die; then, plastic is injected into the mold; after demolding, it is removed and finally cured in a UV curing chamber at a light intensity of 600 mJ / cm. 2 After 5 seconds of exposure to light, the INS film surface treatment on the plastic product is complete.

[0047] The photoinitiators in dual-curing coating resin A and dual-curing coating resin B, which have photosolid system functions in the matte layer and tactile layer, are activated by absorbing ultraviolet radiation energy. They produce active centers in a very short time. Then, these active centers interact with the unsaturated groups in the polyurethane acrylate prepolymer in dual-curing coating resin A and dual-curing coating resin B, initiating the breaking of double bonds in the polyurethane acrylate prepolymer and causing a continuous polymerization reaction, thereby cross-linking to form a film. That is, after the matte layer and tactile layer are cured by ultraviolet light, they are further cross-linked to form a film, thereby further optimizing the overall performance of the INS film.

[0048] Example 2

[0049] The INS film of Example 2 has the same structure as the INS film of Example 1, but the difference lies in the different contents of each component in the tactile layer and matte layer of Example 2 compared to Example 1, as detailed below:

[0050] The dual-curing coating resin B of the tactile layer in Example 2 comprises, by weight, 80 parts of polyurethane acrylate prepolymer, 3 parts of photoinitiator 2-hydroxy-2-methyl-1-phenyl-1-propanone, 1.2 parts of leveling agent organosilicone acrylate, 0.3 parts of defoamer polyether siloxane copolymer, and 7 parts of tactile agent polymethyl methacrylate micro powder, which are mixed and stirred evenly.

[0051] The dual-curing coating resin A of the matte layer in Example 2 comprises, by weight, 120 parts of polyurethane acrylate prepolymer, 4 parts of photoinitiator 2-hydroxy-2-methyl-1-phenyl-1-propanone, 1.5 parts of leveling agent silicone acrylate, 0.7 parts of defoamer polyether siloxane copolymer, and 3 parts of matting agent silica, which are mixed and stirred evenly.

[0052] Example 3

[0053] The INS film of Example 3 has the same structure as the INS film of Example 1. The difference lies in the content of each component in the tactile layer and matte layer of Example 3, which is different from that of Example 1, as detailed below:

[0054] The dual-curing coating resin B of the tactile layer in Example 3 comprises, by weight, 120 parts of polyurethane acrylate prepolymer, 4 parts of photoinitiator 2-hydroxy-2-methyl-1-phenyl-1-propanone, 1.5 parts of leveling agent organosilicone acrylate, 0.7 parts of defoamer polyether siloxane copolymer, and 10 parts of tactile agent polymethyl methacrylate micro powder, which are mixed and stirred evenly.

[0055] The dual-curing coating resin A of the matte layer in Example 3 comprises, by weight, 80 parts of polyurethane acrylate prepolymer, 3 parts of photoinitiator 2-hydroxy-2-methyl-1-phenyl-1-propanone, 1.2 parts of leveling agent organosilicon acrylate, 0.3 parts of defoamer polyether siloxane copolymer, and 7 parts of matting agent silica, which are mixed and stirred evenly.

[0056] Comparative Example 1

[0057] The INS film of Comparative Example 1 has the same structure as the INS film of Example 1, but the composition of the tactile layer and matte layer in Comparative Example 1 is different, as detailed below:

[0058] The coating resin of the tactile layer in Comparative Example 1 comprises, by weight, 90 parts of hydroxyl acrylic resin, 5 parts of hexamethylene diisocyanate curing agent, 1 part of silicone acrylate leveling agent, 0.5 parts of polyether siloxane copolymer defoamer, and 5 parts of polymethyl methacrylate micro powder as tactile agent, which are mixed and stirred evenly.

[0059] The coating resin for the matte layer in Comparative Example 1 comprises, by weight, 90 parts of hydroxyl acrylic resin, 5 parts of hexamethylene diisocyanate as curing agent, 1 part of silicone acrylate as leveling agent, 0.5 parts of polyether siloxane copolymer as defoamer, and 5 parts of silica powder as matting agent, which are mixed and stirred evenly.

[0060] Performance testing of INS membranes in Examples 1-3 and Comparative Example 1

[0061] High-temperature tensile strength and formability: The finished INS film is placed in a vacuum forming equipment, and the film baking temperature is set to 180℃ for 25-30 seconds. The INS film will be stretched according to the mold in the vacuum forming equipment, and the appearance of the film will be observed for any damage. The high-temperature tensile strength is thus measured. In addition, the existing INS film is prone to cracking at the corners of plastic parts, mainly due to the poor tensile strength of the INS film during the high-temperature stretching vacuum forming step. Therefore, the high-temperature tensile strength can be measured to determine its formability.

[0062] Surface hardness: tested using a Mitsubishi hardness tester;

[0063] Chemical resistance test: A gauze was placed on the surface of the INS film, and SPF50, PA++ sunscreen was evenly applied to the gauze. The film was then placed in an 80℃ oven for 24 hours for aging. After aging, the sunscreen was wiped off, and the surface of the INS film was observed.

[0064] The performance test structures of the INS membranes in Examples 1-3 and Comparative Example 1 are shown in Table 1.

[0065] Table 1

[0066] Surface hardness High temperature thermoforming elongation Chemical resistance test Example 1 2H 300％ No visible changes in appearance Example 2 2H 300％ No visible changes in appearance Example 3 2H 300％ No visible changes in appearance Comparative Example 1 H 220％ Swelling, paint film peeling

[0067] The performance test results of the INS film above show that the INS films of Examples 1-3 have better high-temperature thermoforming elongation and surface hardness than Comparative Example 1, and their chemical resistance is also better.

[0068] In addition, from Figure 1 It can be seen that there is no cracking at the corner of the INS film material and the plastic part in Example 1. Figure 2 As can be seen at point A in Comparative Example 1, there is a crack at the corner where the INS film material wraps with the plastic part.

[0069] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A high-plasticity INS film, characterized in that, Including those stacked sequentially from top to bottom: Matte layer, PMMA film layer, ink layer, adhesive layer and ABS substrate layer; The matte layer is formed by printing and coating with dual-curing coating resin A; The amount of each component added in the dual-curing coating resin A includes, by weight, 80-120 parts of polyurethane acrylate prepolymer, 3-5 parts of photoinitiator, 1-1.5 parts of leveling agent, 0.3-0.7 parts of defoamer, and 3-7 parts of matting agent; The polyurethane acrylate prepolymer is formed by reacting polyether diol and difunctional isocyanate compound to form an isocyanate-terminated first polyurethane prepolymer, then reacting the first polyurethane prepolymer with epoxy alcohol compound to form an epoxy-terminated second modified polyurethane prepolymer, and finally reacting the second modified polyurethane prepolymer with acrylic compound and end-capping with unsaturated bonds. The molecular weight of the polyurethane acrylate prepolymer is Mn=8000-12000.

2. The high-plasticity INS film according to claim 1, characterized in that, The matte layer is further provided with a tactile layer, which is formed by printing and coating with dual-curing coating resin B. The amount of each component added in the dual-curing coating resin B includes, by weight, 80-120 parts of polyurethane acrylate prepolymer, 3-5 parts of photoinitiator, 1-1.5 parts of leveling agent, 0.3-0.7 parts of defoamer, and 5-10 parts of tactile agent.

3. The high-plasticity INS film according to claim 1, characterized in that, The matting agent is one or more of silicon dioxide and titanium dioxide.

4. The high-plasticity INS film according to claim 2, characterized in that, The tactile agent is one or more of polyethylene terephthalate micro powder and polymethyl methacrylate micro powder.

5. The high-plasticity INS film according to claim 1 or 2, characterized in that, The photoinitiator is one or more of 2-hydroxy-2-methyl-1-phenyl-1-propanone and 1-hydroxycyclohexylphenyl ketone.

6. The application of the high-plasticity INS film according to any one of claims 1-5, characterized in that, It is used in the surface treatment process of plastic products.

7. The application of the high-plasticity INS film according to claim 6, characterized in that, First, the high-plasticity INS film is stretched three times, cut, and placed into a mold. Then, the plastic product is injected into the mold. After demolding, the product is cured under ultraviolet light in a UV curing oven with a light intensity of 600 mJ / cm². 2 The illumination time is 4-10 seconds.

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