Suction shaping mold, method for shaping resin molded body, and method for manufacturing resin member

Abstract

The suction molding die (10) is provided with a parting surface (13) and a molding surface (12) which is in close contact with the resin molded body (30) in the inner wall surface of the cavity recess (11a), and a step section (14) is provided between the parting surface (13) and the molding surface (12) in the direction intersecting the depth direction of the cavity recess (11a). The step part (14) is provided with a suction hole (15). The ratio a / b of the length a in the depth direction of the step part (14) of the suction shaping mold (10) to the length b in the intersecting direction of the step part (14) is greater than 1.0.

Description

Technical Field

[0001] The present invention relates to a mold for suction shaping, a shaping method for a resin molded body, and a method for manufacturing a resin part. Background Art

[0002] For a long time, as a method for shaping a resin mold such as a sheet or film into a specific shape, there is a shaping method using a suction shaping mold. For example, when shaping a resin mold into a concave shape, the resin mold is sucked as close to the concave bottom of the cavity as possible in the suction shaping mold, so that the resin mold can be shaped into a deep shape (following the shape of the concave portion of the cavity). However, if suction is performed at or near the above-mentioned concave bottom, a suction hole will be provided in the suction shaping mold at the position of the design surface of the resin mold (the so-called shaping surface), and there is a risk of residual traces of the suction hole on the design surface. In addition, when shaping a resin component, etc., the resin may enter the suction hole.

[0003] As one of the means to eliminate the above-mentioned problem, in Patent Document 1, in order to prevent the trace of the suction hole from being left on the design surface, a suction hole is provided in a groove formed on the parting surface at a position away from the shaping surface. Furthermore, in Patent Document 2, a suction hole is provided in the groove formed on the parting surface, and a convex portion is provided on the edge portion of the upper portion of the shaping surface between the shaping surface and the groove, thereby forming a resin molded body into a deeper shape. Furthermore, in Patent Document 3, fine concave-convex processing is performed on the periphery of the suction hole provided on the parting surface, thereby suppressing the clogging of the suction hole.

[0004] It should be noted that in Patent Document 4, a suction hole and a sheet heating hole are provided in a step portion formed in the upper part of the cavity, and the sheet is heated from the top and bottom, so that the upper and lower surfaces of the sheet are evenly heated, thereby enabling the sheet to be shaped into a deeper shape. In addition, in Patent Document 5, a suction hole is provided in a step portion formed in the cavity, and while decompressing the concave space of the cavity concave portion, the gap between the film and the heating device is decompressed, thereby making the two spaces into a vacuum state, and then restoring the gap to normal pressure, thereby enabling the film to be shaped into a deeper shape without leaving traces of the suction hole on the design surface.

[0005] Prior art literature

[0006] Patent Literature

[0007] Patent Document 1: Japanese Patent Application Laid-Open No. 3-124416

[0008] Patent Document 2: Japanese Patent Application Laid-Open No. 10-180798

[0009] Patent Document 3: Japanese Patent Application Laid-Open No. 10-100204

[0010] Patent Document 4: Japanese Patent Application Publication No. 2000-015667

[0011] Patent Document 5: Japanese Patent Application Publication No. 2000-108158 Summary of the invention

[0012] Problems to be solved by the invention

[0013] Generally, the suction shaping of a resin molded body is performed by making the resin molded body, for example, closely fixed to the parting surface of the mold, and using the suction hole to suck the air in the concave part of the cavity. However, as in Patent Documents 1 to 3, when the parting surface (the surface on which the grooves and protrusions are formed) and the shaping surface are connected in an adjacent manner, the possibility of wrinkles in the resin molded body accompanying the suction becomes higher. Specifically, during suction, the resin molded body is stretched into the cavity, and thus elongates starting from the part closely fixed to the mold. As a result, the resin molded body generates redundant parts in the stretching direction and the like, and wrinkles are generated. That is, in Patent Documents 1 to 3, the wrinkles generated on the parting surface are introduced into the shaping surface as they are, so the possibility of the wrinkles entering the design surface becomes higher. In addition, in Patent Documents 4 to 5, it is necessary to heat the film, and the shaping of the resin molded body becomes complicated.

[0014] In view of the above problems, the object of the present invention is to provide a suction shaping mold, a shaping method for a resin molded body, and a manufacturing method for a resin part, which can shape a resin molded body to a deeper position without generating traces of suction holes on the design surface of the resin molded body and can suppress the generation of wrinkles.

[0015] Means for solving problems

[0016] The present invention is as follows. [1]

[0018] A suction shaping mold having a cavity recessed portion, and shaping a resin molded body in a manner that closely fits at least a portion of an inner wall surface of the cavity recessed portion, the suction shaping mold comprising:

[0019] Parting surface; and

[0020] A shaping surface of the inner wall surface to which the resin molded body will closely contact,

[0021] In the intersecting direction intersecting with the depth direction of the cavity recess, a step difference portion is provided between the parting surface and the shaping surface.

[0022] A suction hole is provided in the step difference portion,

[0023] A ratio a / b of a length a of the step portion in the depth direction to a length b of the step portion in the intersecting direction is greater than 1.0. [2]

[0025] The mold for suction shaping according to the above-mentioned [1], wherein

[0026] At the step difference portion,

[0027] A pair of protrusions protruding from the parting surface side toward the shaping surface side in the intersecting direction and extending along the circumferential direction of the step difference portion are arranged in a manner of sandwiching the suction hole in the circumferential direction.

[0028] The ratio c / d of the length c between the pair of protrusions in the circumferential direction to the length d of the protrusion in the intersecting direction is greater than 0.5, and the ratio e / d of the length e of the protrusion in the circumferential direction to the length d of the protrusion in the intersecting direction is greater than 3.0. [3]

[0030] The mold for suction shaping according to the above-mentioned [2], wherein:

[0031] The curvature radius of the corner of the protrusion is 0.5 mm to 3.0 mm. [4]

[0033] A method for shaping a resin molded body, which is a method for shaping a resin molded body using the suction shaping mold described in any one of [1] to [3] above, the method comprising the following steps:

[0034] A sealing mechanism is provided on the parting surface, and the resin molded body is provided on the parting surface including the sealing mechanism, and then a frame-shaped plate is placed thereon to form a state in which the resin molded body is tightly fixed, and the air in the cavity recess is sucked from the suction hole, thereby shaping the resin molded body in the cavity recess. [5]

[0036] The method for shaping a resin molded article according to the above-mentioned [4], comprising:

[0037] The step of immediately subjecting the resin mold to suction while the mold for suction shaping is heated to a predetermined temperature in advance and then closely fixing the molded resin body. [6]

[0039] The method for shaping a resin molded article according to the above-mentioned [5], comprising:

[0040] The step of uniformly heating the resin molded body and then performing suction. [7]

[0042] The method for shaping a resin molded article according to any one of [4] to [6], wherein:

[0043] The resin molded body is a release film, a decorative film, a thermal transfer sheet having a release film and a thermal transfer layer, or a container molding sheet. [8]

[0045] The method for shaping a resin molded article according to [7] above, wherein:

[0046] The resin molded body is the thermal transfer sheet,

[0047] The average thickness of the thermal transfer layer is 0.1 μm to 50 μm. [9]

[0049] A method for producing a resin part using the method for shaping a resin molded body described in any one of [4] to [8], the method comprising the following steps:

[0050] A resin material is placed between the resin molded body disposed in the suction shaping mold and an opposing mold having a convex portion that can be inserted into the concave portion of the cavity, thereby molding a resin component.

[10]

[0052] A method for producing a resin material, which is a method for producing a resin part using the method for shaping a resin molded body described in any one of [4] to [8] above, the method comprising the following steps:

[0053] A resin material is injected between the resin molded body disposed in the suction shaping mold and an opposite side mold or a molding sheet provided with a convex portion that can be inserted into the concave portion of the cavity, thereby molding a resin component.

[11]

[0055] A method for producing a resin part, using the method for shaping a resin molded body as described in any one of [4] to [8], wherein:

[0056] The resin molded body is a release film,

[0057] The manufacturing method includes the following steps: between the resin molded body arranged in the suction shaping mold and the opposite side mold provided with a convex portion that can be inserted into the concave portion of the cavity, a stack of the thermal transfer layer and the resin material is placed in a manner such that the release film is in contact with the thermal transfer layer when the molds are closed, thereby molding the resin part.

[0058] Effects of the Invention

[0059] According to the present invention, there can be provided a suction shaping mold, a shaping method for a resin molded body, and a manufacturing method for a resin part, which can shape a resin molded body to a deeper position without generating traces of suction holes on the design surface of the resin molded body and can suppress the generation of wrinkles.

[0060] According to the above-mentioned structure, a step portion provided with a suction hole is positioned between the parting surface and the aforementioned shaping surface in the above-mentioned intersection direction. In other words, the parting surface and the aforementioned shaping surface are not adjacent to each other in the above-mentioned intersection direction. Therefore, even if wrinkles are generated at the parting surface during shaping (suction), the wrinkles can be prevented from directly propagating from the parting surface to the shaping surface, so that wrinkles are not easily generated on the shaping surface. In addition, according to the above-mentioned structure, the ratio a / b of the length a of the step portion in the depth direction to the length b of the step portion in the intersection direction is greater than 1.0, thereby preventing the resin molded body from clogging the suction hole during shaping (suction), and enabling the resin molded body to be fully sucked by the suction hole. As described above, according to this structure, the followability of the resin molded body to the suction shaping mold (especially the inner wall surface of the cavity recess) becomes good, the shape after shaping is excellent, and shaping can be performed in a short time, and excellent shaping properties can be obtained.

[0061] Moreover, according to the above-mentioned structure, a pair of protrusions that sandwich the suction hole in the circumferential direction are provided in the step difference portion, and the ratio c / d of the length c between the pair of protrusions in the circumferential direction to the length d of the protrusion in the cross direction is greater than 0.5, and the ratio e / d of the length e of the protrusion in the circumferential direction to the length d of the protrusion in the cross direction is greater than 3.0, thereby more appropriately suppressing the clogging of the suction hole by the resin molded body during shaping (suction).

[0062] Furthermore, according to the above configuration, by setting the curvature radius of the corner of the protrusion to 0.5 mm to 3.0 mm, it is possible to suppress the resin molded body from being broken starting from the corner during shaping (suction). BRIEF DESCRIPTION OF THE DRAWINGS

[0063] [ Figure 1 ] Figure 1 This is a schematic plan view showing a suction shaping mold according to one embodiment of the present invention.

[0064] [ Figure 2 ] Figure 2 yes Figure 1 A schematic cross-sectional view of the suction shaping mold shown (where hatching is omitted).

[0065] [ Figure 3 ] Figure 3 It is shown Figure 1 A schematic three-dimensional diagram of part A of FIG.

[0066] [ Figure 4 ] Figure 4is a first diagram showing a method for shaping a resin molded body and a method for manufacturing a resin component (it should be noted that this is equivalent to Figure 2 Schematic cross-sectional view of ).

[0067] [ Figure 5 ] Figure 5 The second figure is a diagram showing a method for forming a resin molded body and a method for manufacturing a resin component (it should be noted that it is equivalent to Figure 2 Schematic cross-sectional view of ).

[0068] [ Figure 6 ] Figure 6 The third figure is a diagram showing a method for shaping a resin molded body and a method for manufacturing a resin component (it should be noted that this is equivalent to Figure 2 Schematic cross-sectional view of ).

[0069] [ Figure 7 ] Figure 7 FIG. 4 is a fourth diagram showing a method for forming a resin molded body and a method for manufacturing a resin component (it should be noted that this is equivalent to Figure 2 Schematic cross-sectional view of ).

[0070] [ Figure 8 ] Figure 8 It is a schematic top view showing a first modified example of the suction shaping mold.

[0071] [ Fig. 9 ] Fig. 9 It is a schematic top view showing a second modified example of the suction shaping mold. DETAILED DESCRIPTION

[0072] <Implementation Method>

[0073] Below, refer to Figure 1 to Figure 7 An embodiment of the present invention will be described in detail.

[0074] For the sake of convenience, the following definitions are given for the “up-down direction”, “radial direction” and “circumferential direction”. Figure 1 The paper depth direction ( Figure 2 The radial direction refers to the direction extending linearly from the central axis to the outer periphery of the main body 11 on a plane perpendicular to the central axis of the main body 11 extending in the vertical direction, and corresponds to the "cross direction" of the present invention. The circumferential direction refers to the direction around the outer periphery of the main body 11 with the central axis as the center on a plane perpendicular to the central axis of the main body 11 extending in the vertical direction, and corresponds to the "circumferential direction" of the present invention.

[0075] In addition, in this specification, "A to B" which shows a range means "A or more and B or less".

[0076] <Suction shaping mold 10>

[0077] like Figure 1 As shown in FIG. 1 and FIG. 2 , the suction shaping mold 10 of the present embodiment is a concave mold (so-called cavity, female mold) composed of a main body 11 and a cavity recess 11a provided in the main body 11. The shape of the main body 11 can be appropriately determined and is not particularly limited.

[0078] like Figure 1 to Figure 3 As shown in FIG. 1 , the suction shaping mold 10 has a step 14 provided between the shaping surface 12 (i.e., the inner wall surface of the cavity concave portion 11a) and the parting surface 13 (the upper end surface in this example) in the radial direction. The step 14 is integrally formed by a plane portion 14a which is a plane perpendicular to the vertical direction, and a vertical wall 14b which is vertically provided from the radially outer end edge of the plane portion 14a in the vertical direction (see FIG. 1 ). Figure 3 ).

[0079] In this example, the vertical wall 14b is formed substantially perpendicular to the flat surface portion 14a, but in a plan view (see FIG. Figure 1 ) When the suction shaping mold 10 is formed, the vertical wall 14b may be formed at an acute angle relative to the plane portion 14a as long as the vertical wall 14b is not covered by the shaping surface 12. In addition, the vertical wall 14b may be formed at an obtuse angle relative to the plane portion 14a, but if it is greater than 120°, the possibility of the resin molded body 30 blocking the suction hole 15 described later during shaping becomes high. Therefore, the angle of the vertical wall 14b is preferably formed at 80° to 120°, more preferably at 85° to 110°, and most preferably at 87° to 100°.

[0080] A plurality of (10 in this example) suction holes 15 are provided at intervals in the circumferential direction on the radially outer side of the flat surface portion 14a. Figure 2 As shown in the figure, the suction hole 15 extends to the side of the main body 11, and a vacuum pump (not shown) is connected to the end 15a of the suction hole 15. However, if the interval between the circumferentially adjacent suction holes 15 is too narrow, the processing cost will be consumed. In addition, if the interval is too wide, uneven suction shaping of the resin molded body will occur. Therefore, for the above-mentioned interval, that is, the circumferential length between the circumferentially adjacent suction holes 15, although it also depends on the size and shape of the suction shaping mold 10, it is preferably formed to be 15mm~180mm, and more preferably formed to be 20mm~150mm. It should be noted that the above-mentioned interval is preferably as equal as possible.

[0081] like Figure 1 to Figure 3As shown, a plurality of protrusions 16 are provided on the step portion 14 so as to protrude radially inward from the upright wall 14b and extend in the circumferential direction. However, the protrusions 16 are provided so as not to extend over the entire radial region of the step portion 14. In the case where the protrusions 16 are provided on the step portion 14 in this manner, the protruding end face of the protrusion 16 corresponds to the upright wall 14b. Similarly, in the above case, the portion along the radial direction from the protruding end face of the protrusion 16 to the radial inner edge of the plane portion 14a corresponds to the plane portion 14a. That is, in other words, it can be said that the step portion 14 is provided with a recessed portion that is recessed radially outward on the upright wall 14b. Therefore, in the above case, in other words, it can be said that the suction hole 15 is provided in the recessed portion of the step portion 14 as described later.

[0082] A pair of circumferentially adjacent protrusions 16 among the plurality of protrusions 16 are arranged so as to sandwich the corresponding suction hole 15 in the circumferential direction. In other words, the step portion 14 divides a plurality of (10 in this example) concave spaces (spaces of the above-mentioned concave portions) between the circumferentially adjacent protrusions 16, and the suction holes 15 corresponding to the concave spaces are arranged in each. In this case, the suction hole 15 is preferably arranged in the center between the adjacent pair of protrusions 16 in the circumferential direction (see Figure 1 ).

[0083] like Figure 1 and Figure 3 As shown, corners 17 are formed at both ends of the protruding edge of the protruding strip 16 in the circumferential direction. In order to suppress the cracking of the resin molded body 30 during shaping, the corners 17 are formed into a rounded shape, that is, they are formed without edges. Specifically, the corners 17 are formed in a manner that the curvature radius is 0.5 mm to 3.0 mm.

[0084] like Figure 4 to Figure 7 As shown, the suction shaping mold 10 is provided with a sealing mechanism 18 on the parting surface 13 .

[0085] The step portion 14 of the present embodiment is constructed so that the ratio a / b of the length a of the vertical wall 14b in the vertical direction (in this example, the length of the protrusion 16 in the vertical direction) and the length b of the plane portion 14a in the cross direction (in this example, the length along the radial direction from the protruding end face of the protrusion 16 to the radial inner edge of the plane portion 14a) is greater than 1.0.

[0086] In addition, the step difference portion 14 of the present embodiment is constructed so that the ratio c / d of the circumferential length c between adjacent protrusions 16 in the circumferential direction (in other words, the length of the concave space in the circumferential direction) to the radial length d of the protrusion 16 (in other words, the length of the concave space in the radial direction) is greater than 0.5, and the ratio e / d of the circumferential length e of the protrusion 16 (in other words, the length of adjacent concave spaces in the circumferential direction) to the radial length d of the protrusion 16 is greater than 3.0.

[0087] The above-mentioned various ratios are insights obtained by the inventors of the present application through various tests (described in detail in the following "Examples"). By satisfying these requirements, the resin molded body 30 can be formed to a deeper position without generating traces of suction holes on the design surface of the resin molded body such as a sheet or film, and the generation of wrinkles can be suppressed.

[0088] It should be noted that the length a of the vertical wall 14b in the vertical direction corresponds to the "length a of the step portion 14 in the depth direction" of the present invention, and the length b of the plane portion 14a in the cross direction corresponds to the "length b of the step portion 14 in the cross direction" of the present invention. In addition, the length d of the protrusion 16 in the radial direction corresponds to the "length d of the protrusion 16 in the cross direction" of the present invention.

[0089] <Method for forming resin molded body>

[0090] The shaping method of the resin molded body according to the present embodiment is a shaping method for shaping the resin molded body 30 by vacuum suction using the above-mentioned suction shaping mold 10 .

[0091] Specifically, a resin molded body 30 is arranged between the suction shaping mold 10 and a frame-shaped plate 19, and the resin molded body 30 is pressed against the sealing mechanism 18 in a manner that does not cause wrinkles, and then the plate 19 (see Figure 4 to Figure 7 ) is fixed to the suction shaping mold 10 (see Figure 4 Then, the vacuum pump is turned on to discharge the air in the cavity concave portion 11a (cavity) of the suction shaping mold 10 (vacuum suction), thereby shaping the resin molded body 30 on the inner wall surface of the cavity concave portion 11a in the suction shaping mold 10, that is, the shaping surface 12 (see Figure 5-6 ).

[0092] It should be noted that the resin mold 30 may be closely fixed and vacuum suction may be performed immediately after the mold for suction shaping is heated to Tβ° C. Alternatively, the resin mold 30 may be uniformly heated and then vacuum suction may be performed as described above.

[0093] [Heating temperature Tβ]

[0094] The heating temperature Tβ is preferably a temperature higher than 70°C, and is preferably 80°C or higher, and more preferably 100°C or higher from the viewpoint of the shape retention (heat resistance) of the resin molded body 30. In addition, from the viewpoint of the thermal decomposition of the resin molded body 30, it is preferably 320°C or lower, and more preferably 300°C or lower. It should be noted that the heating temperature Tβ°C of the suction shaping mold 10 is preferably set to a temperature equivalent to the molding temperature of the resin part.

[0095] The resin contained in the resin component (which may be a resin material before molding) may be a thermoplastic resin or a thermosetting resin, or may be a fiber-reinforced resin containing carbon fibers or glass fibers.

[0096] When the resin contained in the resin component is a thermoplastic resin, when the melting point of the thermoplastic resin is set to T1°C, the molding temperature, i.e., Tβ, is preferably (T1-50)°C or higher. The molding temperature, i.e., Tβ, is preferably (T1-50)°C to (T1+150)°C, more preferably (T1-25)°C to (T1+100)°C, further preferably (T1-10)°C to (T1+75)°C, and particularly preferably (T1)°C to (T1+50)°C.

[0097] When the resin contained in the resin component is a thermosetting resin, when the curing temperature of the thermosetting resin is set to T2°C, the molding temperature, i.e., Tβ, is preferably (T2-50)°C or higher. It should be noted that the curing temperature is the peak temperature of the heat generation curve measured by DSC. The molding temperature, i.e., Tβ, is preferably (T2-50)°C to (T2+50)°C, more preferably (T2-40)°C to (T2+40)°C, further preferably (T2-30)°C to (T2+30)°C, and particularly preferably (T2-20)°C to (T2+20)°C.

[0098] [Resin molded body]

[0099] The resin molded article 30 of the present embodiment is preferably a sheet, and more preferably a release film, a decorative film, a thermal transfer sheet having a release film and a thermal transfer layer, or a container molding sheet.

[0100] From the viewpoint of shape-conforming property, the thickness of the resin molded body 30 of the present embodiment is preferably 1 μm to 1000 μm, more preferably 10 μm to 500 μm, further preferably 15 μm to 300 μm, and particularly preferably 20 μm to 100 μm.

[0101] When the resin molded body 30 of this embodiment is a container molding sheet, the resin molded body 30 formed using the molding method of this embodiment can be applied to, for example, food containers (side dish packaging, egg packaging, etc.), trays, stationery, etc.

[0102] (Release film)

[0103] The resin molded body 30 of the present embodiment may be a release film. The release film is not particularly limited, but preferably has a heat resistance of 100°C or more. In addition, it may be a non-silicone resin sheet or a silicone resin sheet, but preferably a non-silicone resin sheet, such as a fluorine resin sheet (manufactured by Nitto Denko Corporation, NITOFLON), a polyester resin sheet, a polystyrene resin sheet (manufactured by KURABO, Oidys (registered trademark)), a polyamide resin sheet, a polyolefin resin sheet, etc.

[0104] More specifically, the release film includes, for example, unstretched polyamide 6, unstretched polyamide 66, biaxially stretched polyamide 6, biaxially stretched polyamide 66, biaxially stretched polypropylene, biaxially stretched polyethylene terephthalate, biaxially stretched polybutylene terephthalate, unstretched polybutylene terephthalate, easily formed polyethylene terephthalate, cast polytetrafluoroethylene, cut polytetrafluoroethylene, unstretched extrusion-molded tetrafluoroethylene-ethylene copolymer (ETFE), unstretched extrusion-molded tetrafluoroethylene-perfluoroalkoxyethylene copolymer (PFA), unstretched extrusion-molded tetrafluoroethylene-hexafluoropropylene copolymer (FEP), and laminates using these as main layers.

[0105] Among them, biaxially stretched polypropylene, biaxially stretched polyethylene terephthalate, biaxially stretched polybutylene terephthalate, unstretched polybutylene terephthalate, and cut polytetrafluoroethylene are preferred, and biaxially stretched polypropylene, unstretched polybutylene terephthalate, and cut polytetrafluoroethylene are more preferred.

[0106] The release film may be subjected to a release treatment with an appropriate release treatment agent such as silicone on one side or both sides of the release film as necessary.

[0107] (Decorative Film)

[0108] The resin molded body 30 of this embodiment may be a decorative film. As the decorative film, for example, a film having a decorative layer on the resin film exemplified as the above-mentioned release film may be mentioned. As the decorative layer, for example, a printed layer, a metal thin film layer, etc. may be mentioned.

[0109] (Thermal transfer film)

[0110] The resin molded body 30 of the present embodiment may be a thermal transfer sheet including a release film and a thermal transfer layer.

[0111] Here, since the thermal transfer layer in the thermal transfer sheet is in sheet form, it is not coated on the surface of the resin component, but can be integrally formed with the resin material by placing and heating. Therefore, it is possible to prevent unevenness caused by the occurrence of coating film depressions, and to form the thermal transfer layer with a uniform thickness on the surface of the resin component. In addition, when the thermal transfer layer is applied to a portion of the surface of the resin component, it is possible to suppress a reduction in yield due to overflow, etc.

[0112] The thermal transfer layer can also be a surface modification layer.

[0113] In this embodiment, the surface modification layer refers to a layer that can modify the surface of any component, material, etc. For example, it can be a layer that can impart functions such as easy adhesion, coating properties, conductivity, coloring, decorative properties, adhesiveness, and weldability to the surface of a resin component, or a layer that can improve these functions.

[0114] The material used for the surface modification layer of the present embodiment is not particularly limited, and various materials can be used depending on the function to be imparted or enhanced.

[0115] In order to impart or improve easy adhesion and coating properties, it is preferred that the surface modification layer contain a polymer component described below.

[0116] In order to impart or improve conductivity, the surface modification layer preferably contains, for example, a metal mesh, conductive fibers, metal powder, or the like.

[0117] Examples of the metal mesh include a copper mesh, an aluminum mesh, and a stainless steel mesh.

[0118] Conductive fibers include, for example, potassium titanate fibers, metal nanowires, carbon nanotubes, carbon fibers, polyester and nylon fibers mixed with conductive carbon or white metal oxides and obtained by composite spinning, and core-sheath composite spun fibers in which conductive particles are mixed in the core portion of the fiber.

[0119] Examples of the metal powder include metal powders such as tin oxide and carbon black, and powders of metal oxides such as indium zinc composite oxide (IZO), indium gallium zinc composite oxide (IGZO), indium gallium composite oxide (IGO), indium tin composite oxide (ITO), and antimony tin composite oxide (ATO).

[0120] The surface modification layer preferably contains a pigment or a dye in order to impart or enhance colorability.

[0121] In order to impart or improve decorativeness, metal foils such as copper foil, continuous or discontinuous metal sputtering layers, metal vapor deposition layers, metal plating layers, and printed layers can be used as surface modification layers. In addition, the surface of the surface modification layer can also be mirror-finished to form a regular or irregular pattern. The pattern can be formed by giving the surface of the surface modification layer concave and convex by patterning, embossing, embossing, etc.

[0122] The printed layer can be formed by commonly performed screen printing, flexographic printing, gravure printing, offset printing, inkjet printing, laser printer, etc. In addition, the ink used in the printed layer can generally be exemplified by a varnish prepared by dissolving a pigment, dye, oil, natural resin, synthetic resin, etc. in a solvent as a main agent, and adding any lubricant, curing agent, etc. The hue of the ink used in the printed layer can be appropriately determined according to the purpose of the resin component.

[0123] The printing layer can be formed by commonly performed screen printing, flexographic printing, gravure printing, offset printing, inkjet printing, laser printer, etc. In addition, the ink used in the printing layer can generally be exemplified by a varnish prepared by dissolving a pigment, oils, natural resins, synthetic resins, etc. in a solvent as a main agent, and adding any lubricant, curing agent, etc. The hue of the ink used in the printing layer can be appropriately determined according to the purpose of the laminate.

[0124] Alternatively, adhesiveness may be imparted by using an adhesive, or solderability may be imparted by tin plating.

[0125] The surface modification layer of the present embodiment more preferably has good adhesiveness.

[0126] Hereinafter, in this specification, the case where the surface modification layer contains a polymer component and has good adhesion and coating properties will be described as an example.

[0127] The surface modification layer (or the material of the surface modification layer) preferably comprises a polymer component, and more preferably the polymer component has a non-polar unit and a polar unit having a polar group. The content ratio of the above-mentioned polymer component in the surface modification layer is preferably 50% to 100% by mass, more preferably 70% to 100% by mass, further preferably 90% to 100% by mass, particularly preferably 92% to 100% by mass, and most preferably 95% to 100% by mass.

[0128] From the viewpoint of bonding strength, for the resin component of this embodiment, it is preferred that the resin material and the surface modification layer are fused and mixed, or covalently bonded by chemical reaction. Therefore, the polymer component contained in the surface modification layer is preferably appropriately selected in a manner that can be fused and mixed or chemically reacted with the resin contained in the resin material.

[0129] Examples of the nonpolar unit in the polymer component include polyethylene units, polypropylene units, polystyrene units, etc. The nonpolar unit may be present in one type or in two or more types.

[0130] As the polar unit having a polar group in the polymer component, for example, an epoxy group, a carboxyl group, a nitrile group, an amide group, an ester group, a hydroxyl group, an acid anhydride group, a silanol group, etc. As such a polar unit having a polar group, for example, a glycidyl methacrylate unit, a vinyl acetate unit, an acrylonitrile unit, an amide unit, a (meth)acrylate unit, a hydroxyethyl (meth)acrylate unit, a maleic anhydride unit, etc. can be mentioned. The polar unit may be only one kind or two or more kinds.

[0131] The polymer component that may be contained in the surface modification layer may be at least one selected from the group consisting of a methoxymethyl group-containing polymer, a hydroxyl group-containing polymer, a carboxyl group-containing polymer, an amino group-containing polymer, and an amide group-containing polymer.

[0132] Such a polymer component which may be contained in the surface modification layer is preferably an addition type curing agent, and more preferably an addition type curing agent which reacts with a functional group possessed by a resin contained in the resin material described later.

[0133] As the methoxymethyl group-containing polymer, any appropriate polymer may be used as long as it contains a methoxymethyl group (-CH2-OCH3) within the range not impairing the effects of the present invention. Examples of such methoxymethyl group-containing polymers include methoxymethyl group-containing polyamide resins.

[0134] As the methoxymethyl group-containing polymer, a commercially available product may be used. Examples of such commercially available products include "Fine Resin" (registered trademark) series (manufactured by Kinoshita Co., Ltd.).

[0135] The methoxymethyl group-containing polymer may be one kind or two or more kinds.

[0136] As the hydroxyl group-containing polymer, any appropriate polymer may be adopted as long as it contains a hydroxyl group (—OH) within the range not impairing the effects of the present invention. Examples of such a hydroxyl group-containing polymer include hydroxyl group-containing acrylic polymers.

[0137] As the hydroxyl group-containing polymer, a commercially available product can be used. Examples of such commercially available products include "ARUFON (registered trademark) UH-2000 series" (manufactured by Toagosei Co., Ltd.).

[0138] The hydroxyl group-containing polymer may be one kind or two or more kinds.

[0139] As the carboxyl group-containing polymer, any appropriate polymer may be adopted as long as it contains a carboxyl group (—COOH) within the range not impairing the effects of the present invention. Examples of such a carboxyl group-containing polymer include carboxyl group-containing acrylic polymers.

[0140] As the carboxyl group-containing polymer, a commercially available product may be used, and examples of such commercially available products include "ARUFON (registered trademark) UC-3000 series" and "ARUFON (registered trademark) UC-3510 series" (manufactured by Toagosei Co., Ltd.).

[0141] The carboxyl group-containing polymer may be one kind or two or more kinds.

[0142] As the amino group-containing polymer, any appropriate polymer may be adopted as long as it is a polymer containing an amino group (—NH 2 ) within a range not impairing the effects of the present invention.

[0143] As the amino group-containing polymer, a commercially available product can be used.

[0144] The amino group-containing polymer may be one kind or two or more kinds.

[0145] The surface modification layer (or the material of the surface modification layer) may contain at least one selected from the group consisting of a tertiary amine-containing compound and a strong acid.

[0146] As the amide group-containing polymer, any appropriate polymer may be adopted as long as it contains an amide group (—CO—NH 2 ) within the range not impairing the effects of the present invention. Examples of such amide group-containing polymers include polyamide copolymer resins.

[0147] As the amide group-containing polymer, a commercially available product can be used. Examples of such commercially available products include "Amilan CM8000" (manufactured by Toray Industries, Inc.).

[0148] The amide group-containing polymer may be one kind or two or more kinds.

[0149] The polymer component that may be contained in the surface modification layer (or the material of the surface modification layer) may be an unsaturated hydrocarbon group-containing polymer having an unsaturated hydrocarbon group.

[0150] (Polymer containing unsaturated hydrocarbon groups)

[0151] Examples of the polymer containing an unsaturated hydrocarbon group include polymers selected from acrylic polymers, polyester polymers, urethane polymers, polyether polymers, polyamide polymers, and epoxy acrylate polymers and having an unsaturated hydrocarbon group. From the viewpoint of improving adhesion, an acrylic polymer containing an unsaturated hydrocarbon group is preferred.

[0152] The unsaturated hydrocarbon group-containing polymer can be obtained, for example, by reacting a prepolymer having a functional group with an unsaturated hydrocarbon group-containing compound capable of reacting with the functional group to form a bond.

[0153] The term "prepolymer" used in the present specification refers to a polymer obtained by partially polymerizing monomers constituting a polar group-containing polymer.

[0154] ·Acrylic acid polymer containing unsaturated hydrocarbon groups

[0155] The method of introducing the unsaturated hydrocarbon group into the prepolymer is not particularly limited, and various methods can be used. Introducing the unsaturated hydrocarbon group into the side chain of the prepolymer is also advantageous from the viewpoint of molecular design.

[0156] Such a method includes, for example, a method of copolymerizing a monomer having a functional group with a prepolymer in advance and then subjecting a compound having a functional group reactive with the functional group and an unsaturated hydrocarbon group to a condensation or addition reaction while maintaining the thermosetting property of the unsaturated hydrocarbon group.

[0157] For example, when the unsaturated hydrocarbon group-containing polymer is an acrylic polymer containing an unsaturated hydrocarbon group, a hydroxyl-containing acrylic polymer is used as a prepolymer, and the prepolymer can be preferably obtained by an addition reaction with an unsaturated hydrocarbon group-containing compound. The unsaturated hydrocarbon group-containing compound has a predetermined functional group that can react with a hydroxyl group to bond, and the hydroxyl group in the prepolymer reacts with the functional group in the unsaturated hydrocarbon group-containing compound, thereby introducing a side chain containing an unsaturated hydrocarbon group derived from the unsaturated hydrocarbon group-containing compound into the prepolymer, thereby obtaining the unsaturated hydrocarbon group-containing polymer.

[0158] As examples of the combination of these functional groups, carboxyl and epoxy (especially glycidyl), carboxyl and aziridine, hydroxyl and isocyanate, etc. can be cited. Among the combinations of these functional groups, the combination of hydroxyl and isocyanate is preferred from the ease of reaction tracking. In addition, with the combination of these functional groups, as long as it is a combination that generates the above-mentioned unsaturated hydrocarbon-containing polymer, the functional group can be on any side of the prepolymer and the unsaturated hydrocarbon-containing compound.

[0159] For example, the prepolymer may have a hydroxyl group, and the unsaturated hydrocarbon group-containing compound may be an unsaturated hydrocarbon group-containing isocyanate compound. In this case, a hydroxyl group-containing acrylic polymer may be used as the prepolymer.

[0160] Examples of the unsaturated hydrocarbon group-containing isocyanate compound include 2-methacryloyloxyethyl isocyanate (MOI) and 3-isopropenyl-α,α-dimethylbenzyl isocyanate. From the viewpoint of easily introducing an unsaturated hydrocarbon group into a polymer side chain, the unsaturated hydrocarbon group-containing isocyanate compound is preferably MOI.

[0161] The amount of the unsaturated hydrocarbon group-containing compound used in the above reaction is not particularly limited.

[0162] Here, when the molar ratio of the unsaturated hydrocarbon group-containing compound to the hydroxyl-containing monomer as a raw material of the hydroxyl-containing acrylic polymer is less than 1, the obtained unsaturated hydrocarbon group-containing acrylic polymer becomes a polymer also having a hydroxyl group.

[0163] The unsaturated hydrocarbon group-containing acrylic polymer can be obtained, for example, by preparing a reaction solution obtained by adding an unsaturated hydrocarbon group-containing compound and an addition reaction catalyst to a prepolymer solution containing the above-mentioned prepolymer, and subjecting the reaction solution to the above-mentioned addition reaction, thereby obtaining the unsaturated hydrocarbon group-containing acrylic polymer solution containing the unsaturated hydrocarbon group-containing acrylic polymer.

[0164] As the unsaturated hydrocarbon group-containing acrylic polymer, a commercially available product can be used.

[0165] The unsaturated hydrocarbon group-containing acrylic polymer may be one kind or two or more kinds.

[0166] The surface modification layer (or the material of the surface modification layer) may contain other components as required in addition to the above-mentioned polymer components. Examples of other components include fillers such as microparticles, pH adjusters, crosslinking agents, viscosity modifiers (thickeners, etc.), leveling agents, release modifiers, plasticizers, softeners, fillers, colorants (pigments and dyes, etc.), surfactants, antistatic agents, preservatives, anti-aging agents, ultraviolet absorbers, antioxidants, and light stabilizers.

[0167] In the present embodiment, it is preferred that the resin molded body 30 is a thermal transfer sheet, and the average thickness of the thermal transfer layer is 0.1 μm to 50 μm.

[0168] In the present embodiment, the average thickness of the thermal transfer layer is preferably 0.1 μm to 50 μm. This allows pinholes and other irregularities to be filled even when they exist on the surface of the resin material, thereby achieving a more excellent appearance.

[0169] From the viewpoint of filling the pinholes and other unevenness on the surface of the resin material and obtaining a more excellent appearance, the average thickness of the thermal transfer layer is more preferably 0.5 μm or more, and more preferably 0.7 μm or more. In addition, from the viewpoint of adhesive strength, the average thickness of the thermal transfer layer is more preferably 40 μm or less, and more preferably 20 μm or less.

[0170] The thickness of the thermal transfer layer can be measured by measuring the thickness of the thermal transfer sheet with a dial thickness gauge (eg Peacock GC-9), measuring the thickness of the release film from which the thermal transfer layer has been removed, and measuring the difference as the thickness of the thermal transfer layer.

[0171] The average thickness of the thermal transfer layer is an average value obtained by measuring 10 locations.

[0172] (Manufacture of thermal transfer sheets)

[0173] The thermal transfer sheet can be manufactured by any appropriate method. For example, there can be mentioned: a method of dipping a release film into a solution containing a material of a thermal transfer layer and a solvent (composition for forming a thermal transfer layer) and then drying as needed; a method of brushing a solution containing a material of a thermal transfer layer and a solvent onto the surface of a release film and then drying as needed; a method of applying a solution containing a material of a thermal transfer layer and a solvent onto the surface of a release film using various coating machines and then drying as needed; a method of spraying a solution containing a material of a thermal transfer layer and a solvent onto the surface of a release film and then drying as needed; and the like.

[0174] Examples of the composition for forming a thermal transfer layer include a solution obtained by dissolving a material for the thermal transfer layer in a solvent.

[0175] Examples of the solvent include water, alcohols such as methanol, ethanol, and isopropyl alcohol (IPA), ketones such as methyl ethyl ketone, esters such as ethyl acetate, aliphatic, alicyclic, and aromatic hydrocarbons, halogenated hydrocarbons, amides such as dimethylformamide, sulfoxides such as dimethyl sulfoxide, ethers such as dimethyl ether and tetrahydrofuran, etc. The solvent may be one or more.

[0176] It is also preferable to use a polymer solution containing the polymer obtained in the synthesis of the polymer as it is as the composition for forming a thermal transfer layer.

[0177] The solid content concentration in the composition for forming a thermal transfer layer can be appropriately set according to the purpose. From the viewpoint of thickness accuracy of the thermal transfer layer, the solid content is preferably 1% to 60% by mass, more preferably 10% to 50% by mass, and further preferably 15% to 40% by mass.

[0178] The composition for forming a thermal transfer layer may contain other components that can be contained in a thermal transfer layer (surface modification layer) together with the above-mentioned polymer component as needed.

[0179] For example, by adding a colorant, the thermal transfer layer can be visualized, making it easy to identify whether the surface of the resin part has been modified, which has advantages in process management. In addition, it also functions as a base for improving the color development of the coating.

[0180] As the coloring agent, for example, a dye or a pigment can be mentioned. In addition, as the coloring agent, a fluorescent material that can be viewed with black light can also be used.

[0181] (Container forming sheet)

[0182] The resin molded body 30 of this embodiment may also be a container molding sheet. As the container molding sheet, for example, the resin film mentioned as the above-mentioned release film can be cited. In this case, the resin molded body 30 after being shaped by vacuum suction can be used as a container directly.

[0183] <Method for manufacturing resin parts>

[0184] The method for manufacturing a resin component of the present embodiment is a method for manufacturing a resin component by placing a resin material 40 between a resin molded body 30 disposed in a suction shaping mold 10 and a convex portion 22 of an opposing mold 20 (see Figure 4 to Figure 7 For example, when a pair of molds 1 such as a suction shaping mold 10 and an opposite side mold 20 are used, a resin molded body 30 can be placed on the suction shaping mold 10 and shaped by the above-mentioned shaping method, and a resin material 40 can be placed on the opposite side mold 20 (specifically, the convex portion 22) and the molds can be closed.

[0185] Specifically, after the resin mold 30 is shaped using the suction shaping mold 10, a resin can be inserted between the opposite side mold 20 to form the resin part by press molding, transfer molding, reduced pressure press molding, injection molding, etc. Alternatively, after the resin is inserted, an autoclave molding in which a sheet-like material (such as a shaping sheet) is covered and pressurized, or RTM molding in which the interior is reduced in pressure to form the part can be performed. In this case, for example, if the resin mold 30 is a release film, the releasability of the resin part from the suction shaping mold 10 can be improved. In addition, for example, if the resin mold 30 is a thermal transfer sheet, the transfer of the thermal transfer layer and the resin molding can be performed simultaneously.

[0186] In addition, a resin material (not shown) may be injected between the resin molded body 30 disposed in the suction shaping mold 10 and the opposite side mold 20 or the molding sheet (not shown) to mold the resin component to manufacture the resin component. In this case, the molding method of the resin component may be any one of injection molding, autoclave molding, transfer molding, RTM molding, and VaRTM molding. The resin material may be a molten resin.

[0187] The manufacturing method of the resin part of this embodiment can also be the following method, wherein the resin molded body 30 is a release film, and a stack of a thermal transfer layer and a resin material is placed between the release film arranged on the suction shaping mold 10 and the opposite side mold 20 in a manner that the release film and the thermal transfer layer are in contact when the molds are closed, thereby molding the resin material.

[0188] In the method for manufacturing a resin component of the present embodiment, the resin that can be used may be a thermosetting resin or a thermoplastic resin, and may also be a fiber-reinforced resin containing carbon fibers or glass fibers.

[0189] Examples of thermoplastic resins include PP (polypropylene), PA (polyamide), PPE (polyphenylene ether), PPS (polyphenylene sulfide), PET (polyethylene terephthalate), PBT (polybutylene terephthalate), POM (polyacetal), PEEK (polyetheretherketone), PC (polycarbonate), PES (polyether sulfide), EP (epoxy resin), etc. Among these resins, examples of thermoplastic resins that can advantageously exhibit the effects of the present invention include PPS (polyphenylene sulfide), PA (polyamide), PES (polyether sulfide), and EP (epoxy resin).

[0190] As the thermoplastic resin, a fiber reinforced thermoplastic resin (FRTP) may be used.

[0191] Examples of the fiber reinforced thermoplastic resin (FRTP) include carbon fiber reinforced thermoplastic resin (CFRTP) and glass fiber reinforced thermoplastic resin (GFRTP).

[0192] Examples of the carbon fiber reinforced thermoplastic resin (CFRTP) include PPS-based carbon fiber reinforced thermoplastic resin, PA-based carbon fiber reinforced thermoplastic resin, PES-based carbon fiber reinforced thermoplastic resin, EP-based carbon fiber reinforced thermoplastic resin, and PP-based carbon fiber reinforced thermoplastic resin.

[0193] Examples of the glass fiber reinforced thermoplastic resin (GFRTP) include PPS-based glass fiber reinforced thermoplastic resin, PA-based glass fiber reinforced thermoplastic resin, and PP-based glass fiber reinforced thermoplastic resin.

[0194] Examples of the thermosetting resin include unsaturated polyester resins, vinyl ester resins, epoxy resins, melamine resins, phenol resins, urethane resins, polyisocyanate resins, polyisocyanurate resins, and polyimide resins.

[0195] Examples of the shape of the resin member precursor include a plate shape having a flat surface, a plate shape having a curved surface, a sheet shape, and a film shape.

[0196] The thickness of the resin member precursor is, for example, 0.001 mm to 10 mm.

[0197] The resin component precursor may be a prepreg. A prepreg is a material that is obtained by impregnating a reinforcing material such as carbon fiber or glass fiber with a thermosetting resin mixed with an additive such as a curing agent, and then heating or drying the material to a semi-cured state.

[0198] In addition, the resin material used as the precursor of the resin part may be SMC (sheet molding compound) or BMC (bulk molding compound). There is no particular limitation on the SMC and BMC used, and examples thereof include SMC in sheet form and BMC in block form, which are obtained by impregnating a reinforcing material such as carbon fiber or glass fiber with a thermosetting resin mixed with additives such as a curing agent.

[0199] [Opposite side mold 20]

[0200] like Figure 6 As shown in the figures, the opposite side mold 20 of the present embodiment is a convex mold (so-called core, male mold) composed of a main body 21 and a convex portion 22 protruding from the main body 21 and capable of being inserted into the cavity concave portion 11a of the suction shaping mold 10.

[0201] <Other methods>

[0202] It should be noted that the present invention is not limited to the above-mentioned embodiments, and can be appropriately deformed, improved, etc. In addition, the material, shape, size, quantity, configuration position, etc. of each component in the above-mentioned embodiment can be arbitrary and not limited as long as the present invention can be realized.

[0203] [First Modification]

[0204] The suction shaping mold 10 of the above embodiment has a protrusion 16 on the step 14. Figure 8 As shown, the protrusion 16 may not be provided on the step portion 14 of the suction shaping mold 10 .

[0205] [Second Modification]

[0206] In the above-described embodiment of the suction shaping mold 10, the proportion of the protrusions 16 in the step portion 14 is greater than the proportion of the concave spaces defined between the protrusions 16 adjacent in the circumferential direction in the step portion 14. Fig. 9 As shown, the ratio of the concave space in the step portion 14 may be larger than the ratio of the protrusion 16 in the step portion 14 .

[0207] As described above, this specification discloses the following matters. [1]

[0209] A suction shaping mold (10) is provided with a cavity recess (11a) and is used to shape a resin molded body (30) in such a manner as to closely fit at least a portion of an inner wall surface of the cavity recess. The suction shaping mold comprises:

[0210] Parting surface (13); and

[0211] A shaping surface (12) on the inner wall surface to which the resin molded body will closely contact,

[0212] In the intersecting direction (radial direction) intersecting the depth direction (up and down direction) of the cavity recess, a step difference portion (14) is provided between the parting surface (13) and the shaping surface (12).

[0213] The step difference portion (14) is provided with a suction hole (15),

[0214] A ratio a / b of a length a of the step portion (14) in the depth direction (vertical direction) to a length b of the step portion (14) in the intersecting direction (radial direction) is greater than 1.0. [2]

[0216] The suction shaping mold (10) according to the above-mentioned [1], wherein:

[0217] At the step difference portion (14),

[0218] A pair of protruding strips (16) protruding from the parting surface (13) side toward the shaping surface (12) side in the intersecting direction and extending along the circumferential direction of the step difference portion are arranged in a manner of sandwiching the suction hole (15) in the circumferential direction.

[0219] The ratio c / d of the length c between the pair of protrusions (16) in the circumferential direction to the length d of the protrusion (16) in the cross direction (radial direction) is greater than 0.5, and the ratio e / d of the length e of the protrusion (16) in the circumferential direction to the length d of the protrusion (16) in the cross direction (radial direction) is greater than 3.0. [3]

[0221] The suction shaping mold (10) according to the above-mentioned [2], wherein:

[0222] The curvature radius of the corner portion (17) of the protrusion portion (16) is 0.5 mm to 3.0 mm. [4]

[0224] A method for shaping a resin molded body, which is a method for shaping a resin molded body using the suction shaping mold (10) described in any one of [1] to [3] above, the method comprising the following steps:

[0225] A sealing mechanism (18) is provided on the parting surface (13), and the resin molded body (30) is provided on the parting surface (13) including the sealing mechanism (18), and then a frame-shaped plate (19) is placed thereon to form a state in which the resin molded body (30) is tightly fixed, and the air in the cavity recess (11a) is sucked from the suction hole (15), thereby giving the resin molded body (30) shape to the cavity recess (11a). [5]

[0227] The method for shaping a resin molded article according to the above-mentioned [4], comprising the following steps:

[0228] The mold (10) for suction shaping is preheated to a predetermined temperature, the resin molded body (30) is closely fixed and suction is immediately performed. [6]

[0230] The method for shaping a resin molded body according to the above-mentioned [5] includes the step of uniformly heating the resin molded body (30) and then performing suction. [7]

[0232] The method for shaping a resin molded article according to any one of [4] to [6], wherein:

[0233] The resin molded body (30) is a mold release film, a decorative film, a thermal transfer sheet having a mold release film and a thermal transfer layer, or a container molding sheet. [8]

[0235] The method for shaping a resin molded article according to [7] above, wherein:

[0236] The resin molded body (30) is the thermal transfer sheet.

[0237] The average thickness of the thermal transfer layer is 0.1 μm to 50 μm. [9]

[0239] A method for producing a resin part using the method for shaping a resin molded body described in any one of [4] to [8], the method comprising the following steps:

[0240] A resin material is placed between the resin molded body (30) disposed in the suction shaping mold (10) and an opposite side mold (20) provided with a convex portion (22) that can be inserted into the cavity concave portion (11a), thereby molding a resin component.

[10]

[0242] A method for producing a resin material, which is a method for producing a resin part using the method for shaping a resin molded body described in any one of [4] to [8] above, the method comprising the following steps:

[0243] Resin material is injected between the resin molded body (30) arranged on the suction shaping mold (10) and the opposite side mold (20) or the molding sheet provided with a convex portion (22) capable of being inserted into the cavity concave portion (11a), thereby molding the resin part.

[11]

[0245] A method for producing a resin part, using the method for shaping a resin molded body as described in any one of [4] to [8], wherein:

[0246] The resin molded body (30) is a release film,

[0247] The manufacturing method includes the following steps: between the resin molded body (30) arranged on the suction shaping mold (10) and the opposite side mold (20) provided with a convex portion (22) capable of being inserted into the cavity recess (11a), a laminate of the thermal transfer layer and the resin material is placed in a manner such that the release film is in contact with the thermal transfer layer when the molds are closed, thereby molding the resin part.

[12]

[0249] The method for manufacturing a resin component according to the above-mentioned [9] is a predetermined compression molding.

[13]

[0251] The method for producing a resin part according to the above

[10] is at least one of injection molding, autoclave molding and transfer molding.

[0252] Example

[0253] Hereinafter, the present invention will be specifically described by way of examples, but the present invention is not limited to these examples.

[0254] <Experiment>

[0255] In the examples and comparative examples, various resin molded bodies were used as the mold for suction shaping, and tests were conducted under the following test conditions to determine whether the resin molded bodies could be shaped well.

[0256] [Example 1]

[0257] Use a step portion with a suction hole and a width X (see Figure 1 ) is 80mm, width Y (see Figure 1 ) is 60mm, the depth Z of the cavity concave part (see Figure 2 ) is 30mm. A sheet (release film: biaxially stretched polypropylene film (OT-P2171, manufactured by Toyobo Co., Ltd.)) as a resin molded body is arranged at room temperature (23°C) in a manner covering the concave portion of the cavity of the suction shaping mold, and is tightly fixed with the frame of the suction shaping mold. Then, a vacuum pump (DAP-6D manufactured by ULVAC Kiko Co., Ltd.) is used to perform vacuum suction from the suction hole to shape the sheet. At this time, the suction is stopped at the moment when the movement of the release film stops. It should be noted that the suction shaping mold of Example 1 is, for example, Figure 8 The suction shaping mold shown.

[0258] [Example 2]

[0259] A suction shaping mold is used in which a protrusion is provided on the step portion and the suction holes are arranged between the protrusions adjacent to each other in the circumferential direction. Otherwise, the sheet is shaped by vacuum suction in the same manner as in Example 1. It should be noted that the suction shaping mold of Example 2 is, for example, Fig. 9 The suction shaping mold shown.

[0260] [Example 3]

[0261] Compared with Example 2, a suction shaping mold having a larger proportion of the protrusions in the step difference portion is used. Otherwise, the sheet is shaped by vacuum suction in the same manner as in Example 1. It should be noted that the suction shaping mold of Example 3 is, for example, Figure 1 to Figure 7 The suction shaping mold shown.

[0262] [Examples 4 to 8]

[0263] The suction shaping mold was used except that the type of release film and various sizes were changed as shown in Table 1 compared with Example 3. The sheet was shaped by vacuum suction in the same manner as in Example 1 except for the above.

[0264] In addition, the sheet used in Example 8 is described as follows.

[0265] 100 parts by mass of a polyamide copolymer resin (Amilan CM8000 manufactured by Toray Industries, Ltd.) and 2 parts by mass of an acrylic polymer (ARUFON UC-3510 manufactured by Toagosei Co., Ltd.) were dispersed and dissolved in a mixed solvent of ethanol (EtOH) / water / isopropyl alcohol (IPA) = 68% by mass / 12% by mass / 20% by mass at 40° C. to prepare a solution having a solid content of 20% by mass (surface modification composition).

[0266] The prepared surface modified composition was filtered through a nylon mesh with a mesh opening of 188 μm, applied onto a biaxially stretched polypropylene film (OT-P2171, manufactured by Toyobo Co., Ltd.) using a coater, and dried at 100°C for 2 minutes using a constant temperature dryer to prepare a sheet having a release film (thickness 30 μm) and a surface modified layer (thermal transfer layer: thickness 10 μm).

[0267] [Comparative Example 1]

[0268] A suction shaping mold having a different size from that of Example 1 as shown in Table 1 was used. Sheet shaping was performed in the same manner as in Example 1 by vacuum suction except for the above.

[0269] [Comparative Example 2]

[0270] A suction shaping mold without a step portion was used compared to Examples 1 to 8. That is, the suction shaping mold of Comparative Example 2 had a shaping surface and a parting surface adjacent to each other in the radial direction when viewed from above, and the suction hole was provided near the inner edge of the parting surface. Other than this, the sheet was shaped by vacuum suction in the same manner as in Example 1.

[0271] [Comparative Example 3]

[0272] A suction shaping mold having a cavity concave portion provided at the inner edge of the parting surface as in Example 3 was used in comparison with Comparative Example 2. In the suction shaping mold of Comparative Example 3, the suction hole was provided in the concave space as in Example 3. Except for this, the sheet was shaped by vacuum suction in the same manner as in Example 1.

[0273] [Comparative Example 4]

[0274] A suction shaping mold having a different size as shown in Table 2 was used compared to Comparative Example 3. Sheet shaping was performed by vacuum suction in the same manner as in Example 1 except for the above.

[0275] [Comparative Examples 5-6]

[0276] The suction shaping mold was used except that the type of the release film was changed as shown in Table 1 in Comparative Example 2. The sheet was shaped by vacuum suction in the same manner as in Example 1 except for the above.

[0277] [Example 9]

[0278] A step portion with a suction hole and a width X (see Figure 1 ) is 80mm, width Y (see Figure 1 ) is 60mm, the depth Z of the cavity concave part (see Figure 2 ) is a suction shaping mold of 20 mm. In addition, the same sheet as in Example 7 was used. In addition, a resin material was prepared by stacking twill carbon fiber reinforced thermosetting epoxy resin prepreg green sheets (TORAYCA manufactured by Toray Industries, Inc.) in a manner of about 1 mm in thickness.

[0279] A sheet (resin molded body) is arranged between the above-mentioned suction shaping mold heated to 150°C and the plate, and the sheet (resin molded body) is pressed against the sealing mechanism in a manner that does not cause wrinkles, and then the plate is fixed to the suction shaping mold. Then, the vacuum pump is turned on to exhaust the air in the cavity concave portion (cavity), thereby shaping the resin molded body sheet onto the inner wall surface (shaping surface) of the cavity concave portion.

[0280] Next, the prepared resin material is placed on the opposite side mold and molded. At this time, the resin material is placed between the shaped sheet (resin molded body) and the opposite side mold. The mold is closed for 5 minutes at 3MPa. Then, after cooling to 40°C in the closed state, the suction shaping mold is opened and the molded resin part is demolded.

[0281] [Comparative Example 7]

[0282] A suction shaping mold having a different size than that of Example 9 as shown in Table 3 was used. A sheet was shaped by vacuum suction in the same manner as in Example 9 except for the above.

[0283] [Example 10]

[0284] The same suction shaping mold was used as in Example 9. Also, as a sheet, the same sheet was used as in Example 8. In Example 10, a pre-lamination method was used.

[0285] Specifically, the heat transfer layer is bonded to the resin material in advance, and the release film is suction-shaped to the suction shaping mold, and then the resin material is placed between the suction shaping mold and the opposite side mold. At this time, the resin material is placed in a manner that the heat transfer layer is located on the suction shaping mold side. The mold is closed at 3MPa for 5 minutes. Then, after cooling to 40°C in the closed state, the suction shaping mold is opened and the molded resin part is demolded.

[0286] [Comparative Example 8]

[0287] A suction shaping mold having a different size than that of Example 10 as shown in Table 4 was used. A sheet was shaped by vacuum suction in the same manner as in Example 10 except for the above.

[0288] [evaluate]

[0289] The shapes of the shaped sheets of Examples 1 to 10 and Comparative Examples 1 to 8 were evaluated. The results are shown in Tables 1 to 4.

[0290] The shaping depth was determined by measuring the vertical distance between the bottom and top of the sheet after shaping into a concave shape.

[0291] The uniformity of the forming was checked visually for the presence of wrinkles and cracks.

[0292] The shaping uniformity was visually observed for the presence or absence of local elongation, and the case with no local elongation and good was marked as "○", the case with local elongation was marked as "×", and the case that could not be measured due to breakage or the like was marked as "-".

[0293] The film appearance was visually observed for the presence of wrinkles and cracks, and the presence of wrinkles and cracks was recorded as "yes", and the absence of wrinkles and cracks was recorded as "no".

[0294] Furthermore, the resin parts obtained in Examples 9 and 10 and Comparative Examples 7 and 8 were evaluated. The results are shown in Tables 3 and 4.

[0295] The film appearance was visually observed for the presence or absence of cracks, and a film without cracks was marked as "○", and a film with cracks was marked as "×".

[0296] Regarding the transferability of the surface modification layer, the case where the adhesion to the resin member was good as observed visually was rated as “◯”, and the case where wrinkles or pinholes were present was rated as “×”.

[0297] The appearance of the resin parts was visually checked. Pinholes were recorded as “None” if they could not be confirmed. Wrinkle transfer was recorded as “None” if it could not be confirmed, and “Yes” if wrinkles were present.

[0298] Examples and comparative examples are shown in Tables 1 to 4.

[0299] [Table 1]

[0300]

[0301] [Table 2]

[0302]

[0303] [Table 3]

[0304]

[0305] [Table 4]

[0306]

[0307] The release films described in the table are as follows.

[0308] OPP: Biaxially oriented polypropylene film (OT-P2171) manufactured by Toyobo Co., Ltd., thickness 30 μm

[0309] PBT: Unstretched soft polybutylene terephthalate (BS-50) manufactured by OG Film Co., Ltd. Thickness: 50 μm

[0310] PTFE: Cutting-molded polytetrafluoroethylene film (NITOFLON No.900UL) manufactured by Nitto Denko Corporation, thickness 50 μm

[0311] In Examples 1 to 10, wrinkles, local elongation (local thinning), and rupture did not occur in the shaped sheet, and the sheet was shaped to a sufficient depth.

[0312] On the other hand, in Comparative Example 1 in which a step portion is provided but a / b is 1.0, although wrinkles, local elongation (local thinning), and ruptures are not generated on the sheet after shaping, the sheet cannot be shaped to a sufficient depth. In addition, in Comparative Examples 2, 5 to 8 in which no step portion is provided, if the sheet is shaped to a sufficient depth, wrinkles and local elongation are confirmed in the sheet after shaping. In particular, in Comparative Examples 3 to 4, ruptures are confirmed in the sheet. The reasons for the above situation are believed to be that the sheet located near the surface of the suction shaping mold preferentially stretches, causing the suction hole to be blocked in advance, and / or because the shaping surface is adjacent to the parting surface, wrinkles are easily transferred directly from the parting surface to the shaping surface.

[0313] The present invention is not limited to the above-described embodiments, and various modifications can be made within the scope of the claims. Embodiments obtained by appropriately combining technical means disclosed in different embodiments are also included in the technical scope of the present invention.

[0314] While the present invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope of the present invention.

[0315] This application is based on the Japanese patent application (Japanese Patent Application No. 2022-155388) filed on September 28, 2022, the contents of which are incorporated herein by reference.

[0316] Industrial Applicability

[0317] According to the suction shaping mold, the shaping method of a resin molded body and the manufacturing method of a resin part of the present invention, it is possible to shape a resin molded body to a deeper position without generating traces of suction holes on the design surface of the resin molded body and to suppress the generation of wrinkles.

[0318] Description of Reference Numerals

[0319] 1 pair of molds

[0320] 10. Mold for suction shaping

[0321] 11 Main body

[0322] 11a cavity recess

[0323] 12 Shaped surface

[0324] 13 Parting surface

[0325] 14 Step difference

[0326] 14a Flat surface

[0327] 14b Vertical wall

[0328] 15 Suction hole

[0329] 15a End

[0330] 16 protrusion

[0331] 17 corner

[0332] 18 Sealing mechanism

[0333] 19 Plate

[0334] 20 Opposite side mold

[0335] 21 Main body

[0336] 22 convex part

[0337] 30 Resin molded body

[0338] 40 Resin material

Claims

1. A suction shaping mold, comprising a cavity recess, and shaping a resin molded body so as to closely fit at least a portion of an inner wall surface of the cavity recess, the suction shaping mold comprising: Parting surface; and A shaping surface of the inner wall surface to which the resin molded body will closely contact, In the intersecting direction intersecting with the depth direction of the cavity recess, a step difference portion is provided between the parting surface and the shaping surface. A suction hole is provided in the step difference portion, A ratio a / b of a length a of the step portion in the depth direction to a length b of the step portion in the intersecting direction is greater than 1.

0.

2. The suction shaping mold according to claim 1, wherein: At the step difference portion, A pair of protrusions protruding from the parting surface side toward the shaping surface side in the intersecting direction and extending along the circumferential direction of the step difference portion are arranged in a manner of sandwiching the suction hole in the circumferential direction. The ratio c / d of the length c between the pair of protrusions in the circumferential direction to the length d of the protrusion in the intersecting direction is greater than 0.5, and the ratio e / d of the length e of the protrusion in the circumferential direction to the length d of the protrusion in the intersecting direction is greater than 3.

0.

3. The suction shaping mold according to claim 2, wherein: The curvature radius of the corner of the protrusion is 0.5 mm to 3.0 mm.

4. A method for shaping a resin molded body, which is a method for shaping a resin molded body using the suction shaping mold according to claim 1, the method comprising the following steps: A sealing mechanism is provided on the parting surface, and the resin molded body is provided on the parting surface including the sealing mechanism, and then a frame-shaped plate is placed thereon to form a state in which the resin molded body is tightly fixed, and the air in the cavity recess is sucked from the suction hole, thereby shaping the resin molded body in the cavity recess.

5. The method for shaping a resin molded article according to claim 4, comprising the following steps: The resin molded body is closely fixed in a state where the mold for suction shaping is preheated to a predetermined temperature, and suction is immediately performed. 6 . The method for shaping a resin molded body according to claim 5 , comprising the step of uniformly heating the resin molded body and then performing suction.

7. The method for shaping a resin molded article according to claim 4, wherein: The resin molded body is a release film, a decorative film, a thermal transfer sheet having a release film and a thermal transfer layer, or a container molding sheet.

8. The method for shaping a resin molded article according to claim 7, wherein: The resin molded body is the thermal transfer sheet, The average thickness of the thermal transfer layer is 0.1 μm to 50 μm.

9. A method for producing a resin part, using the shaping method for a resin molded body according to any one of claims 4 to 8, the method comprising the following steps: A resin material is placed between the resin molded body disposed in the suction shaping mold and an opposing mold having a convex portion that can be inserted into the concave portion of the cavity, thereby molding a resin component.

10. A method for producing a resin material, which is a method for producing a resin part using the shaping method of a resin molded body according to any one of claims 4 to 8, the method comprising the following steps: A resin material is injected between the resin molded body disposed in the suction shaping mold and an opposite side mold or a molding sheet provided with a convex portion that can be inserted into the concave portion of the cavity, thereby molding a resin component.

11. A method for producing a resin part, using the method for shaping a resin molded body according to any one of claims 4 to 8, wherein: The resin molded body is a release film, The manufacturing method includes the following steps: between the resin molded body arranged in the suction shaping mold and the opposite side mold provided with a convex portion that can be inserted into the concave portion of the cavity, a stack of the thermal transfer layer and the resin material is placed in a manner such that the release film is in contact with the thermal transfer layer when the molds are closed, thereby molding the resin part.

Images