Resin molding and method for manufacturing the same

Abstract

To provide a resin molding which has a polycarbonate-based resin base material and is excellent in adhesion between a design layer and a urethane-based resin coat layer, and a method for manufacturing the same.SOLUTION: A resin molding has at least a polycarbonate-based resin base material, a polyester-based resin sheet, an adhesive design layer, and a urethane-based resin coat layer, wherein the adhesive design layer contains a polyurethane-based resin.SELECTED DRAWING: None

Description

Technical Field

[0001] The present invention relates to a resin molded body and a method for manufacturing the same.

Background Art

[0002] Conventionally, various molded products have been manufactured using polycarbonate resins. Such molded products have various shapes on their surfaces to exhibit design properties, and characters or patterns are applied to the surfaces.

[0003] As a polycarbonate substrate having characters or patterns applied to the surface as described above, a polycarbonate substrate including a substrate ink printed and cured on the surface of the substrate and a silicone hard coating system applied on the substrate ink has been proposed (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] Generally, in a resin molded body using a polycarbonate resin as a base material, when a layer structure having a design layer formed by ink is provided on the base material, since the base material is injection molded at a temperature such as 300°C and is at a high temperature, it is necessary to use an ink having heat resistance, and there is a problem that the range of ink selection becomes narrow.

[0006] On the other hand, when a laminate of a polyester resin sheet and a design layer is subjected to insert molding and a base material is injection molded on the polyester resin sheet side, an ink that does not exhibit heat resistance can also be used for the design layer.

[0007] Furthermore, in resin molded articles, a urethane-based resin coating layer may be formed to protect the surface and to provide a tactile feel and aesthetic appeal. However, when this urethane-based resin coating layer is applied on top of the aesthetic layer, there is a problem in that the adhesion between the aesthetic layer and the urethane-based resin coating layer is poor.

[0008] Therefore, in resin molded articles as described above, there is a need for the development of resin molded articles with excellent adhesion between the design layer and the urethane resin coating layer, as well as a method for manufacturing the same.

[0009] The present invention aims to provide a resin molded article having a polycarbonate-based resin substrate and exhibiting excellent adhesion between a design layer and a urethane-based resin coating layer, as well as a method for manufacturing the same. [Means for solving the problem]

[0010] As a result of diligent research, the inventors have discovered that the above objective can be achieved by providing a resin molded article having at least a polycarbonate resin substrate, a polyester resin sheet, an adhesive design layer, and a urethane resin coating layer, wherein the adhesive design layer contains a specific resin, and have thus completed the present invention.

[0011] In other words, the present invention relates to the following resin molded articles and methods for manufacturing the same. 1. Having at least a polycarbonate resin substrate, a polyester resin sheet, an adhesive design layer, and a urethane resin coating layer, The aforementioned adhesive design layer contains a polyurethane resin. A resin molded article characterized by the following features. 2. The resin molded article according to item 1, wherein the content of the polyurethane resin in the adhesive design layer is 90 to 100% by mass. 3. The resin molded article according to claim 1 or 2, wherein the polyurethane resin is a polyurethane resin derived from at least one polyol component selected from the group consisting of polyether polyols and polyester polyols. 4. The resin molded article according to item 1 or 2, wherein the adhesive design layer is a solid print layer or a pattern layer. 5. A method for manufacturing a resin molded article, The process includes an insert molding step in which a laminate of a polyester resin sheet and an adhesive design layer is subjected to insert molding, thereby forming a polycarbonate resin substrate on the polyester resin sheet side and a urethane resin coating layer on the adhesive design layer side. The aforementioned adhesive design layer contains a polyurethane resin. A method for manufacturing a resin molded article, characterized by the following: 6. The manufacturing method according to item 5, further comprising a laminate formation step, in which, prior to the insert molding step, an adhesive design layer forming composition containing the polyurethane resin is applied to one side of the polyester resin sheet to form the laminate. 7. The manufacturing method according to item 6, wherein the content of the polyurethane resin in the adhesive design layer forming composition is 5 to 40% by mass. 8. The method for producing polyurethane resin according to any one of items 5 to 7, wherein the polyurethane resin is a polyurethane resin derived from at least one polyol component selected from the group consisting of polyether polyols and polyester polyols. 9. The manufacturing method according to any one of items 5 to 7, wherein the adhesive design layer is a solid print layer or a pattern layer.

[0012] Furthermore, the present invention relates to the following resin molded articles and methods for manufacturing the same. 1. Having at least a polycarbonate resin substrate, a polyester resin sheet, an adhesive design layer, and a urethane resin coating layer, The aforementioned adhesive design layer contains a polyurethane resin. A resin molded article characterized by the following features. 2. The resin molded article according to item 1, wherein the content of the polyurethane resin in the adhesive design layer is 90 to 100% by mass. 3. The resin molded body according to item 1 or 2, wherein the polyurethane-based resin is a polyurethane-based resin derived from at least one polyol component selected from the group consisting of a polyether polyol and a polyester polyol. 4. The resin molded body according to any one of items 1 to 3, wherein the adhesive design layer is a solid printing layer or a pattern layer. 5. A method for manufacturing a resin molded body, having an insert molding step of subjecting a laminate of a polyester-based resin sheet and an adhesive design layer to insert molding to form a polycarbonate-based resin substrate on the polyester-based resin sheet side and a urethane-based resin coat layer on the adhesive design layer side, wherein the adhesive design layer contains a polyurethane-based resin. A method for manufacturing a resin molded body, characterized by the above. 6. The manufacturing method according to item 5, having a laminate forming step of applying a composition for forming an adhesive design layer containing the polyurethane-based resin to one surface of the polyester-based resin sheet before the insert molding step to form the laminate. 7. The manufacturing method according to item 6, wherein the content of the polyurethane-based resin in the composition for forming the adhesive design layer is 5 to 40% by mass. 8. The manufacturing method according to any one of items 5 to 7, wherein the polyurethane-based resin is a polyurethane-based resin derived from at least one polyol component selected from the group consisting of a polyether polyol and a polyester polyol. 9. The manufacturing method according to any one of items 5 to 8, wherein the adhesive design layer is a solid printing layer or a pattern layer.

Advantages of the Invention

[0013] The manufacturing method of the present invention can manufacture a resin molded body excellent in adhesion between the design layer and the urethane-based resin coat layer.

Brief Description of the Drawings

[0014] [Figure 1] It is a schematic diagram showing an example of the resin molded body of the present invention. [Figure 2] It is a figure showing the measurement result of peel strength.

Mode for Carrying Out the Invention

[0015] Hereinafter, the resin molded body and the manufacturing method of the present invention will be described.

[0016] 1. Resin molded body The resin molded body of the present invention has at least a polycarbonate resin base material, a polyester resin sheet, an adhesive design layer, and a urethane resin coat layer, and the adhesive design layer is a resin molded body containing a polyurethane resin.

[0017] The resin molded body of the present invention contains a polyurethane resin and has a urethane resin coat layer on an adhesive design layer showing designability and adhesiveness. Therefore, the adhesion between the adhesive design layer and the urethane resin coat layer is excellent. Further, the adhesive design layer is formed on one surface of the polyester resin sheet, and even when the polycarbonate resin base material formed on the surface opposite to the adhesive design layer is formed by injection molding, the adhesive design layer is not exposed to high heat, and the resin forming the adhesive design layer does not need to exhibit heat resistance.

[0018] An example of the resin molded body of the present invention is shown in FIG. 1. In FIG. 1, the resin molded body 1 has a polycarbonate resin base material 11, a polyester resin sheet 12, an adhesive design layer 13, and a urethane resin coat layer 14 in this order.

[0019] The layer structure of the resin molded body of the present invention only needs to have at least a polycarbonate resin base material, a polyester resin sheet, an adhesive design layer, and a urethane resin coat layer, and may have other layers. However, as shown in FIG. 1, it preferably consists of a polycarbonate resin base material 11, a polyester resin sheet 12, an adhesive design layer 13, and a urethane resin coat layer 14.

[0020] The following describes each layer that constitutes the resin molded article of the present invention.

[0021] (Polycarbonate resin base material) The polycarbonate resin substrate is a resin substrate formed by insert molding in the manufacturing method of the present invention, which will be described later.

[0022] The polycarbonate resin contained in the polycarbonate resin substrate is not particularly limited and includes, for example, aromatic polycarbonates that are homopolymers or copolymers; and alloy materials such as ABS, ASA, PBT, and PET. The polycarbonate resin substrate may also contain reinforcing agents such as glass fiber, talc, and wollastonite; and colorants.

[0023] The thickness of the polycarbonate resin substrate is not particularly limited, but is preferably 1 to 30 mm, more preferably 2 to 8 mm, and even more preferably 2 to 4 mm.

[0024] (Polyester resin sheet) The polyester resin sheet is a resin sheet that forms a laminate by laminating an adhesive design layer in the manufacturing method of the present invention, which will be described later.

[0025] The polyester resin sheet is not particularly limited as long as it contains a polyester resin. Examples of polyester resins include polycarbonate resins, polyethylene terephthalate, polybutylene terephthalate, and polyethylene naphthalate. Among these, polycarbonate resins are preferred; that is, the polyester resin sheet is preferably a polycarbonate resin sheet.

[0026] The polycarbonate resin sheet is not particularly limited as long as it contains a polycarbonate resin. Examples of polycarbonate resins include aromatic polycarbonate resins, polyorganosiloxane-containing aromatic polycarbonate resins, aliphatic polycarbonate resins, and alicyclic polycarbonate resins.

[0027] The polyester resin sheet may be a laminate, in which case the outer layer (the layer on which the polycarbonate resin substrate is laminated, and the layer on which the adhesive design layer is laminated) may be a polyester resin layer. Furthermore, the resin forming the inner layer sandwiched between the outer layers is not particularly limited, and examples include acrylic resins.

[0028] As the polycarbonate resin sheet, commercially available polycarbonate resin films can be used. Examples of such commercially available products include MakrofolPE248 1-1, manufactured by Covestro.

[0029] The thickness of the polyester resin sheet is not particularly limited, but is preferably 0.1 to 0.5 mm, and more preferably 0.2 to 0.4 mm.

[0030] (Adhesive design layer) The adhesive design layer is formed on the polycarbonate resin sheet and exhibits adhesion to the urethane resin coating layer.

[0031] The adhesive design layer is formed using a composition for forming an adhesive design layer containing a polyurethane resin (hereinafter also referred to as the "adhesive design layer forming composition"). As the adhesive design layer forming composition, for example, an ink containing a polyurethane resin with a curing agent added as needed can be used.

[0032] The above polyurethane resin can be synthesized using various commonly used, known polyol components. One or more polyol components may be used in combination. Preferably, the polyurethane resin contained in the adhesive design layer is a polyurethane resin derived from at least one polyol component selected from the group consisting of polyether polyols and polyester polyols. By using the above polyurethane resin, the adhesion between the adhesive design layer and the urethane resin coating layer is further improved. The above polyester polyol may be a polyester polyol obtained by ring-opening polymerization of a cyclic ester compound.

[0033] Examples of polyol components that form polyurethane resins include, more specifically, (1) polyether polyols of polymers or copolymers such as methylene oxide, ethylene oxide, and tetrahydrofuran; (2) ethylene glycol, 1,2-propanediol, 1,3-propanediol, 2-methyl-1,3-propanediol, 2-ethyl-2-butyl-1,3-propanediol, 1,3-butanediol, 1,4-butanediol, neopentyl glycol, pentanediol, 3-methyl-1,5-pentanediol, hexanediol, octanediol, 1,4-butynediol, 1,4-butylenediol, diethylene glycol, triethylene glycol, polypropylene glycol, dipropylene glycol, glycerin, trimethylolpropane, trimethylolethane, 1,2,6-hexanetriol, 1,2,4-butanetriol, sorbitol, pentaestritol, and other saturated or unsaturated low molecular weight polyols; (3) these low molecular weight polyols Polyester polyols obtained by dehydration condensation or polymerization of polycarboxylic acids such as adipic acid, phthalic acid, isophthalic acid, terephthalic acid, maleic acid, fumaric acid, succinic acid, oxalic acid, malonic acid, glutaric acid, pimelic acid, superiric acid, azelaic acid, sebacic acid, trimellitic acid, pyromellitic acid, or their anhydrides; (4) Polyester polyols obtained by ring-opening polymerization of cyclic ester compounds, such as lactones such as polycaprolactone, polyvalerolactone, and poly(β-methyl-γ-valerolactone); (5) Polycarbonate polyols; (6) Polybutadiene glycols; (7) Glycols obtained by adding ethylene oxide or propylene oxide to bisphenol A; (8) Acrylic polyols; (9) Polyether polyols obtained by polymerizing oxirane compounds such as ethylene oxide, propylene oxide, butylene oxide, and tetrahydrofuran using a low molecular weight polyol as an initiator.

[0034] Among these, propylene glycol, polyester polyols obtained by polymerizing low molecular weight polyols with adipic acid, polytetramethylene ether glycol, poly(ε-caprolactone)diol, and acrylic polyol are preferred, with polytetramethylene ether glycol, poly(ε-caprolactone)diol, and acrylic polyol being more preferred. Furthermore, it is even more preferable to contain both polytetramethylene ether glycol and poly(ε-caprolactone)diol. By using the above polyurethane resin, the adhesion between the adhesive design layer and the urethane resin coating layer is further improved.

[0035] The isocyanate component that forms the polyurethane resin is not particularly limited as long as it can react with the polyol component to form a polyurethane resin; conventionally known polyisocyanate components may be used.

[0036] The polyurethane resin content in the adhesive design layer is preferably 90 to 100% by mass, and more preferably 95 to 100% by mass. Having a polyurethane resin content within this range further improves the adhesion between the adhesive design layer and the urethane resin coating layer.

[0037] The adhesive design layer may contain other components. Examples of such other components include curing agents, inorganic pigments, organic pigments, dyes, and the like.

[0038] The curing agent is not particularly limited as long as it can cure the polyurethane resin in the adhesive design layer, and polyisocyanate compounds such as aliphatic polyisocyanates can be used. The content of the curing agent in the adhesive design layer is not particularly limited, but is preferably 3 to 20 parts by mass, and more preferably 4 to 15 parts by mass, based on 100 parts by mass of the polyurethane resin in the adhesive design layer.

[0039] Examples of inorganic pigments include amorphous silica, carbon black, titanium white, iron oxide, zinc oxide, red iron oxide, Prussian blue, and cadmium red.

[0040] Examples of organic pigments include lake pigments, anthraquinone pigments, quinacridone pigments, phthalocyanine pigments, isoindolinone pigments, and dioxazine pigments.

[0041] Examples of dyes include polyiodine, azo compounds, anthraquinone compounds, and dioxazine compounds.

[0042] The adhesive design layer may be a solid print layer formed over the entire surface of the polyester resin sheet, or a patterned layer formed only on a portion of the polycarbonate resin sheet.

[0043] The thickness of the adhesive design layer is not particularly limited, but is preferably 10 to 100 μm, and more preferably 15 to 50 μm.

[0044] (Urethane resin coating layer)

[0045] The urethane resin coating layer is a layer formed by insert molding on the adhesive design layer side in the manufacturing method of the present invention described later.

[0046] The urethane resin included in the urethane resin coating layer is not particularly limited, and conventionally known urethane resins used for resin coating layers on the surface of resin molded articles can be used. Examples of such urethane resins include polyurethane resins derived from polyether polyols.

[0047] The thickness of the urethane resin coating layer is not particularly limited, but is preferably 0.1 to 5 mm, and more preferably 0.3 to 3 mm.

[0048] 2. Method for manufacturing resin molded articles The present invention provides a method for manufacturing a resin molded article, comprising an insert molding step in which a laminate of a polyester resin sheet and an adhesive design layer is subjected to insert molding to form a polycarbonate resin substrate on the polyester resin sheet side and a urethane resin coating layer on the adhesive design layer side, wherein the adhesive design layer contains a polyurethane resin. The manufacturing method of the present invention, having the above features, provides excellent adhesion between the adhesive design layer and the urethane resin coating layer because the urethane resin coating layer is formed on an adhesive design layer containing a polyurethane resin that exhibits design properties and adhesiveness. Furthermore, since the adhesive design layer is formed on one side of the polyester resin sheet, even if the polycarbonate resin substrate formed on the opposite side of the adhesive design layer is formed by injection molding, the adhesive design layer is not exposed to high heat, and the resin forming the adhesive design layer does not need to exhibit heat resistance. Furthermore, the manufacturing method of the present invention allows for the easy production of a resin molded article with excellent adhesion between the design layer and the urethane resin coating layer by subjecting a laminate of a polyester resin sheet and an adhesive design layer to insert molding.

[0049] Figure 1 shows a schematic diagram of an example of a resin molded article manufactured by the manufacturing method of the present invention. Figure 1 is also a schematic diagram showing an example of a resin molded article of the present invention. In Figure 1, the resin molded article 1 has a polycarbonate resin base material 11, a polyester resin sheet 12, an adhesive design layer 13, and a urethane resin coating layer 14 in this order. Furthermore, according to the manufacturing method of the present invention, the resin molded article 1 has a laminate of a polyester resin sheet 12 and an adhesive design layer 13, and the polycarbonate resin base material 11 is formed on the polyester resin sheet 12 side by insert molding, and the urethane resin coating layer 14 is formed on the adhesive design layer 13 side.

[0050] In the manufacturing method of the present invention, insert molding is a method for producing a resin molded body in which the layers are integrated by placing the laminate in a mold, forming a polycarbonate resin substrate on the polyester resin sheet side within the mold, and forming a urethane resin coating layer on the adhesive design layer side within the mold.

[0051] [Insert molding process] In the manufacturing method of the present invention, a laminate of a polyester resin sheet and an adhesive design layer is subjected to insert molding.

[0052] (Polyester resin sheet) Polyester resin sheets are resin sheets that form a laminate with an adhesive design layer and are used for insert molding.

[0053] As the polyester resin sheet, the polyester resin sheet described in the resin molded article of the present invention above can be used.

[0054] (Adhesive design layer) The adhesive design layer is formed on the polycarbonate resin sheet and exhibits adhesion to the urethane resin coating layer.

[0055] The adhesive design layer contains a polyurethane resin. As the polyurethane resin, the polyurethane resin contained in the adhesive design layer described in the resin molded article of the present invention above can be used.

[0056] The adhesive design layer can be formed by applying an adhesive design layer forming composition, which is a composition for forming an adhesive design layer containing the polyurethane resin described above. The polyurethane resin content in the adhesive design layer forming composition is preferably 5 to 40% by mass, more preferably 10 to 30% by mass, and even more preferably 20 to 30% by mass. By having a polyurethane resin content within the above range, the adhesion between the adhesive design layer and the urethane resin coating layer is further improved.

[0057] The composition for forming an adhesive design layer preferably contains a polyurethane resin dissolved in a solvent. The solvent is not particularly limited as long as it can dissolve the polyurethane resin, and examples include isopropyl alcohol, ethyl acetate, propyl acetate, methyl isobutyl ketone, methyl ethyl ketone, ethylene glycol monoisopropyl ether, and n-propyl alcohol.

[0058] The composition for forming an adhesive design layer may contain other components. Examples of such other components include curing agents, inorganic pigments, organic pigments, dyes, and the like.

[0059] The curing agent is not particularly limited as long as it can cure the polyurethane resin in the adhesive design layer forming composition, and aliphatic polyisocyanates and the like can be used. The content of the curing agent in the adhesive design layer forming composition is not particularly limited, but is preferably 3 to 20 parts by mass, and more preferably 4 to 15 parts by mass, based on 100 parts by mass of the polyurethane resin in the adhesive design layer forming composition. The curing agent may also be used after being dissolved in a solvent.

[0060] As inorganic pigments, organic pigments, and dyes, those contained in the adhesive design layer described above in the resin molded article of the present invention can be used.

[0061] As a composition for forming an adhesive design layer, a commercially available ink containing a polyurethane resin, to which a curing agent may be added as needed, can be used. Examples of such commercially available inks include Toyo Ink Co., Ltd.'s product names LSNT Medium and ELUR Medium.

[0062] The composition for forming an adhesive design layer may be applied to the entire surface of a polyester resin sheet to form an adhesive design layer as a solid print layer, or it may be applied to only a portion of a polycarbonate resin sheet to form an adhesive design layer as a pattern layer.

[0063] The coating thickness of the adhesive design layer forming composition is not particularly limited, but is preferably 10 to 100 μm, and more preferably 15 to 50 μm.

[0064] The adhesive design layer is formed on one side of the polyester resin sheet, thereby forming a laminate of the polyester resin sheet and the adhesive design layer. In the manufacturing method of the present invention, the laminate of the polyester resin sheet and the adhesive design layer is subjected to insert molding.

[0065] (Polycarbonate resin base material) In the insert molding process, one method for forming a polycarbonate resin substrate on the polycarbonate resin sheet side of the laminate within the mold is to inject polycarbonate resin into the polycarbonate resin sheet side within the mold.

[0066] As the polycarbonate resin used to form the polycarbonate resin substrate, the polycarbonate resin contained in the polycarbonate resin substrate described in the resin molded article of the present invention above can be used.

[0067] The method for injecting the polycarbonate resin into the polyester resin sheet within the mold is not particularly limited, but injection molding is preferred. The conditions for injection molding are not particularly limited, but examples include a mold temperature of 60 to 160°C, an injection speed of 10 to 160 mm / sec, a holding pressure of 30 to 160 MPa, a holding pressure time of 5 to 30 seconds, and a cooling time of 15 to 120 seconds.

[0068] The thickness of the injected polycarbonate resin is not particularly limited, but is preferably 1 to 30 mm, more preferably 2 to 8 mm, and even more preferably 2 to 4 mm.

[0069] (Urethane resin coating layer) In the insert molding process, a method for forming a urethane-based resin coating layer on the adhesive design layer side of the laminate within the mold includes injecting urethane-based resin into the adhesive design layer side within the mold.

[0070] As the urethane resin for forming the urethane resin coating layer, the urethane resin included in the urethane resin coating layer described in the resin molded article of the present invention can be used.

[0071] The conditions for injecting urethane resin into the adhesive design layer within the mold are not particularly limited, but examples include a mold temperature of 60-120°C, a resin injection rate of 10-120 g / sec, and an injection volume of 15-500 g.

[0072] The thickness of the injected urethane resin is not particularly limited, but is preferably 0.1 to 5 mm, and more preferably 0.3 to 3 mm.

[0073] The resin molded body is manufactured through the insert molding process described above.

[0074] [Laminate formation process] The manufacturing method of the present invention may include a laminate formation step, prior to the insert molding step, in which an adhesive design layer forming composition is applied to one side of the polyester resin sheet to form the laminate.

[0075] As the composition for forming the adhesive design layer, the one described in the insert molding process above can be used.

[0076] The method for applying the adhesive design layer-forming composition to one side of the polyester resin sheet is not particularly limited and can be applied by conventionally known application methods. Examples of such application methods include spray coating, gravure printing, and screen printing.

[0077] The coating thickness of the adhesive design layer forming composition is not particularly limited, but is preferably 10 to 100 μm, and more preferably 15 to 50 μm.

[0078] In the laminate formation process, the adhesive design layer formation composition hardens to form an adhesive design layer. The hardening method is not particularly limited; the composition may be hardened by evaporating the solvent from it by leaving it at room temperature for 30 minutes to 7 days, or it may be hardened by drying it in a constant temperature bath at 40 to 80°C for 30 seconds to 3 days.

[0079] A laminate can be formed by the laminate formation process described above. [Examples]

[0080] The present invention will be described in more detail below with reference to examples and comparative examples. However, the present invention is not limited to these examples.

[0081] The raw materials used in the examples, comparative examples, and reference examples are as follows.

[0082] (Composition for forming adhesive design layers) A composition for forming an adhesive design layer (hereinafter also simply referred to as "the composition") containing the following components was prepared.

[0083] Composition 1 (Main component (ink):LPNYB additive (hardener) = 100:3 (mass ratio)) • Main component (ink) Resin components (15% by mass): Polyurethane resin (Polyol components: Propylene glycol, adipic acid) • LPNYB additive (hardener) Aliphatic polyisocyanate (45% by mass)

[0084] Composition 2 (Main component (ink):LPNYB additive (hardener) = 100:3 (mass ratio)) • Main component (ink) Resin components (25% by mass): Polyurethane resin (Polyol components: Polytetramethylene ether glycol, poly(ε-caprolactone) and its diol) • LPNYB additive (hardener) Aliphatic polyisocyanate (45% by mass)

[0085] Composition 3 Resin components (30% by mass): Acrylic resin (methyl methacrylate, ethyl acrylate)

[0086] Composition 4 Resin component (35% by mass): Acrylic resin (methyl methacrylate)

[0087] (Polyester resin sheet) As a polyester resin sheet, we prepared a polycarbonate resin sheet manufactured by Covestro, product name: MakrofolPE248 1-1, measuring 364mm x 455mm with a thickness of 0.4mm.

[0088] (Urethane-based resin coating layer forming resin) A resin for forming a urethane-based resin coating layer was prepared by mixing Ruehl's products, product name: puroclear3351IT and product name: puronate960 / 1, in a ratio of 1:2.29 (by mass).

[0089] (Polycarbonate resin base material) Makrolon AL2447 was prepared as the resin for forming the polycarbonate resin substrate.

[0090] Examples, Comparative Examples A pattern was printed onto a polycarbonate resin sheet using the above-mentioned composition, and an adhesive design layer was formed by leaving it at 60°C for 30 seconds and then at 40°C for 3 days. A laminate was then prepared.

[0091] The laminate was subjected to insert molding. Specifically, the laminate was placed in a mold, and AL2447 was injection-molded onto the polycarbonate resin sheet side of the laminate to form a polycarbonate resin substrate. In addition, a urethane resin coating layer was injection-molded onto the adhesive design layer side of the laminate to form a urethane resin coating layer. The injection molding conditions were a mold temperature of 80°C, an injection rate of 25 g / sec, and an injection volume of 28 g.

[0092] The resin molded articles of the examples and comparative examples were manufactured using the method described above. The thickness of the resin molded articles was 4.5 mm. The thicknesses of each layer were as follows: polycarbonate resin substrate 3.6 mm, polycarbonate resin sheet 0.4 mm, adhesive design layer 30 μm, and urethane resin coating layer 0.5 mm.

[0093] Reference example A resin molded article was manufactured in the same manner as in the above examples and comparative examples, except that a polycarbonate resin sheet having an adhesive design layer was not inserted.

[0094] The properties of the obtained resin molded articles were measured and evaluated under the following measurement conditions.

[0095] Adhesion The adhesion between the adhesive design layer and the urethane resin coating layer was evaluated using the following evaluation method. Specifically, a resin molded body (thickness 4.5 mm) was cut to a length of 180 mm and a width of 10 mm to prepare a test specimen. Using this test specimen, the maximum peel strength between the design layer and the urethane resin coating layer was measured under the conditions of a peel speed of 100 mm / min, room temperature, and a peel angle of 90 degrees using a testing machine (SHIMADZU product name AG-IS) and a roller-type printed circuit board 90° peel test apparatus (SHIMADZU), and the adhesion was evaluated by defining the peel strength as the peel strength.

[0096] The results are shown in Table 1 and Figure 2.

[0097] [Table 1] [Explanation of Symbols]

[0098] 1. Resin molded body 11. Polycarbonate resin substrate 12. Polyester resin sheet 13. Adhesive design layer 14. Urethane resin coating layer

Claims

1. It has at least a polycarbonate resin base material, a polyester resin sheet, an adhesive design layer, and a urethane resin coat layer, wherein the adhesive design layer contains a polyurethane resin. A resin molded body characterized by this.

2. The resin molded body according to Claim 1, wherein the content of the polyurethane resin in the adhesive design layer is 90 to 100% by mass.

3. The resin molded body according to Claim 1 or 2, wherein the polyurethane resin is a polyurethane resin derived from at least one polyol component selected from the group consisting of polyether polyol and polyester polyol.

4. The resin molded body according to Claim 1 or 2, wherein the adhesive design layer is a solid printing layer or a pattern layer.

5. A method for manufacturing a resin molded body, particularly the resin molded body according to Claim 1 or 2, comprising an insert molding step of subjecting a laminate of a polyester resin sheet and an adhesive design layer to insert molding to form a polycarbonate resin base material on the polyester resin sheet side and a urethane resin coat layer on the adhesive design layer side, wherein the adhesive design layer contains a polyurethane resin. A method for manufacturing a resin molded body characterized by this.

6. The manufacturing method according to Claim 5, having a laminate forming step of applying a composition for forming an adhesive design layer containing the polyurethane resin to one surface of the polyester resin sheet before the insert molding step to form the laminate.

7. The manufacturing method according to Claim 6, wherein the content of the polyurethane resin in the composition for forming the adhesive design layer is 5 to 40% by mass.

8. The manufacturing method according to Claim 5, wherein the polyurethane resin is a polyurethane resin derived from at least one polyol component selected from the group consisting of polyether polyol and polyester polyol.

9. The manufacturing method according to Claim 5, wherein the adhesive design layer is a solid printing layer or a pattern layer.

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