Resin molded body with vapor deposition layer and molding method thereof

Abstract

To create a resin molded body and a method for molding the same that can suppress separation between a topcoat layer provided on a vapor deposition layer and a secondary molding body that is insert-molded thereon by improving an adhesion between them.SOLUTION: A resin molded body with a secondary molding body 15 made of transparent resin partially covering a vapor deposition layer 13 formed on a base material 11 consists of a topcoat layer 14 formed with a paint containing vinyl chloride resin between the vapor deposition layer 13 and the secondary molding body 15.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to a resin molded article in which a synthetic resin is insert-molded onto the surface of a vapor-deposited layer, and a molding method thereof. [Background technology]

[0002] For example, Patent Document 1 describes a prior art flexible container having a base body 3 formed into a bottle shape from polyethylene terephthalate (PET) resin, an undercoat layer 4 made of acrylic resin, a metallic luster layer 5 formed by vapor deposition of indium by sputtering, and a topcoat layer 6 made of colorless and transparent acrylic resin laminated in this order, and having a metallic luster S derived from indium on its surface. Furthermore, Patent Document 2 describes a prior art relating to a molded product having a metallic appearance, characterized in that the surface of a molded product that has been primarily molded with a thermosetting resin molding material is then secondarily molded with a thermosetting resin molding material that contains a metal vapor deposition foil. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2011-046437 A [Patent Document 2] Japanese Patent Application Publication No. 57-077561 Summary of the Invention [Problem to be solved by the invention]

[0004] However, no prior art is recognized regarding a resin molded body formed by forming a metal vapor deposition layer on the surface of a primary molded article and then insert molding (secondary molding) a transparent resin onto the surface of the primary molded article (metal vapor deposition layer) via a top coat layer. Here, in the case of a resin molded product in which a topcoat is applied to the surface of a primary molded product with a vapor deposition layer, and a transparent resin (secondary molded product) is secondarily molded on top of that by insert molding, so that the vapor deposition layer applied to the primary molded product can be seen through this transparent resin, the topcoat layer applied on top of the vapor deposition layer and the secondary molded product (transparent resin) are prone to peeling. In particular, in the case of products in which the topcoat layer is not entirely covered with the secondary molded product for design reasons, but rather is partially covered with the secondary molded product so that part of the topcoat layer is exposed, there is a problem that peeling is likely to occur at the boundary between the secondary molded product and the topcoat layer after molding.

[0005] In order to solve the problems in the conventional technology described above, an object of the present invention is to create a resin molded body and a molding method thereof that improves adhesion between a topcoat layer provided on a vapor deposition layer and a secondary molded body insert-molded thereon, thereby suppressing peeling between the two. [Means for solving the problem]

[0006] Among the means for solving the above problems, the first main means of the present invention is: It is made of a primary molded product that has a front, back and a pair of side surfaces and is formed with a rectangular cross section. Base material an undercoat layer formed on the surface of the substrate; and a surface of the undercoat layer. The deposition layer formed on and the surface of the deposition layer A secondary molded body made of a transparent resin that partially covers the and, A resin molded body comprising: The secondary molded body covers only the pair of side surfaces of the base material, excluding the front surface and the back surface, The present invention is characterized in that a topcoat layer formed of a paint containing a vinyl chloride resin is provided between the vapor deposition layer and the secondary molded body. In the first main aspect of the present invention, a topcoat layer formed from a paint containing a vinyl chloride resin is placed between the vapor deposition layer and the secondary molded body, thereby increasing the adhesion between the topcoat layer and the secondary molded body and suppressing peeling between them. Furthermore, in the above-mentioned means, the area partially covered by the secondary molded body can be set according to the design of the resin molded body. In this case, the vinyl chloride resin preferably has a solid content of 50% or more.

[0007] Another aspect of the present invention is the first main aspect of the present invention, further comprising the addition that the substrate is made of polycarbonate. In the above-mentioned means, the substrate can be made of a material that is transparent and has good mechanical strength.

[0008] Another aspect of the present invention is any one of the above aspects, further comprising the step of forming the secondary molded body from an acrylonitrile-styrene copolymer. In the above-mentioned method, the secondary molded body can be formed from a material that is transparent and has excellent moldability.

[0009] Another aspect of the present invention is any one of the above aspects, further comprising the addition that the top coat layer is formed from a paint containing a vinyl chloride resin and an acrylic resin. The above-mentioned measures also make it possible to suppress peeling between the topcoat layer and the secondary molded article.

[0011] The second main aspect of the present invention is Any of the above means Manufacturing method of resin molded body And, A first step of forming a base material having a predetermined shape by primary molding; A second step of forming an undercoat layer on the surface of the substrate; a third step of forming a deposition layer on the surface of the undercoat layer; a fourth step of forming a topcoat layer on the surface of the vapor deposition layer using a paint containing a vinyl chloride resin or a paint containing a vinyl chloride resin and an acrylic resin; and a fifth step of insert molding a secondary molded body of a predetermined shape onto the surface of the top coat layer using the base material formed through the first step to the fourth step as an insert material. In the second main aspect of the present invention, a resin molded article can be produced that suppresses peeling between the top coat layer and the secondary molded article.

[0012] Another aspect of the present invention is the second main aspect of the present invention, further comprising the step of forming the substrate from polycarbonate in the first step. In the above-mentioned means, the substrate can be made of a material that is transparent and has good mechanical strength.

[0013] Another aspect of the present invention is any of the above-mentioned aspects, further comprising the step of forming an undercoat layer by applying a coating material containing an acrylic resin to a layer thickness of 8 to 15 μm in the second step. The above-mentioned means can improve the adhesion between the substrate and the deposition layer.

[0014] Another aspect of the present invention is any one of the above aspects, further comprising the step of forming the deposition layer by depositing aluminum to a thickness in the range of 0.06 to 0.12 μm in the third step. With the above-mentioned means, it is possible to improve the decorativeness and obtain a resin molding with a luxurious feel.

[0015] Another aspect of the present invention is any one of the above aspects, further comprising the step of forming a topcoat layer to a thickness of 8 to 15 μm in the fourth step. In this manner, the transparency of the topcoat layer can be maintained.

[0016] Another aspect of the present invention is any of the above aspects, further comprising the step of forming the secondary molded body from an acrylonitrile-styrene copolymer in the fifth step. In the above-mentioned method, the secondary molded body constituting the resin molded body can be made of a transparent material having excellent moldability. Effect of the Invention

[0017] In the present invention, the adhesion between the topcoat layer provided on the vapor deposition layer and the secondary molded body formed on top of it by insert molding can be increased, thereby suppressing peeling between the vapor deposition layer and the secondary molded body. [Brief description of the drawings]

[0018] [Figure 1] FIG. 2 is a top view showing a cap as one embodiment of the resin molded article of the present invention. [Diagram 2] FIG. 2 is a cross-sectional view taken along line II-II in FIG. [Diagram 3] FIG. 2 is a half cross-sectional view taken along line III-III in FIG. [Figure 4] FIG. 2 is a bottom view of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. The resin molded article 1 of the present invention can be used in a variety of products, but the following description will be directed to its use in a cap 2 that constitutes a part of a stick-shaped lipstick case. First, the configuration of the cap 2, which is the resin molded body 1, will be described. As shown in Figures 1 to 4, the cap 2 (resin molded body 1) shown in this embodiment is a cylindrical member having a top surface 4 at the upper part of a body 3 formed in a rectangular tube shape (square cross section) having a front surface 3A and a back surface 3B arranged opposite each other, and a pair of side surfaces 3C and 3D also arranged opposite each other, and having an open lower end and an internal space 5, and is formed with multiple layers on the surface of a base material 11 having a square cross section obtained by primary molding of a synthetic resin material as described below.

[0020] That is, as shown in FIG. 2, in the resin molded body 1 shown in this embodiment, a pair of side surfaces 3C, 3D and a top surface 4 constituting the cap 2 are formed, from the inner layer to the outer layer, with a base material 11 which is a primary molded product, an undercoat layer 12, a vapor deposition layer 13 for decoration, a topcoat layer 14 and a secondary molded body 15.

[0021] On the other hand, as shown in Figure 3, for design reasons, the front surface 3A and the back surface 3B are configured to have, from the inner layer to the outer layer, a base material 11, an undercoat layer 12, a deposition layer 13, and a topcoat layer 14, which are primary molded products. However, unlike the sides 3C and 3D, there is no secondary molded body 15 outside the topcoat layer 14. The front surface 3A and the rear surface 3B are formed to have widths slightly greater than the pair of side surfaces 3C and 3D.

[0022] Next, a method for manufacturing the cap 2, which is the resin molded body 1 having the above-mentioned structure, will be described. First, a substrate 11 (primary molded product) having a predetermined shape (a square cylinder with a bottom in this embodiment) is formed by primary molding (first step). In this embodiment, the substrate 11 is formed of polycarbonate (PC), but it can also be made of other synthetic resin materials such as polystyrene, polyamide, polyethylene, polypropylene, polyacetal, polyester, etc. The primary molding can be performed using a molding method such as compression molding, transfer molding, injection molding, extrusion molding, etc., using a predetermined mold not shown.

[0023] Next, after molding, the substrate 11 (primary molded product) is removed from the mold, and a paint for forming an undercoat layer 12 is applied to the entire surface of the substrate 11, i.e., the front surface 3A, the back surface 3B, the side surfaces 3C and 3D, and the top surface 4 (second step). The paint for forming the undercoat layer 12 is preferably a paint having a function of increasing the adhesion between the substrate 11 and the deposition layer 13, and is preferably, for example, a paint containing an acrylic resin. The thickness of the undercoat layer 12 is preferably in the range of 8 to 15 μm.

[0024] Next, a decorative deposition layer 13 is formed on the surface of the undercoat layer 12 by depositing, for example, aluminum in a thin film having a thickness of 0.06 to 0.12 μm (600 to 1200 Å) (third step). This enhances the decorativeness and gives the cap 2 a luxurious feel after molding. The deposition layer 13 may be formed of other metals or metal alloys such as chromium, nickel, gold, silver, copper, brass, etc., and the deposition layer 13 is preferably formed by vacuum deposition, but may also be formed by other methods such as ion plating and sputtering.

[0025] Next, a transparent paint for forming a topcoat layer 14 is applied to the surface of the deposition layer 13 in a layer thickness range of 8 to 15 μm (fourth step). The transparent paint for forming the topcoat layer 14 is preferably a paint containing a vinyl chloride resin, or a paint containing a vinyl chloride resin and an acrylic resin, in order to enhance adhesion between the topcoat layer 14 and the secondary molded body 15. Specifically, paints such as UR3131M-3, UR3131M-IJ, and UR3131M-IJ2 manufactured by Toho Kaken Kogyo Co., Ltd. are suitable, and paints such as UR3131M-IJ and UR3131M-IJ2, which contain 50% or more of vinyl chloride resin in solid content, are more suitable.

[0026] In addition, a configuration that does not have a topcoat layer 14 (a configuration in which the secondary molded body 15 is directly molded on the vapor deposition layer 13) and a configuration in which a paint consisting only of an acrylic resin is used as the topcoat layer 14 are not suitable because the adhesion between the topcoat layer 14 and the secondary molded body 15 is low and peeling cannot be effectively suppressed.

[0027] Finally, as shown in FIG. 2, a secondary molded body 15 having a predetermined shape (in this embodiment, a U-shaped cross section) is formed on the topcoat layer 14 (step 5). The secondary molded body 15 can be formed by insert molding in which the base material 11 formed through steps 1 to 4, i.e., the base material 11 having the undercoat layer 12, the deposition layer 13, and the topcoat layer 14 laminated on the surface in this order, is set as an insert material in a predetermined mold (not shown). In this case, the secondary molded body 15 is formed by injecting a colorless and transparent thermosetting synthetic resin such as molten acrylonitrile-styrene copolymer (SAN: Stylene AcryloNitrille copolymer) onto the topcoat layer 14 and molding it into a predetermined shape in the mold, thereby forming the cap 2, which is the resin molded body 1. In this embodiment, for design reasons, the secondary molded body 15 is formed on the side surfaces 3C, 3D, and top surface 4, excluding the front surface 3A and back surface 3B. As the acrylonitrile-styrene copolymer (SAN) for forming the secondary molded body 15, for example, AS-C-820 manufactured by Denka Co., Ltd. is suitable. Then, by releasing the mold after the resin has hardened, the cap 2 as the resin molded body 1 described above can be obtained.

[0028] In the above-mentioned cap 2, by configuring the side surfaces 3C and 3D to have secondary molded bodies 15, the side surfaces 3C and 3D can be formed with width dimensions slightly wider than the front surface 3A and the back surface 3B, making it possible to easily distinguish the front surface 3A and the back surface 3B from the side surfaces 3C and 3D. On the sides 3C and 3D, the decoration of the vapor deposition layer 13 provided on the inside can be seen through the top coat layer 14 and the secondary molded body 15 formed from a transparent resin, while on the front 3A and back 3B, the decoration of the vapor deposition layer 13 provided on the inside can be seen only through the top coat layer 14. Cap 2 manufactured by the above method was stored at 5° C. for 24 hours and then dropped from a specified height, and it was confirmed that no peeling occurred.

[0029] Although the configuration and the effects of the present invention have been described above based on the embodiments, the present invention is not limited to the above embodiments.

[0030] For example, in the above embodiment, a cap 2 for a lipstick case was shown and described as an example of the resin molded body 1, but the resin molded body 1 is not limited to this and may be other products, such as a lid for a cosmetic compact case.

[0031] In the above embodiment, the base material 11 is described as a primary molded product made of synthetic resin. However, the present invention is not limited to the above embodiment, and the base material 11 may be made of other materials such as metal, glass, ceramic, etc. [Industrial Applicability]

[0032] The present invention can expand the range of applications in the field of resin molded articles having a vapor-deposited layer into even wider areas. [Explanation of symbols]

[0033] 1: Resin molding 2: Cap 3: Torso 3A: Front 3B: Back 3C: Side 3D: Side 4: Top 5 : Space 11: Base material (primary molded product) 12: Undercoat layer 13: Vapor deposition layer 14: Topcoat layer 15: Secondary molded body

Claims

1. A resin molded body comprising: a substrate (11) made of a primary molded product having a front surface (3A), a back surface (3B) and a pair of side surfaces (3C, 3D) and formed into a rectangular cross-section; an undercoat layer (12) formed on the surface of the substrate (11); a vapor deposition layer (13) formed on the surface of the undercoat layer (12); and a secondary molded body (15) made of a transparent resin partially covering the surface of the vapor deposition layer (13), The secondary molded body (15) covers only the pair of side surfaces (3C, 3D) of the substrate (11) and excludes the front surface (3A) and the back surface (3B), A resin molded article characterized in that a topcoat layer (14) formed from a paint containing a vinyl chloride resin is provided between the vapor deposition layer (13) and the secondary molded article (15).

2. A resin molded body as described in claim 1, wherein the polyvinyl chloride resin has a solid content ratio of 50% or more.

3. 3. The resin molded article according to claim 1, wherein the substrate (11) is made of polycarbonate (PC).

4. 4. The resin molded body according to claim 1, wherein the secondary molded body (15) is made of acrylonitrile-styrene copolymer (SAN).

5. 5. The resin molded article according to claim 1, wherein the top coat layer (14) is formed from a paint containing a vinyl chloride resin and an acrylic resin.

6. A method for producing a resin molded body according to any one of claims 1 to 5, comprising the steps of: A first step of forming a substrate (11) having a predetermined shape by primary molding; A second step of forming an undercoat layer (12) on the surface of the substrate (11); a third step of forming a vapor deposition layer (13) on the surface of the undercoat layer (12); a fourth step of forming a topcoat layer (14) on the surface of the vapor-deposited layer (13) using a paint containing a vinyl chloride resin or a paint containing a vinyl chloride resin and an acrylic resin; and a fifth step of insert-molding a secondary molded body (15) having a predetermined shape onto a surface of the top coat layer (14) using the base material (11) formed through the first step to the fourth step as an insert material.

7. 7. The method for producing a resin molded article according to claim 6, wherein in the first step, the substrate (11) is made of polycarbonate (PC).

8. The method for producing a resin molded product according to claim 6 or 7, wherein in the second step, the undercoat layer (12) is formed by applying a paint containing an acrylic resin to a layer thickness in the range of 8 to 15 μm.

9. The method for producing a resin molded article according to any one of claims 6 to 8, wherein in the third step, the deposition layer (13) is formed by depositing aluminum to a layer thickness in the range of 0.06 to 0.12 µm.

10. The method for producing a resin molded article according to any one of claims 6 to 9, wherein in the fourth step, a top coat layer (14) is formed to a layer thickness in the range of 8 to 15 µm.

11. 11. The method for producing a resin molded article according to claim 6, wherein in the fifth step, the secondary molded article (15) is formed of acrylonitrile-styrene copolymer (SAN).

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