DECORATED RESIN MOLDED ARTICLE AND METHOD FOR PRODUCING THE SAME

• US 20090068425A1
• Filed: 09/02/2008
• Published: 03/12/2009
• Est. Priority Date: 09/10/2007
• Status: Active Grant

• Current Assignee: Kojima Press Industry Company Limited (Kojima Industries Corporation)
• Original Assignee: Kojima Press Industry Company Limited (Kojima Industries Corporation)
• Inventors: ITO, Kaoru, MATSUI, Hirotoshi, Suzuki, Takane, NOGUCHI, Masumi
• Granted Patent: US 9,364,860 B2
• Time in Patent Office: Days
• US Class Current: 428/209
• CPC Class Codes: B05D 2350/65 metal layer
• CPC Class Codes: B05D 5/067 Metallic effect
• CPC Class Codes: B05D 7/02 to macromolecular substances, e.g. rubber treatment or coating of shaped articles made of macromolecular substances C08J7/00
• CPC Class Codes: B29C 2045/0079 applying a coating or covering
• CPC Class Codes: B29L 2009/003 comprising a metal layer
• CPC Class Codes: B29L 2031/3005 Body finishings
• CPC Class Codes: B29L 2031/722 Decorative or ornamental articles
• CPC Class Codes: Y10T 428/24917 including metal layer

Abstract

A decorated resin molded article that can secure a high durability and can represent a sufficiently realistic metal texture in appearance is provided as follows. A metal thin film is directly formed on a design surface of a substrate by either a physical vapor deposition method or a chemical vapor deposition method to provide a metallic decoration. Additionally, a topcoat layer is formed with a thickness of 10 to 40 μm on the metal thin film. The topcoat layer comprises a transparent coating film having an adhesive property to both of the substrate and the metal thin film.

Claims

1. A decorated resin molded article, comprising:

a substrate having a design surface provided with a metallic decoration, the substrate being constituted by a resin molded article;

a metal thin film providing the metallic decoration on the design surface, the metal thin film being directly formed on the substrate by either a physical vapor deposition method or a chemical vapor deposition method; and

a topcoat layer having a thickness of 10 to 40 μ

m formed on the metal thin film, the topcoat layer being constituted by a transparent coating film having an adhesive property to both of the substrate and the metal thin film.

2. The decorated resin molded article according to claim 1, wherein the metal thin film has a thickness of 0.001 to 1 μ

m.

3. The decorated resin molded article according to claim 1, wherein the metal thin film is formed of a metallic material having a linear expansion coefficient of 6.0×

10−

6 or more.

4. The decorated resin molded article according to claim 3, wherein the metal thin film is formed of any one kind of metallic materials selected from gold, silver, platinum, copper, aluminum, zinc, nickel, chrome, tin, titanium, and molybdenum or an alloy material comprising two or more kinds of metallic materials selected therefrom.

5. The decorated resin molded article according to claim 3, wherein the metal thin film is formed of a stainless steel.

6. The decorated resin molded article according to claim 1, wherein the resin molded article constituting the substrate is formed of an amorphous resin material.

7. The decorated resin molded article according to claim 1, wherein the resin molded article constituting the substrate is formed of a microcrystalline resin material.

8. The decorated resin molded article according to claim 1, wherein the resin molded article constituting the substrate is formed of a mixture of an amorphous resin material and a microcrystalline resin material.

9. The decorated resin molded article according to claim 1, wherein the transparent coating film is formed of a coating material including a matting agent.

10. The decorated resin molded article according to claim 1, wherein the transparent coating film is a colored transparent coating film.

11. The decorated resin molded article according to claim 1, wherein the transparent coating film is formed of a two-liquid reactive-type coating material comprising a first liquid containing a first component and a second liquid containing a second component, the first component having a functional group exhibiting an adhesiveness to resin and the second component having a functional group exhibiting an adhesiveness to metal.

12. The decorated resin molded article according to claim 1, wherein on the design surface of the substrate is provided with a first decorated portion having a pattern formed by at least one of a large number of fine concave portions and a large number of fine convex portions, and

wherein the metal thin film is directly formed on the first decorated portion by either the physical vapor deposition method or the chemical vapor deposition method to provide the metallic decoration on the design surface.

13. The decorated resin molded article according to claim 1, wherein on the design surface of the substrate is provided with a second decorated portion having an even and smooth surface, and

wherein the metal thin film is directly formed on the second decorated portion by either the physical vapor deposition method or the chemical vapor deposition method to provide the metallic decoration on the design surface.

14. The decorated resin molded article according to claim 1, wherein at least two kinds of decorated portions selected from the group consisting of plural kinds of first decorated portions and a second decorated portion are provided so as to adjacent to each other on the design surface of the substrate, the first decorated portions having patterns formed by at least one of a large number of fine concave portions and a large number of fine convex portions in which depths of the concave portions, heights of the convex portions, or kinds of the patterns are mutually different and the second decorated portion having an even and smooth surface, and

wherein the metal thin film is directly formed on the at least two kinds of the decorated portions by either the physical vapor deposition method or the chemical vapor deposition method to provide a plural kinds of metallic decorations having different appearances on the design surface.

15. The decorated resin molded article according to claim 1, wherein the decorated resin molded article is an automobile interior part.

16. A method for producing a decorated resin molded article having a metallic decoration on a design surface of a substrate constituted by a resin molded article, the method comprising the steps of:

directly forming a metal thin film on the design surface of the substrate by either a physical vapor deposition method or a chemical vapor deposition method to provide the metallic decoration; and

forming a topcoat layer having a thickness of 10 to 40 μ

m on the metal thin film, the topcoat layer being formed of a transparent coating film having an adhesive property to both of the substrate and the metal thin film.