Decorative sheet for in-mold decorating injection molding, decorative molding and in-mold decorating injection molding method

• US 7,001,659 B2
• Filed: 02/07/2001
• Issued: 02/21/2006
• Est. Priority Date: 02/10/2000
• Status: Expired due to Fees

• Current Assignee: Dai Nippon Printing Company Limited
• Original Assignee: Dai Nippon Printing Company Limited
• Inventors: Iriyama, Hideyuki
• Primary Examiner(s): Dye, Rena
• Assistant Examiner(s): FERGUSON, LAWRENCE D
• Application Number:
  US09/778,096
• Publication Number:
  US 20010019761A1
• Time in Patent Office: 1,840 Days
• Field of Search: 428/200, 428/412, 428/201, 428/204, 428/518, 428/520, 428/522, 428/195.1
• US Class Current: 428/195.1
• CPC Class Codes: B29C 45/14811 Multilayered articles B29C45/14827 takes precedence
• CPC Class Codes: B29K 2633/08 Polymers of acrylic acid esters, e.g. PMA, i.e. polymethylacrylate
• CPC Class Codes: Y10T 428/24802 Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/24843 with heat sealable or heat releasable adhesive layer
• CPC Class Codes: Y10T 428/31855 Of addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/3192 Next to vinyl or vinylidene chloride polymer
• CPC Class Codes: Y10T 428/31928 Ester, halide or nitrile of addition polymer
• CPC Class Codes: Y10T 428/31935 Ester, halide or nitrile of addition polymer

Abstract

A decorative sheet (S) for in-mold decorating injection molding has a base sheet (1A) and a resin layer (2) formed on a surface of the base sheet (1A) to be brought into contact with an injection-molded molding and containing an acrylic-modified polyolefin resin. The acrylic-modified polyolefin resin is a resin composed by grafting-copolymerizing an acrylic monomer and/or an acrylic prepolymer on principal chains of a polypropylene resin. The decorative sheet (S) includes, for example, a base sheet (1A) of an acrylic resin, a decorative layer (3) of a binder resin and at least either an acrylic resin contained in the binder resin or a polyvinyl chloride-acetate resin, and a bonding layer (2) containing an acrylic-modified polyolefin resin. A primer layer (4) may be sandwiched between the bonding layer (2) and the decorative layer (3).

Claims

1. A decorative molding, comprising:

a decorative sheet for in-mold decorating injection molding, the decorative sheet comprising a base sheet having a first surface and a second surface, a decorative layer formed on the first surface, and a resin layer formed on the second surface; and

an injection-molded resin molding to which the resin layer is bonded;

wherein;

the decorative layer comprises a binder resin, the binder resin comprising at least one of an acrylic resin and a polyvinyl chloride-acetate resin;

the resin layer comprises an acrylic-modified polyolefin resin formed by graft-copolymerizing at least one of an acrylic monomer and an acrylic prepolymer on principal chains of a polypropylene resin.

2. The decorative molding of claim 1, wherein the resin layer is a second decorative layer and the acrylic-modified polyolefin resin is a binder in the second decorative layer.

3. The decorative molding of claim 1, wherein the base sheet comprises an acrylic resin.

4. The decorative molding of claim 1, wherein the injection-molded resin molding comprises a polyolefin resin.

5. A decorative molding, comprising:

a decorative sheet for in-mold decorating injection molding, the decorative sheet comprising a base sheet, a decorative layer formed on the base sheet, a primer layer formed on the decorative layer, and a resin layer formed on the primer layer; and

an injection-molded resin molding to which the resin layer is bonded;

wherein;

the decorative layer comprises a binder resin, the binder resin comprising at least one of an acrylic resin and a polyvinyl chloride-acetate resin;

the resin layer comprises an acrylic-modified polyolefin resin formed by graft-copolymerizing at least one of an acrylic monomer and an acrylic prepolymer on principal chains of a polypropylene resin.

6. The decorative molding of claim 5, wherein the primer layer comprises at least one of an acrylic resin and a polyvinyl chloride-acetate resin.

7. The decorative molding of claim 5, wherein the base sheet comprises an acrylic resin.

8. The decorative molding of claim 5, wherein the resin layer is a second decorative layer and the acrylic-modified polyolefin resin is a binder in the second decorative layer.

9. The decorative molding of claim 5, wherein the injection-molded resin molding comprises a polyolefin resin.

10. A decorative molding, comprising:

a decorative sheet for in-mold decorating injection molding, the decorative sheet comprising a base sheet, a decorative layer formed on the base sheet, and a resin layer formed on the decorative layer; and

an injection-molded resin molding to which the resin layer is bonded;

wherein;

the base sheet is a laminated sheet having at least two layers;

the decorative layer comprises a binder resin, the binder resin comprising at least one of an acrylic resin and a polyvinyl chloride-acetate resin; and

the resin layer comprises an acrylic-modified polyolefin resin formed by graft-copolymerizing at least one of an acrylic monomer and an acrylic prepolymer on principal chains of a polypropylene resin.

11. The decorative molding of claim 10, wherein the injection-molded resin molding comprises a polyolefin resin.

12. The decorative molding of claim 10, wherein the resin layer is a second decorative layer and the acrylic-modified polyolefin resin is a binder in the second decorative layer.

13. The decorative molding of claim 10, wherein the base sheet comprises an acrylic resin.