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

• US 7,318,905 B2
• Filed: 11/29/2005
• Issued: 01/15/2008
• 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): Lee; Edmund H.
• Application Number:
  US11/288,345
• Publication Number:
  US 20060071366A1
• Time in Patent Office: 777 Days
• Field of Search: None
• US Class Current: 264/266
• 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. An in-mold decorating injection molding method for injection molding a decorative molding comprising the steps of:

preparing a decorative sheet for in-mold decorating injection molding including a base sheet and a resin layer formed on a surface of the base sheet to be brought into contact with an injection-molded resin molding and containing an acrylic-modified polyolefin resin;

inserting the decorative sheet in a space between a pair of molds in an open state;

clamping the pair of molds;

injecting an injection-molding resin into a cavity formed by the pair of molds so that the injection-molding resin comes into contact with the resin layer containing an acrylic-modified polyolefin resin;

solidifying the injection-molding resin injected into the cavity in an injection-molded resin molding and adhesively bonding the decorative sheet for in-mold decorating injection molding to a surface of the injection-molded resin molding to form a decorative molding formed of the decorative sheet for in-mold decorating injection molding and the injection-molded resin molding; and

parting the pair of molds and taking out the decorative molding from the pair of molds,

wherein the decorative molding comprises;

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

the 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 in-mold decorating injection molding method according to claim 1, wherein the injection-molding resin is a polyolefin resin.

3. An in-mold decorating injection molding method for injection molding a decorative molding comprising the steps of:

preparing a decorative sheet for in-mold decorating injection molding including a base sheet and a resin layer formed on a surface of the base sheet to be brought into contact with an injection-molded resin molding and containing an acrylic-modified polyolefin resin;

inserting the decorative sheet in a space between a pair of molds in an open state;

clamping the pair of molds;

injecting an injection-molding resin into a cavity formed by the pair of molds so that the injection-molding resin comes into contact with the resin layer containing an acrylic-modified polyolefin resin;

solidifying the injection-molding resin injected into the cavity in an injection-molded resin molding and adhesively bonding the decorative sheet for in-mold decorating injection molding to a surface of the injection-molded resin molding to form a decorative molding formed of the decorative sheet for in-mold decorating injection molding and the injection-molded resin molding; and

parting the pair of molds and taking out the decorative molding from the pair of molds,

wherein the decorative molding comprises;

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

the 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.

4. The in-mold decorating injection molding method according to claim 3, wherein the injection-molding resin is a polyolefin resin.

5. An in-mold decorating injection molding method for injection molding a decorative molding comprising the steps of:

preparing a decorative sheet for in-mold decorating injection molding including a base sheet and a resin layer formed on a surface of the base sheet to be brought into contact with an injection-molded resin molding and containing an acrylic-modified polyolefin resin;

inserting the decorative sheet in a space between a pair of molds in an open state;

clamping the pair of molds;

injecting an injection-molding resin into a cavity formed by the pair of molds so that the injection-molding resin comes into contact with the resin layer containing an acrylic-modified polyolefin resin;

solidifying the injection-molding resin injected into the cavity in an injection-molded resin molding and adhesively bonding the decorative sheet for in-mold decorating injection molding to a surface of the injection-molded resin molding to form a decorative molding formed of the decorative sheet for in-mold decorating injection molding and the injection-molded resin molding; and

parting the pair of molds and taking out the decorative molding from the pair of molds,

wherein the decorative molding comprises;

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

the 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.

6. The in-mold decorating injection molding method according to claim 5, wherein the injection-molding resin is a polyolefin resin.