Film for in-molding, in-mold molded product, and method for manufacturing in-mold molded product

Patent metadata

Field	Value
Publication number	US-9821595-B2
Application number	US-201515327370-A
Country	US
Kind code	B2
Filing date	Nov 27, 2015
Priority date	Jun 4, 2015
Publication date	Nov 21, 2017
Grant date	Nov 21, 2017

Abstract

A film for in-molding is configured with a transfer film which is transferred to a surface of an injection molding resin, and a carrier film which is not transferred. The transfer film includes a coloring layer which includes ink which is an organic material formed of a thermoplastic resin and applies a design to an in-mold molded product, and inorganic polymer layers formed of a thermosetting resin, and the coloring layer comes into contact with the inorganic polymer layers and is interposed between the inorganic polymer layers.

First claim

The invention claimed is:

1. A film for in-molding comprising:
a transfer film which is transferred to a surface of an injection molding resin; and
a carrier film which is not transferred,
wherein the transfer film includes a coloring layer which includes ink which is an organic material formed of a thermoplastic resin and applies a design to an in-mold molded product, and inorganic polymer layers formed of a thermosetting resin, and
the coloring layer is into contact with the inorganic polymer layers and is interposed between the inorganic polymer layers.

2. The film for in-molding of claim 1 ,
wherein a glass transition temperature of the inorganic polymer layers is higher than a glass transition temperature of the coloring layer.

3. The film for in-molding of claim 1 ,
wherein the inorganic polymer layers are formed by using a sol-gel method.

4. The film for in-molding of claim 1 ,
wherein the inorganic polymer layers comprise metal oxide microparticles and an inorganic matrix resin, and a proportion of the metal oxide microparticles is from 5% by mass to 90% by mass inclusive.

5. The film for in-molding of claim 4 ,
wherein the metal oxide microparticles are porous fillers.

6. The film for in-molding of claim 1 ,
wherein a film thickness of each of the inorganic polymer layers is equal to or greater than 0.05 μm and smaller than 0.2 μm.

7. The film for in-molding of claim 1 ,
wherein the carrier film comprises in a stacked state,
a base film which continuously supplies the transfer film, and
a peeling layer which is provided for peeling the transfer film from the base film, and

the transfer film comprises in a stacked state,
a protective layer or a hard coat layer which protects an in-mold molded product,
a primer layer which connects the protective layer or the hard coat layer and the inorganic polymer layers to each other,
a first inorganic polymer layer which is a part of the inorganic polymer layers,
the coloring layer,
a second inorganic polymer layer which is a part of the inorganic polymer layers,
a hiding layer which hides a color of the coloring layer, and
an adhesive layer which bonds the transfer film to an injection molding resin.

8. An in-mold molded product comprising:
the transfer film of the film for in-molding of claim 1 ; and
an injection molding resin having a surface to which the transfer film is transferred.

9. A method for manufacturing an in-mold molded product comprising:
the disposing the film for in-molding of claim 1 between a first die and a second die;
flowing a molten injection molding resin into a cavity formed by clamping the first die and the second die together;
cooling and solidifying the injection molding resin flowed into the cavity; and
releasing the first die and the second die from each other to extract an in-mold molded product including the cooled injection molding resin and the transfer film formed on a surface of the in-mold molded product.

Assignees

• Panasonic Ip Man Co Ltd

Inventors

• Shibata Gakuei
• Kaneuchi Kazuhiko

Classifications

• B29K2709/00

  Use of inorganic materials not provided for in groups {B29K2703/00 - B29K2707/00}, for preformed parts, e.g. for inserts · CPC title

• B44C1/1704 Primary

  Decalcomanias provided with a particular decorative layer, e.g. specially adapted to allow the formation of a metallic or dyestuff layer on a substrate unsuitable for direct deposition (B44C1/1716, B44C1/1737 take precedence) · CPC title

• B29K2995/007

  Hardness · CPC title

• B29K2995/002

  Coloured · CPC title

• B29C45/1418

  the inserts being deformed or preformed, e.g. by the injection pressure · CPC title