# US 9,434,096 B2 · Decorative resin sheet, and molded resin article and process for production thereof

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- Number: US 9,434,096 B2
- Document ID: US9434096B2
- Status: Granted
- Kind: B2
- Application number: 13/877,867
- Filed: 2011-09-06
- Published: 2013-08-22
- Granted: 2016-09-06
- Earliest claimed: 2010-10-05
- Assignees: Kaneka Corporation; Tatsuta Chemical Co., Ltd.
- Applicants: Koichi Yamashita; Shigehiro Kanou; Masami Nishikawa; Kaoru Yaguchi; Fumihito Tonomura
- Inventors: Koichi Yamashita; Shigehiro Kanou; Masami Nishikawa; Kaoru Yaguchi; Fumihito Tonomura
- Web page: https://patentgrep.com/patent/US9434096B2

## CPC

- B29C 45/14827: {using a transfer foil detachable from the insert}
- B29C 37/0032: {the coating being applied upon the mould surface before introducing the moulding compound, e.g. applying a gelcoat (B29C44/14 and B29C44/32 take precedence)}
- B29C 37/0053: {Moulding articles characterised by the shape of the surface, e.g. ribs, high polish (mould construction therefor B29C33/42; surface shaping of articles B29C59/00; by incorporating filler in or near the surface B29C70/64)}
- B29C 45/372: {provided with means for marking or patterning, e.g. numbering articles}
- B29D 7/01: Films or sheets
- B32B 3/263: {characterised by a layer having non-uniform thickness}
- B32B 3/30: characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)}
- B32B 27/08: of synthetic resin
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B29C 2035/0827: {using UV radiation}
- B29C 2035/0833: {using actinic light}
- B29C 2035/085: {using gamma-ray}
- B29C 2035/0877: {using electron radiation, e.g. beta-rays}
- B29C 2037/0042: {the coating being applied in solid sheet form, e.g. as meltable sheet}
- B29C 2037/0046: {In-mould printing, in-mould transfer printing}
- B32B 2451/00: Decorative or ornamental articles
- Y10T 428/24355: Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
- Y10T 428/24479: including variation in thickness
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

Provided are a decorative resin sheet that sufficiently brings together embossing property and embossment-retaining property, and a molded resin article on which an embossment excellent in design is formed and a method of manufacturing the molded resin article. The method of manufacturing a molded resin article includes the steps of: providing a resin sheet having a mold layer containing a polyolefin-based resin as a main component, followed by formation of an embossment on the resin sheet so that the embossment is formed on a surface of the mold layer; crosslinking the mold layer on which the embossment is formed so that a 100% modulus of the resin sheet at 200° C. becomes 0.02 MPa or more, which is measured in conformity with JIS K6251 (2004 version); placing the resultant resin sheet (10) in an injection molding die (20) so that the surface (11) of the mold layer faces a side from which a molten resin (30) is injected; injecting the molten resin (30) onto a side of the surface (11) of the mold layer in the injection molding die (20) to mold a molded resin article; and separating the molded resin article and the mold layer.

## Claims

### Claim 1

A method of manufacturing a molded resin article, the method comprising:
a providing step of providing a decorative resin sheet, which comprises a crosslinked mold layer having a first surface and a second surface and contains 50 wt % or more, with respect to the entirety of resin components in the mold layer, of a polyolefin-based elastomer, by irradiating the mold layer in an uncrosslinked state with an energy ray at a defined acceleration voltage and irradiation dosage so as to crosslink the mold layer and provide the decorative resin sheet with a 100% modulus at 200° C. of 0.02 MPa or more, which modulus is measured at a tension speed of 200 mm/min by a method including setting a distance between a pair of chucks for holding both ends of a test piece of a dumbbell shape No. 3 at a time of initiation of a test to 60 mm and defining a time point at which the distance between the pair of chucks reaches 120 mm as a time point at which a tensile elongation of the test piece becomes 100% in JIS K6251 (2004 version), wherein an embossment is formed on the second surface of the mold layer;
a placing step of placing the decorative resin sheet after the crosslinking in an injection molding die so that the second surface of the mold layer faces a side of the injection molding die from which a molten resin is injected:
a molding step of injecting the molten resin in a direction toward the second surface of the mold layer placed in the injection molding die to mold an injection molded resin article into conformity with the embossment, wherein the first surface of the mold layer directly contacts an inner surface of the injection molding die during the molding step; and
a separating step of separating the molded resin article from the decorative resin sheet, thereby transferring the embossment onto a surface of the molded resin article.

### Claim 2 (depends on 1)

The method of manufacturing a molded resin article according to claim 1, wherein the mold layer is also crosslinked by chemical crosslinking.

### Claim 3 (depends on 1)

The method of manufacturing a molded resin article according to claim 1, wherein the decorative resin sheet has a transfer layer laminated over the second surface of the mold layer during the injection molding step, wherein an embossment corresponding to the embossment of the second surface of the mold layer is formed on a surface of the transfer layer as well.

### Claim 4 (depends on 3)

The method of manufacturing a molded resin article according to claim 3, wherein the embossment of the transfer layer has a ten-point average roughness (RzJIS), which is measured in conformity with JIS B0601-2001, larger than a thickness of the transfer layer.

### Claim 5 (depends on 3)

The method of manufacturing a molded resin article according to claim 3, wherein the transfer layer has a thickness of 0.5 μm to 150 μm.

### Claim 6 (depends on 3)

The method of manufacturing a molded resin article according to claim 3, wherein the transfer layer includes a protective layer and/or a pattern layer.

### Claim 7 (depends on 1)

The method of manufacturing a molded resin article according to claim 1, wherein the decorative resin sheet is constituted only by the mold layer.

### Claim 8 (depends on 1)

The method of manufacturing a molded resin article according to claim 1, wherein the embossment has a ten-point average roughness (RzJIS) of 10 μm to 400 μm, which is measured in conformity with JIS B0601-2001.

### Claim 9 (depends on 1)

The method of manufacturing a molded resin article according to claim 1, wherein the acceleration voltage is from 100 to 300 kV.

### Claim 10 (depends on 1)

The method of manufacturing a molded resin article according to claim 1, wherein the irradiation dose is from 30 to 2,000 kGy.

### Claim 11 (depends on 1)

The method of manufacturing a molded resin article according to claim 1, wherein the energy ray is selected from electron beam, γ-ray, UV light, and visible light.

### Claim 12 (depends on 1)

The method of manufacturing a molded resin article according to claim 1, wherein the energy ray is an electron beam.