Decorative sheet, process for producing the same, and injection-molded article with decorative sheet

Abstract

A decorative sheet for injection-molding and decorating a resin simultaneously, the decorative sheet containing two resin sheets laminated on each other with at least one patterned layer intervening therebetween, and the two resin sheets having a difference in linear expansion coefficient of 4×10 −5 /° C. (41 to 50° C.) or less. Even after subjecting to three-dimensional processing, such as vacuum molding, the decorative sheet suffers no warpage, and can be easily released from a mold for the three-dimensional processing, and even when the decorative sheet is set in a mold for injection molding, the decorative sheet does not fall off from the mold, a resin injected does not permeate a gap between the outer surface of the decorative sheet and the mold, and the decorative sheet suffers no peeling between the sheets constituting the decorative sheet.

1 . A simultaneous injection molding-decorative sheet capable of attaining injection molding of a resin and decoration simultaneously, the decorative sheet comprising two resin sheets laminated on each other with at least one patterned layer intervening therebetween, the two resin sheets having a difference in linear expansion coefficient of 4×10 −5 /° C. (41 to 50° C.) or less. 
     
     
         2 . The decorative sheet as claimed in  claim 1 , wherein among the two resin sheets, a material for the resin sheet on a surface side is at least one selected from polyurethane, polyester, an acrylate resin, polyolefin and polycarbonate, and a material for the resin sheet in contact with a resin to be molded is at least one selected from a polyolefin, an acrylonitrile-butadiene-styrene resin (ABS resin), polycarbonate and polyester. 
     
     
         3 . The decorative sheet as claimed in  claim 1 , wherein the decorative sheet further comprises an adhesive layer between the two resin sheets. 
     
     
         4 . The decorative sheet as claimed in  claim 1 , wherein the two resin sheets are laminated by a dry laminating method, a hot laminating method, an extrusion laminating method or a heat laminating method. 
     
     
         5 . A process for producing a decorative sheet comprising two resin sheets having a difference in linear expansion coefficient of 4×10 −5 /° C. (41 to 50° C.) or less, at least one patterned layer being provided between the resin sheets, and the process comprising laminating the two resin sheets by a dry laminating method, a hot laminating method, an extrusion laminating method or a heat laminating method. 
     
     
         6 . An injection-molded article with a decorative sheet, the injection-molded article being produced by subjecting the decorative sheet as claimed in  claim 1  to three-dimensional processing and punching, and then molding the decorative sheet integrally with a molding resin by an injection molding method using a mold.