Decorated Readily Formable Paper and Method of Manufacturing In-Mold Decorated Fibrous Molded Article

Abstract

The present invention relates to a decorated readily formable paper suitable for an in-mold decorated fibrous molded article and the invention relates also to a method of manufacturing an in-mold decorated fibrous molded article. Provided are a decorated readily formable paper which suffers no ink running during molding and which also has superior friction resistance and a method of manufacturing an in-mold decorated fibrous molded article using such paper. A decorated readily formable paper 11 includes a readily formable paper 1 , a pattern layer 8 formed on one face of the readily formable paper 1 , a varnish layer 9 formed on the readily formable paper 1 and the pattern layer 8 , and a protection layer 10 formed on the varnish layer 9 . The pattern layer 8 , the varnish layer 9 and the protection layer 10 are printed layers 2.

1 . A decorated readily formable paper comprising:
 a readily formable paper whose apparent size is reduced by formation of fine creases on one face thereof;   a pattern layer formed on one face of the readily formable paper;   a varnish layer formed on the readily formable paper and the pattern layer; and   a protection layer formed on the varnish layer, the protection layer being comprised of an ink composition containing a polyol-based compound and a multifunctional isocyanate.   
     
     
         2 . A decorated readily formable paper comprising:
 a readily formable paper whose apparent size is reduced by formation of fine creases on one face thereof;   a varnish layer formed on one face of the readily formable paper;   a pattern layer formed on the varnish layer; and   a protection layer formed on the pattern layer, the protection layer being comprised of an ink composition containing a polyol-based compound and a multifunctional isocyanate.   
     
     
         3 . The decorated readily formable paper according to  claim 1 , wherein a weight ratio between the polyol-based compound and the multifunctional isocyanate ranges from 100/3 to 100/20 parts. 
     
     
         4 . The decorated readily formable paper according to  claim 1 , wherein the ink composition of the protection layer further contains silica solid particles by 5 to 25 wt. %. 
     
     
         5 . The decorated readily formable paper according to  claim 1 , wherein the polyol-based compound comprises acryl polyol having an OH value ranging from 20 to 90. 
     
     
         6 . The decorated readily formable paper according to  claim 1 , wherein the polyol-based compound comprises acryl polyol having an OH value ranging from 80 to 90. 
     
     
         7 . The decorated readily formable paper according to  claim 1 , wherein the polyol-based compound comprises acryl polyol having an OH value ranging from 20 to 30. 
     
     
         8 . The decorated readily formable paper according to  claim 1 , wherein the isocyanate comprises hexamethylene diisocyanate type. 
     
     
         9 . A method of manufacturing an in-mold decorated fibrous molded article, comprising the steps of:
 fitting the decorated readily formable paper according to  claim 1  in a mold;   clamping the mold;   preparing a mixture by adding polymer binder and water to a fibrous main raw material and mixed/kneaded together as a molding material and charging the molding material within a cavity of the mold which is heated;   forming a gap ranging from 0.02 to 0.50 mm between parting faces of the mold and discharging and removing vapor generated within the cavity from the gap, and allowing the molding material to be dried and solidified; and   opening the mold and obtaining therefrom a fibrous molded article having the decorated readily formable paper integrally formed on its surface.   
     
     
         10 . The method of manufacturing in-mold decorated fibrous molded article according to  claim 9 , wherein the readily formable paper before being fitted in the mold has a water content ranging from 5 to 10%. 
     
     
         11 . The decorated readily formable paper according to  claim 2 , wherein a weight ratio between the polyol-based compound and the multifunctional isocyanate ranges from 100/3 to 100/20 parts. 
     
     
         12 . The decorated readily formable paper according to  claim 2 , wherein the ink composition of the protection layer further contains silica solid particles by 5 to 25 wt. %. 
     
     
         13 . The decorated readily formable paper according to  claim 2 , wherein the polyol-based compound comprises acryl polyol having an OH value ranging from 20 to 90. 
     
     
         14 . The decorated readily formable paper according to  claim 2 , wherein the polyol-based compound comprises acryl polyol having an OH value ranging from 80 to 90. 
     
     
         15 . The decorated readily formable paper according to  claim 2 , wherein the polyol-based compound comprises acryl polyol having an OH value ranging from 20 to 30. 
     
     
         16 . The decorated readily formable paper according to  claim 2 , wherein the isocyanate comprises hexamethylene diisocyanate type. 
     
     
         17 . A method of manufacturing an in-mold decorated fibrous molded article, comprising the steps of:
 fitting the decorated readily formable paper according to  claim 2  in a mold;   clamping the mold;   preparing a mixture by adding polymer binder and water to a fibrous main raw material and mixed/kneaded together as a molding material and charging the molding material within a cavity of the mold which is heated;   forming a gap ranging from 0.02 to 0.50 mm between parting faces of the mold and discharging and removing vapor generated within the cavity from the gap, and allowing the molding material to be dried and solidified; and   opening the mold and obtaining therefrom a fibrous molded article having the decorated readily formable paper integrally formed on its surface.   
     
     
         18 . The method of manufacturing in-mold decorated fibrous molded article according to  claim 17 , wherein the readily formable paper before being fitted in the mold has a water content ranging from 5 to 10%.