JP2003112399A - Metallic decorative sheet and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a metallic-tone decorative sheet which can impart a sophisticated duralumin-tone appearance and texture to a commodity by attaching or insert-molding. SOLUTION: This metallic-tone decorative sheet has a metallic layer arranged on one of the sides of a thermoplastic resin film showing 90% or higher of total light permeability, 30 to 70% of diffusion permeability, 33 to 78% of haze and 40% or lower of glossiness.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a metallic decorative sheet, and more particularly to a metallic decorative sheet capable of imparting a light metal-like texture such as duralumin or alumite.

[0002]

2. Description of the Related Art Materials such as aluminum, magnesium and their alloys (aircraft aluminum alloys, etc.), represented by high-grade attache cases, which have a metallic luster of light metal, have been used for the exterior of notebook computers for several years. However, in addition, it is being applied to interior and exterior of automobiles, home appliances such as refrigerators, furniture, system kitchens, etc. to give a futuristic impression, and is being put into practical use.

However, in practice, when these light metals are used, it is difficult to perform deep drawing by a press or to process them into a complicated shape, and further, it is difficult to recycle them because of the cold feel due to the cost, weight and high heat conductivity. In addition, there are problems such as being oxidized by oxygen in the air, the initial appearance and texture cannot be maintained, and dents easily occur when shocked.

Therefore, a method of applying a metallic finish to the surface of another material such as resin or laminating a metallic finish film to finish only the image into a metallic look is being studied.

However, unlike the metallic luster imparting films such as chromium and nickel which have been conventionally studied in the field of so-called molding, the luster of duralumin tone or alumite tone (hereinafter, simply referred to as "deralumin tone") has a gloss. Although it has a unique depth and matte feel, it has been difficult to achieve a metallic decorative sheet that imparts such a texture with painting and vapor deposition products to date.

[0006]

DISCLOSURE OF THE INVENTION The present invention improves the above-mentioned conventional problems, that is, imparts a high-grade duralumin-like appearance and texture to an article by pasting or insert molding. It is an object of the present invention to provide a metal-like decorative sheet that can be manufactured.

[0007]

In order to solve the above-mentioned problems, the metallic decorative sheet of the present invention has the following features.
Total light transmittance 80% or more, diffuse transmittance 35% or more 80%
The following is a metal-like decorative sheet having a structure in which a metal layer is arranged on one surface of a thermoplastic resin film having a haze value of 40% or more and 85% or less and a glossiness of 45% or less.
High-grade, futuristic duralumin-like metallic appearance for items,
A texture can be added.

The method for producing the metallic decorative sheet of the present invention is, as described in claim 3, a total light transmittance of 80% or more, a diffuse transmittance of 35% or more and 80% or less, a haze value of 40% or more and 85% or less, and a gloss. A method for producing a metal-like decorative sheet in which a metal layer is provided on one surface of a thermoplastic resin film having a degree of 45% or less. With such a structure, a high-grade, near-futuristic duralumin-like metal appearance and texture is imparted to an article. A metallic decorative sheet that can be applied can be obtained.

As described in claim 6, the shell for a case of the present invention has a total light transmittance of 80% or more, a diffuse transmittance of 35% or more and 80% or less, a haze value of 40% or more and 85% or less, and a gloss of 45.
% Or less of a thermoplastic resin film on one surface of which a metal layer, an adhesive layer, and a resin layer are arranged in this order, and is a shell for a case, which has a futuristic duralumin-like metallic appearance and texture. It is possible to form a lightweight and agile case that does not cause a dent or the like when using.

[0010]

BEST MODE FOR CARRYING OUT THE INVENTION As the thermoplastic resin film for directly disposing the metal layer used in the present invention, polymethylmethacrylate, polypropylene, various polyesters, polyvinyl alcohol, polyurethane, fluorine resin, ethylene-vinyl acetate copolymer Resin films such as system resins, polycarbonate, polystyrene, polyvinyl chloride, and polyvinylidene chloride are used. In terms of durability, polymethylmethacrylate, polyester, polycarbonate,
Alternatively, it is preferably a fluorine-based resin film. The thickness of the thermoplastic resin film is usually 5 μm or more and 500 μm or less, and is preferably 20 to 200 μm in consideration of processability, economy, durability and the like.

The total light transmittance of the thermoplastic resin film on which the metal layer used in the present invention is directly arranged is 80% or more, the diffuse transmittance is 35% or more and 80% or less, the haze value is 40% or more and 85% or less, and the glossiness is 45% or less. It is necessary to be. Unless any of these parameters is satisfied, a metallic decorative sheet having a duralumin-like metallic appearance and texture cannot be obtained.

In order to satisfy such conditions, the kind and the amount of the filler to be added are adjusted, as well as the kind and the degree of polymerization of the raw material polymer. Alternatively, it may be achieved by printing at least one of them, and these are combined to form a film satisfying a predetermined optical performance.

The type of the filler is one usually used for film production, for example, one or more selected from calcium carbonate, aluminum hydroxide, silica, talc, titanium dioxide, zinc white, and rubber-containing polymer, and satisfying the above parameters. And uniformly add.

If this thermoplastic resin film has a hairline finish on at least one side,
It has the same appearance and texture as duralumin that has been hairline-processed, and can give a more luxurious feel.

Further, when this hairline processing is applied to the surface of the thermoplastic resin film on which the metal layer is arranged,
Since the hairline processed surface is not exposed to the outside, there is no change in the texture due to wear.

The above optical performance is not necessarily required to be satisfied by the film as a whole. For example, a portion where a logo, brand mark, pattern required for design, etc. are printed is satisfied. It doesn't matter if you don't.

The metal layer is usually formed on one surface of the thermoplastic resin film directly as a base by a thin film forming technique such as vacuum deposition, sputtering, ion plating, and plasma CVD. The metal forming the metal layer is aluminum, zinc, gallium, nickel, tin, silver, chromium,
Titanium, platinum, palladium, nickel, indium, and other simple substances, aluminum alloys, stainless steel, hastelloy, and other alloys, or silicon, which is not a metal, but gives a metallic tone impression, but among them, it has a high-class feel A metal layer made of aluminum is desirable because it can give an aircraft aluminum alloy-like texture and appearance.

The thickness of the metal layer should be such that it can withstand various types of processing, and is usually 10 to 200 nm, and particularly 20 to 100 nm when deep drawing is performed. FIG. 1 shows a model cross-sectional view of the metal-finished decorative sheet according to the present invention in which the metal layer is thus provided.

Further, a metal-like decorative sheet in which a thermoplastic resin film having a metal layer on one side is further laminated with another thermoplastic resin film on the metal layer side via an adhesive layer (model cross section of FIG. 2) (See the figure), the handling is improved, and when it is used for three-dimensional molding, the duralumin-like appearance may be lost even if so-called deep-drawing is performed, even in the deep-drawing part or the part with a small radius of curvature. No, a good appearance is retained throughout.

It is believed that the metal layer is stretched while being supported by the resin film from above and below, thereby preventing the occurrence of locally high stretch ratio portions. For this reason, it is possible to realize a deep drawing and a complicated shape that are difficult to achieve when using metal, and various designs are possible.

In the case of a molded product such as an insert using the metallic decorative sheet of the present invention, its appearance is affected by the color tone of the adhesive layer or another thermoplastic resin film arranged via the adhesive layer. That is, although the appearance of the molded product is completely metallic to the naked eye, it can be seen by observing with a microscope that the mesh cracks are generated in the entire metal layer, not limited to the deep drawing portion and the portion with a small radius of curvature. .

The appearance of the molded product is influenced by the color tone of the other thermoplastic resin film thereunder via the adhesive layer and the adhesive layer via the mesh cracks. Therefore, the adhesive layer or other thermoplastic resin film, pigment, dye, metal powder,
By arranging mica, silica, and the like, the appearance of the molded product can be finely adjusted, and the finished product can be made closer to the high-quality aircraft aluminum alloy-like texture and appearance.

The molded product using the metallic decorative sheet of the present invention can be made to have flexibility due to its constitution (soft plastic, elastomer, etc.), and in that case, it is easily affected by impact or the like. It can be as flexible as an indented metal product.

As the adhesive layer, one having a required adhesive force and a required heat resistance can be used, but in general, a polyurethane adhesive or the like can be used. Since the surface of the metal layer of the metallic decorative sheet of the present invention is protected by the resin film, its oxidation is prevented and the initial appearance and texture are maintained.

To prepare a shell for an attache case using the metallic decorative sheet of the present invention, a metallic decorative sheet having a four-layer structure shown in the model cross-sectional view of FIG. 2 is used, and the resin is provided on the other thermoplastic resin film side. It is possible to be integrated with a layer, an MDF (mid-density fiber) base material, a layer made of metal, or the like, which has a strength required as a shell for a case such as a business case, by adhesion or integral molding. However, considering the lightness required as a shell for a business case and the freedom of design, it is desirable to integrally form a resin layer having a thickness of about 1 to 10 mm.

The case shell to which the present invention can be applied is not limited to a business case but may be, for example, a personal computer case, a camera / video case, a travel case,
Examples include shells for school bags, casual bags, various measuring / measuring devices, communication devices, tool boxes, instrument cases, and other cases.

As a method for forming such a shell for a case, specifically, the metallic decorative sheet of the present invention is formed into a desired shape in advance by vacuum forming or the like, and the sheet is put into a mold cavity as an insert, and then a resin layer is formed. Is preferable because it has a high degree of design freedom and is easy to manufacture.

As the resin constituting this resin layer, if the same thermoplastic resin film as that of the metal decorative sheet of the present invention (having a four-layer structure shown in the model sectional view of FIG. 2) is used. Although it is desirable to integrate it with other resin films, it is necessary to satisfy various performances required as a shell for business cases such as impact resistance, heat resistance, and cold resistance. As such, ABS (Acrylonitrile-butadiene-styrene copolymer), P
Examples include P (polypropylene) and PC (polycarbonate).

The shell is an outer plate that forms the outer shell of a bag (bag) or case, and is usually formed of a curved plate as described above, but is formed of a plurality of members (for example, a flat plate and a frame). However, the case where the metallic decorative sheet of the present invention is applied to the surface of the member forming these shells is also included in the case shell of the present invention. )

[0030]

EXAMPLES The metallic decorative sheet of the present invention will be specifically described below. The total light transmittance, the diffuse transmittance and the haze value (haze) are values measured according to JIS K7105, and the glossiness is measured according to the K7105 60-degree specular glossiness evaluation method.

The appearance and texture are evaluated by the monitor 10.
It was done by people. Comparison with a commercially available air craft aluminum alloy attache case (unused item, silver (unpainted), with and without hairline), 5 with the same level of texture and appearance, 3 with slightly inferior Inferiority is evaluated as 1, and a total of 45 or more is “◎”, 40 or more and 44 or less is “◯”, 30 or more and 39
The following was evaluated as “Δ” and 29 or less as “x”.

Example 1 Thickness 50 μm, total light transmittance 95%, diffuse transmittance 54%, haze 57%, gloss 18%
After performing hairline processing on one surface of the polymethylmethacrylate (PMMA) film (having a rubber-containing polymer added as a filler), a thickness of 55 nm is applied to the hairline processed surface by vacuum deposition. The aluminum layer was formed to obtain a metal-like decorative sheet A of the present invention having a two-layer structure.

Further, 2 is formed on the surface of the obtained aluminum layer.
Liquid curing type polyurethane adhesive with a thickness of 300
By a dry lamination with a sheet of acrylonitrile-butadiene-styrene copolymer (ABS) having a thickness of μm, a metallic decorative sheet according to the present invention having a four-layer structure was obtained.

An ABS sheet having a thickness of 0.3 mm (for forming a resin layer as a shell structure material) is further formed on the ABS sheet side of the metallic decorative sheet according to the present invention having a four-layer structure by an extrusion laminating method. ) Is laminated, and the obtained composite sheet is vacuum-formed to produce an attache case shell having a shape substantially similar to that of the aircraft aluminum alloy attache case. When the cross section of the shell for this attache case was observed, the ABS sheet of the metallic decorative sheet A and the ABS sheet as the structural material of the shell were completely integrated.

[Examples 2 to 6, Comparative Examples 1 to 5] Similar to the above examples, except that the total light transmittance was 95%, the diffuse transmittance was 54%, the haze value was 57%, and the glossiness was 18%. In place of the polymethylmethacrylate film, various commercially available thermoplastic resin films were used, and shells for attaché cases were similarly prepared.

[Evaluation of Samples Produced in Examples 1 to 6 and Comparative Examples 1 to 5] Table 1 shows the properties of the films used in these examples and the evaluation results of the attach case shells (in the table). "PET" is a film made of polyethylene terephthalate, "PVdF.MMA alloy" is a polyvinylidene fluoride / polymethylmethacrylate alloy film, and "PC / PBT alloy" is a polycarbonate / polybutylene terephthalate alloy film.

[0037]

[Table 1]

It can be seen from Table 1 that when the metallic decorative sheet of the present invention is used, an excellent duralumin-like appearance and texture can be obtained.

When the attache case was actually assembled using the shell for an attache case using the above-mentioned metallic decorative sheet and tried, it was found that the attache case had the rigidity and strength necessary for the attache case while being extremely lightweight. confirmed. In addition, the conventional aircraft aluminum alloy attach case was subjected to a "bump" test that causes dents (plastic deformation), but no dents were found, and it is superior to the aircraft aluminum alloy attach case in terms of "bump" deformation. Was confirmed.

Using the four-layered metal-like decorative sheet according to the present invention produced above, it is formed into a center console panel for automobiles by vacuum forming,
After trimming unnecessary parts, we set it in the injection mold cavity and injection-molded, and obtained a panel with a futuristic impression, which is indistinguishable from that made using real duralumin. .

Further, the metallic decorative sheet A having the above-mentioned two-layer structure
Was dry-laminated with a polypropylene resin sheet (thickness: 500 μm) using a two-component curing type polyurethane adhesive to obtain a four-layered metal-like decorative sheet. When this was laminated to an MDF (Mid Density Fiber) base material by a vacuum lamination method to produce a kitchen door, a kitchen door having an impression as if it was made of duralumin was obtained. -It has a texture.

[0042]

The metallic decorative sheet of the present invention is a thermoplastic resin having a total light transmittance of 90% or more, a diffuse transmittance of 30% or more and 70% or less, a haze value of 33% or more and 78% or less, and a gloss of 40% or less. It is a metal-like decorative sheet having a structure in which a metal layer is arranged on one surface of the film, and is an excellent metal-like decorative sheet capable of imparting a duralumin-like appearance and texture.

[Brief description of drawings]

FIG. 1 is a model cross-sectional view of a metallic decorative sheet (having a two-layer structure) according to the present invention.

FIG. 2 is a diagram showing a model cross-sectional view of another metal-like decorative sheet (having a four-layer structure) according to the present invention.

Continued front page    (72) Inventor Chikatsu Akisada             3-12-1, Kachidoki, Chuo-ku, Tokyo Japan             Inside Way Block Co., Ltd. (72) Inventor Takashi Kosuge             Kodama, 1-1-12 Ueno, Taito-ku, Tokyo             Gaku Kogyo Co., Ltd. F-term (reference) 4F100 AB01B AB10 AK01A AK01C                       AK25 AK74 BA02 BA03 BA07                       BA10A BA10B BA10C EH23                       EH66 EJ811 GB90 HB00                       HB40A HB40C JB16A JB16C                       JN08A JN21A YY00A

Claims (7)

[Claims] 1. A total light transmittance of 80% or more, a diffuse transmittance of 3
A metal-like decorative sheet, characterized in that a metal layer is provided on one side of a thermoplastic resin film having a haze value of 5% or more and 80% or less, a haze value of 40% or more and 85% or less, and a glossiness of 45% or less. 2. A thermoplastic resin film having a metal layer disposed on one side thereof, and another thermoplastic resin film is further laminated on the metal layer side of the thermoplastic resin film via an adhesive layer. The metal-like decorative sheet according to claim 3. 3. A total light transmittance of 80% or more, a diffuse transmittance of 3
A method for producing a metallic decorative sheet, comprising disposing a metal layer on one surface of a thermoplastic resin film having a haze value of 5% or more and 80% or less, a haze value of 40% or more and 85% or less, and a glossiness of 45% or less. 4. The method for producing a metallic decorative sheet according to claim 3, further comprising a step of subjecting the thermoplastic resin film to a hairline process. 5. The hairline processing is performed before arranging the metal layer on the thermoplastic resin film, and is performed on the surface on which the metal layer is arranged. Manufacturing method of the metallic decorative sheet. 6. A total light transmittance of 80% or more, a diffuse transmittance of 3
5% or more and 80% or less, haze value of 40% or more and 85% or less, glossiness of 45% or less metal layer on one side
A case shell characterized in that an adhesive layer and a resin layer are arranged in this order. 7. The case shell according to claim 6, wherein the case is one of a business case, a travel case, a school bag, and a casual bag.