JP2011079273A - Method of manufacturing decorative film, and method of manufacturing decorative molded body - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a decorative film developing excellent three-dimensional designability and having processing adequacy in insert molding, and a method of manufacturing a decorative molded body using the decorative film. <P>SOLUTION: The method of manufacturing a decorative film 10 includes: an ink layer forming process forming the ink layer 12 on a base material film 11; and a thermocompression bonding process thermocompression-bonding a laminate formed by disposing a transparent film 13 with one of the surfaces irregularly formed on the base material film 11 with the ink layer 12 formed thereon, so that the irregularly processed face 13a is in contact with the ink layer 12. A method of manufacturing a decorative molded body using the decorative film 10 thus obtained is also provided. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a decorative film and a method for producing a decorative molded body using the decorative film.

For parts such as interior and exterior parts of automobiles, home appliances, OA equipment, and building materials, decorative molded bodies in which a decorative film with a metallic or wood grain pattern and a resin molded body are integrated are widely used. Has been.
As a method for producing a decorative molded body, a method of integrating a decorative film and a resin molded body by placing a decorative film in a mold cavity and injecting a molten resin into the cavity (insert molding) )It has been known. At this time, the decorative film may be three-dimensionally formed in advance along the shape of the cavity and disposed in the cavity, or may be disposed in the cavity while being planar. When it arrange | positions with a flat form, the three-dimensional shaping | molding of a decorating film and integration of a decorating film and a resin molding are performed simultaneously by injection | pouring of molten resin.

  As a decorative film used in this way, on a base film made of ABS resin (acrylonitrile-butadiene-styrene resin) or the like, from a pattern layer printed in a metallic or woody tone, and from a transparent resin such as an acrylic resin There is known a decorative film formed by sequentially forming a surface film.

The decorative film has not only processing suitability at the time of insert molding, but in recent years, it has a complex and deep color depending on the angle at which patterns such as metal and woodgrain are seen, and it is a three-dimensional image that looks three-dimensional. It is required to have design properties.
Therefore, for example, in Patent Document 1, a negative-shaped unevenness is formed on one surface of a transparent thermoplastic resin sheet material, and a coating film is formed by applying ink or paint containing a glittering material to the uneven surface. A decorative sheet is disclosed. The decorative sheet is manufactured as follows.
First, a shaping member on which positive irregularities are formed is pressed against one side of a sheet material while being heated, and negative irregularities of the irregularities of the shaping member are transferred to one side. Next, the sheet material is cooled, and then a negative-shaped unevenness transferred to the sheet material is reflected on the surface by applying ink or paint containing a glittering material to the uneven surface of the sheet material to form a coating film. A decorative sheet is obtained. The obtained decorative sheet is placed in the cavity of the mold, and the molten resin is injected into the cavity so that the coating film of the decorative sheet is in contact with the molten resin (decorated molded article). Get.

JP 2000-135756 A

However, in the decorative sheet obtained by the method described in Patent Literature 1, when the decorative molded body is manufactured by integrating with the resin molded body by insert molding, the unevenness of the decorative sheet is easily crushed or deformed. . As a result, the decorative molded body obtained could not sufficiently express the three-dimensional design of the decorative sheet.
Further, when the molten resin is injected into the cavity, the molten resin is not sufficiently filled into the concave portions constituting the concave and convex portions of the decorative sheet, and the adhesion between the decorative sheet and the resin molded body may be lowered.

  The present invention has been made in view of the above circumstances, a method for producing a decorative film capable of expressing excellent three-dimensional design properties and having processing suitability during insert molding, and a decorative molded body using the decorative film A manufacturing method is provided.

The method for producing a decorative film of the present invention includes an ink layer forming step of forming an ink layer on a base film, and a transparent film having one surface of which an uneven surface is processed on the base film on which the ink layer is formed. It is characterized by having a laminated body in which the uneven surface is in contact with the ink layer, and a thermocompression bonding step of thermocompression bonding the laminated body.
The ink layer forming step is preferably performed by transferring the ink layer onto a substrate film from a transfer film having a release film and an ink layer formed on the release film.

Furthermore, the thermocompression bonding step is preferably performed by placing a transparent surface film on the surface of the transparent film opposite to the concavo-convex surface.
The surface film preferably has a transparent pattern layer formed on the surface on the transparent film side.
Further, the thermocompression bonding step includes a pair of heating rolls, a pair of cooling rolls provided on the rear stage side of the heating rolls, and wound around the same side of the heating rolls and the cooling rolls. This is performed using a thermocompression bonding means provided with a pair of endless metal belts that are pressing surfaces that sandwich and press the laminated body, and a pair of pressurizing units that act so that the pressing surfaces of the endless metal belts approach each other. It is preferable.

  Further, in the method for producing a decorative molded body of the present invention, the decorative film produced by any one of the methods described above is disposed in a cavity of a mold, molten resin is injected into the cavity, It has the integral molding process which fuse | melts and integrates the resin molding which consists of molten resin to the surface at the side of the base film of a decorating film.

According to the method for producing a decorative film of the present invention, it is possible to produce a decorative film that can exhibit excellent three-dimensional design properties and has processing suitability during insert molding.
Moreover, according to the manufacturing method of the decorative molded body of this invention, the decorative molded body which can express the outstanding three-dimensional design property can be manufactured.

It is sectional drawing which shows an example of the decorating film obtained by this invention. It is a schematic block diagram which shows an example of the apparatus used with the manufacturing method of this invention. It is a schematic block diagram which shows the thermocompression-bonding means in FIG. It is sectional drawing which shows the other example of the decorating film obtained by this invention. It is sectional drawing which shows an example of the decorative molded body obtained by this invention.

Hereinafter, the present invention will be described in detail with reference to the drawings.
Drawing 1 is a sectional view showing an example of a decoration film manufactured with a manufacturing method of a decoration film of the present invention. The decorative film 10 of this example was formed on the base film 11, the ink layer 12 formed on the base film 11, and the ink layer 12, and the surface on the ink layer 12 side was processed to be uneven. A transparent film 13 and a transparent surface film 14 formed on the transparent film 13 are provided.
2 to 5, the same components as those in FIG.
In the present invention, “transparent” means that the visible light transmittance is 80% or more.

  There is no restriction | limiting in particular as a material of the base film 11, For example, ABS resin, polyvinyl chloride (PVC) resin, polypropylene (PP) resin, polyethylene (PE) resin etc. are mentioned. Moreover, you may use the laminated film of several resin, such as PP / PET (polyethylene terephthalate), for example. As described above, the decorative film 10 is integrated with the resin molded body by insert molding or the like. Considering the adhesion to the resin molded body, it is preferable to use the same material as the material of the resin molded body as the material of the base film 11.

  The thickness of the base film 11 can be set as appropriate according to the type of resin, but when an ABS resin film having a thickness in the range of 0.2 to 0.8 mm is used, the obtained decorative film 10 is used as an automobile. When used for interior such as a front panel, it is preferable because it is easy to be integrally formed with an automobile interior base material (resin molded body) and is excellent in recyclability when disused.

The ink layer is formed from a paint used in a printing method or an image forming method. The paint contains a binder component, a pigment, and a solvent.
The binder component is not particularly limited as long as it can be used as a binder component such as gravure ink, screen ink, paint, etc., for example, acrylic, vinyl chloride, vinylidene chloride, vinyl chloride-vinyl acetate, ethylene- Various resins such as vinyl acetate, urethane-based, polyester-based, polyelephine-based, chlorinated olefin-based, polyamide-based, urea-based, epoxy-based, and cellulose derivative-based resins can be used, and one or more of these can be used.

  As the pigment, general pigments used in paints can be used. Examples include bright materials such as aluminum; colored pigments such as titanium and carbon; extender pigments such as calcium carbonate, talc and mica; and pearl pigments. Among them, if a glittering material is used as a pigment, a decorative film that has glitter and can exhibit more excellent three-dimensional design properties can be obtained. Further, when a glitter material and a pigment other than the glitter material are used in combination, it is easy to develop a desired color while having a glitter property.

Examples of the bright material include aluminum, metals such as copper and nickel, and alloys of copper / zinc / iron and iron / chromium / nickel / molybdenum. Among these, aluminum is preferable.
The size of the glittering material is not particularly limited, but is preferably 1 to 20 μm in the form of flakes and uniformly dispersed and arranged from the viewpoint of expressing higher glitter.

  The solvent is not particularly limited as long as it can be used as a solvent for paints. For example, mineral spirits, aliphatic hydrocarbons such as hexane, heptane, cyclohexane and octane, and aromatic hydrocarbons such as benzene, toluene and xylene. , Halogenated hydrocarbons such as chlorobenzene, trichlorobenzene, perchlorethylene and trichloroethylene, alcohols such as methanol, ethanol, n-propyl alcohol and n-butanol, and ketones such as n-propanone, 2-butanone and methyl ethyl ketone , Esters such as ethyl acetate and propyl acetate, ethers such as tetrahydrofuran, diethyl ether and ethyl propyl ether, and other turpentine oils, and one or more of these can be used.

As shown in FIG. 1, the transparent film 13 has an uneven surface on the ink layer 12 side.
As for the depth (D) of the uneven part of the unevenness | corrugation of the transparent film 13, 1 micrometer or more is preferable. If the depth (D) of the concave portion is 1 μm or more, the light is easily irregularly reflected by the unevenness of the transparent film 13, and excellent three-dimensional design properties can be expressed. The three-dimensional design property due to irregular reflection of light is more easily expressed as the depth (D) of the concave portion is deeper. However, if the depth is too deep, the ink layer 12 and the transparent film 13 tend to be difficult to be thermocompression bonded. It will be difficult to get inside. Therefore, the upper limit value of the depth (D) of the recess is preferably 30 μm or less.
In addition, the depth (D) of a recessed part is an average value of the depth of 10 arbitrarily selected recessed parts.

Moreover, as for the space | interval (W) of an uneven | corrugated recessed part, 1-200 micrometers is preferable. If the distance (W) between the recesses is within the above range, the design can be maintained well.
The “interval between recesses” refers to the distance from the center of the recess to the center of the adjacent recess, and is an average value of the interval between 10 arbitrarily selected recesses.

The method for uneven processing is not particularly limited, and examples thereof include embossing and hairline processing.
Direct embossing is particularly preferred when embossing is employed. In a general embossing process, an uneven pattern is transferred to the film surface by embossing a transparent film using a mold having a desired uneven shape, but the uneven surface is restored to its original state by heating. In some cases, so-called surface return may occur. On the other hand, in direct embossing, a resin having a desired concavo-convex shape is poured into a mold or the like as a raw material for a transparent film to solidify the raw material to form a film, and at the same time, the concavo-convex shape of the mold is transferred to the film surface. Therefore, in the case of direct embossing, the uneven surface is difficult to return even when heated, and the uneven shape can be maintained better.
The uneven shape is not limited to a cone (cone or pyramid) shape as shown in FIG. 1, and may be, for example, a column (column or prism).

Examples of the material of the transparent film 13 include polycarbonate (PC) resin, acrylic resin, PVC resin, fluororesin (polyvinylidene fluoride, etc.), PP resin, PE resin, and other transparent resins. Among them, a film obtained from a PC resin or an acrylic resin is preferable in that it does not easily return to the surface. However, since these resins are slightly inferior in workability, it is preferable to use a resin having a low melting point such as a PET resin.
A commercially available film may be used as the transparent film 13 whose surface is uneven. For example, “DCP50HL-22” manufactured by Goyo Paper Co., Ltd. is suitable.

The surface film 14 is a film having transparency that allows the ink layer 12 to be visually recognized through the transparent film 13 when the decorative film 10 is formed.
As the material of the surface film 14, acrylic resin, urethane resin, fluororesin, or the like can be used. A laminated film in which a plurality of films made of these resins are laminated may be used.
Although the thickness in particular of the surface film 14 is not restrict | limited, It is preferable from the point of a weather resistance, a moldability, and workability as it is 50-250 micrometers.

  As shown in FIG. 1, the decorative film 10 obtained according to the present invention has a surface on the ink layer 12 side of the transparent film 13 that has been subjected to uneven processing (hereinafter, the uneven surface is referred to as an “uneven surface 13a”). .) When the ink layer 12 enters the concave and convex portions formed by the concave and convex processing, the light passing through the surface film 14 is irregularly reflected by the concave and convex portions of the transparent film. As a result, the decorative film 10 emits a complex and deep color depending on the viewing angle, and becomes three-dimensional and exhibits excellent three-dimensional design.

Here, an example of the manufacturing method of the decorative film 10 shown in FIG. 1 is demonstrated using FIGS.
The method for producing a decorative film of the present invention includes an ink layer forming step of forming an ink layer on a base film, and a transparent film having one surface of which an uneven surface is processed on the base film on which the ink layer is formed. And a thermocompression bonding step of thermocompression bonding the laminate.

  The ink layer forming step is a step of forming an ink layer on the base film. In the ink layer forming step, an ink layer may be formed on the base film by various printing methods and image forming methods. However, when the base film is made of a resin having no printing suitability such as an ABS resin. The ink layer forming step is preferably performed as follows. That is, the ink layer is transferred onto a base film from a transfer film having a release film and an ink layer formed on the release film.

Here, as the transfer film, a clear ink layer can be formed and the releasability is good and the transfer is easy. Therefore, a PET film having a thickness of 0.01 to 0.05 mm is used as a release film, and various printing methods are used. Or an ink layer printed on the entire surface by an image forming method is preferred.
As the release film, other than PET, other resin films such as polyester resin, polyolefin resin, polyvinyl chloride resin, and fluorine resin may be used, or a laminated film of a plurality of resins may be used.

The ink layer is formed on the release film by a printing method or an image forming method using the above-described paint containing a binder component, a pigment, and a solvent.
Examples of printing methods include gravure printing method, gravure offset printing method, offset printing method, dry offset printing method, flexographic printing method, letterpress printing method, screen printing method, inkjet printing method, electrostatic printing method, etc. Examples of the method include various coating methods such as a roll coating method, a gravure coating method, a knife coating method, a lip coating method, a die coating method, and a comma coating method, a photolithographic method, an electrophotographic method, and a transfer method.

  The thickness of the ink layer formed on the release film is preferably 0.5 to 20 μm. If the thickness of the ink layer is 0.5 μm or more, the ink layer can sufficiently enter the recesses forming the irregularities on the surface of the transparent film, and the recesses can be filled with the ink layer. On the other hand, when the thickness of the ink layer is 20 μm or less, the handling property of the transfer film, the handling property and the workability of the substrate film with an ink layer described later can be maintained well. In addition, the cohesive strength of the ink can be maintained.

When forming an ink layer on a base film using a transfer film, specifically, it is performed as follows.
As shown in FIG. 2, the base film 11 is fed out from the first supply roll 20, while the transfer film 21 having an ink layer formed on one side of the release film is fed out from the second supply roll 22. Next, the base film 11 and the transfer film 21 are supplied to the laminating apparatus 23 in a state where the ink layer (not shown) formed on the transfer film 21 is in contact with the base film 11, and the ink layer is supplied. Transferred to the surface of the base film 11. Next, the substrate film (substrate film with an ink layer) 11 ′ to which the ink layer has been transferred is cooled by a cooling roll 24, while the release film 21 ′ from which the ink layer has been separated is collected by a winder 25. Here, the feeding speed of the first supply roll 20 and the second supply roll 22 is 4 to 5 m / min.

In this example, the laminating apparatus 23 includes four single rolls 23a, 23b, 23c, and 23d, and a pair of transfer rolls 23e and 23f, and the base film 11 and the transfer film 21 include the single rolls 23a, 23b, 23c, After being heated to a predetermined temperature by 23d, the ink layer is transferred by being sandwiched between transfer rolls 23e and 23f.
Here, the single roll indicated by reference numeral 23a is at 30 to 80 ° C. so as not to deform the printing surface, the single roll indicated by reference numeral 23b is at 100 to 170 ° C., and the single roll indicated by reference numeral 23c is a single roll indicated by reference numeral 23d. It is preferable that the temperature is higher than that of the single roll 23f, and more specifically 130 ° C to 200 ° C. It is preferable that the single roll shown by the code | symbol 23d shall be 100-150 degreeC. The transfer roll 23e on the side in contact with the transfer film 21 is at room temperature.
In addition, the temperature of these rolls 23a, 23b, 23c, 23d, 23e, and 23f can be appropriately changed when the positions of the base film 11 and the transfer film 21 are reversed.

  The thus obtained base film 11 ′ with an ink layer is preheated by three single rolls 26a, 26b, and 26c controlled to 110 ± 5 ° C., and then supplied to the thermocompression bonding means 30 for thermocompression bonding. A process is performed.

  In the thermocompression bonding step, a transparent film having one surface with unevenness is arranged on the substrate film 11 ′ with an ink layer so that the unevenness surface is in contact with the ink layer to form a laminate. Is a step of thermocompression bonding. In that case, as shown in FIG. 1, it is preferable to arrange | position the transparent surface film 14 on the surface 13b on the opposite side to the uneven | corrugated processed surface 13a of the transparent film 13 and to carry out.

FIG. 3 is a schematic configuration diagram of the thermocompression bonding means 30. A heating medium oil (not shown) circulates inside and is provided at a rear stage side of a pair of heating rolls 31 heated to a predetermined temperature. A pair of cooling rolls 32 controlled to a predetermined temperature or lower, and a pair of endless metal belts 33 wound around the same side of the heating roll 31 and the cooling roll 32 are provided.
Here, the opposed surfaces of the endless metal belt 33 are arranged with a predetermined distance from each other, and are respectively made of pressing surfaces 33a and 33b made of stainless steel having a mirror finish. Further, the thermocompression bonding means 30 is further provided with a pair of pressurizing means 34 that act so that the pressing surfaces 33a and 33b approach each other by press-fitting a fluid pressure medium such as hydrocarbon synthetic oil, The pressure when the pressing surfaces 33a and 33b are brought closer to each other can be controlled by changing the supply amount of the fluid pressure medium to be pressed, and the surface temperature of the pressing surfaces 33a and 33b can be controlled by changing the temperature of the fluid pressure medium. It has become. The pair of pressurizing means 34 in this example is divided into a front stage side 34a and a rear stage side 34b, and the supply amount and temperature of the fluid pressure medium can be independently controlled for each. Moreover, since the pressing surfaces 33a and 33b are made of stainless steel having a mirror finish, the surface film 14 can be mirror finished.

  In the thermocompression bonding step, 110 ± 5 after being fed from the base film 11 ′ with the ink layer and the third supply roll 27 so as to be sandwiched between the pressing surfaces 33a, 33b facing the endless metal belt 33. A transparent film 13 that is preheated by a single roll 29 ° C. and has an uneven surface on the side in contact with the ink layer of the base film 11 ′ with an ink layer, and a surface film 14 that is fed from a fourth supply roll 28. Supply.

  Then, these three films are laminated, and this laminated body 10 ′ is uniformly heated to about 150 to 200 ° C. by the endless metal belt 33 heated by the heating roll 31. Next, a fluid pressure medium whose temperature is controlled to be equal to or lower than the heat deformation temperature of the resin forming the transparent film 13 is pressed into the front side 34a and the rear side 34b of the pressurizing means 34, and the pressing surfaces 33a and 33b approach each other. Then, the laminated body 10 ′ is sandwiched, pressed and molded at a pressure of about 1.8 to 3.5 MPa, and then cooled by the cooling roll 21.

As a result, the surface of the base film 11 ′ with the ink layer on which the ink layer is formed is in contact with the uneven surface, and the transparent film 13 is thermocompression bonded, and the opposite surface of the transparent film 13 is opposite to the uneven surface. The surface film 14 is thermocompression bonded to the surface.
Next, the laminated body 10 ′ is sent to the pair of cooling rolls 32 while being sandwiched between the pressing surfaces 33 a and 33 b, and is uniformly cooled to 70 ° C. or less by the action of the cooling rolls 32.
As a result, the decorative film 10 in which the ink layer 12 is formed on the base film 11 and the transparent film 13 and the surface film 14 are sequentially laminated as shown in FIG. 1 is obtained.

  As described above, in the thermocompression bonding process, when the laminate 10 ′ is heated by the endless metal belt 33 and is sandwiched and pressed by the pressing surfaces 33 a and 33 b, ink is formed in the recesses that form the unevenness on the surface of the transparent film 13. Since the thermocompression bonding is performed while the layer enters, the unevenness is reinforced by the ink layer. Therefore, it is possible to keep the concavo-convex shape well without causing the concavo-convex of the transparent film to be crushed or deformed in the thermocompression bonding step. As a result, the decorative film which can diffusely reflect the light which passed the surface film 14 with the unevenness | corrugation of the transparent film 13, and can express the outstanding three-dimensional design property is obtained.

Moreover, the decorative film 10 obtained is normally integrated with a resin molded body by insert molding and used as a decorative laminate. Although temperature and pressure are applied at the time of insert molding, the unevenness of the transparent film 13 is reinforced by the ink layer entering the recess, so that the unevenness of the transparent film 13 is not easily crushed or deformed at the time of insert molding.
In insert molding, the decorative film is placed in the cavity of the mold, and the molten resin is injected into the cavity so that the surface on the base film side is in contact with the molten resin. Unlike the decorative sheet described in Patent Document 1, the surface of the base film in contact with the molten resin has no irregularities, so that the molten resin can easily spread on the surface of the base film, A decorative molded body having excellent adhesion to the resin molded body is obtained.
Therefore, the decorative film 10 obtained according to the present invention is suitable for insert molding because it has processing suitability during insert molding. In addition to the insert molding, the decorative film can be applied to so-called TOM molding, for example, in which a resin molded body is prepared in advance and used instead of a mold.

  The decorative film 10 obtained according to the present invention can exhibit excellent three-dimensional design properties even if the surface film 14 is not provided, and has processing suitability at the time of insert molding, but the surface film 14 is provided on the transparent film 13. Thereby, since the surface film 14 plays the role of a protective film, the resistance (weather resistance, chemical resistance, water resistance, etc.) of the decorative film 10 is improved.

  Moreover, the decorative film 10 obtained by this invention is not limited to what was mentioned above, For example, even if the transparent design layer 15 is formed in the surface at the side of the transparent film 13 of the surface film 14 as shown in FIG. Good. When the pattern layer 15 is formed, the unevenness of the transparent film 13 and the ink layer 12 are seen through the pattern layer 15. Therefore, the pattern formed by the pattern layer 15 and the irregular reflection that occurs due to the unevenness of the transparent film 13 combine to provide a decorative film that is more complex and deep and has excellent three-dimensional design.

  In order to form the pattern layer 15 between the transparent film 13 and the surface film 14, the pattern layer 15 is formed in a desired pattern on one surface of the surface film 14 in advance by various printing methods or image forming methods. Pattern printing may be performed, and this may be arranged so that the pattern layer 15 is in contact with the transparent film 13, and a thermocompression bonding process may be performed.

  When the surface film 14 is made of a resin that does not have printing suitability, the pattern layer 15 may be formed on one surface of the surface film 14 in the same manner as the ink layer forming step as described above. That is, the design layer is transferred onto the surface film from a transfer film having a release film and a design layer formed on the release film. What is necessary is just to use what transferred the pattern layer to the transfer film by the printing method and image formation method which were mentioned above on the peeling film.

The ink for forming the pattern layer 15 is not particularly limited as long as it is transparent, and ordinary paints used in the printing method and image forming method described above can be used.
The thickness of the pattern layer 15 is preferably 0.5 to 10 μm.

In addition, the manufacturing method of the decorating film of this invention is not limited to the method mentioned above. For example, although the thermocompression bonding process has been described using a double belt press device provided with a heating roll and a cooling roll as shown in FIG. 3, the present invention is not limited to this, and a batch press device or a pair of heating rolls is used. A thermocompression bonding step may be performed.
However, in the case of a batch type press apparatus, workability tends to be lowered and productivity is inferior. Moreover, since the decorative film of the magnitude | size exceeding the processing limit of a press apparatus cannot be manufactured, size adaptability is also scarce.

On the other hand, when thermocompression bonding is performed with a pair of heating rolls, a decorative film can be produced continuously and efficiently, but there are concerns about the following.
The pair of heating rolls are metal rolls in which one roll is heated to a high temperature, and the object (laminated body) is thermocompression bonded while applying heat or pressure when passing through the heating roll. And although it cools, after pulling out the thermocompression-bonded laminated body from a heating roll, since a metal roll is heated at high temperature, a laminated body does not peel easily from a metal roll. Therefore, when pulling out the laminated body from the heating roll, it is necessary to pull the laminated body with a force sufficient to peel it off from the metal roll, but excessive force is easily applied to the unevenness of the transparent film, and the unevenness may be crushed. . When the unevenness is crushed, sufficient three-dimensional design properties are hardly expressed.

On the other hand, the double belt type pressing apparatus as shown in FIG. 3 can uniformly heat the object by the endless metal belt 33 heated by the heating roll 31, and presses it with a uniform pressure by the action of the pressurizing means 34. Since it can cool and a decorative film can be manufactured continuously and efficiently, it is suitable for manufacture of a decorative film.
Moreover, when laminated body 10 'passes the heating roll 31, since the pressure and temperature which are thermocompression-bonded are not applied, laminated body 10' leaves | separates easily from the heating roll 31 (peeling off). Therefore, the laminate 10 ′ is pulled out from the heating roll 31 without applying excessive force to the unevenness of the transparent film 13. Further, when the laminated body 10 ′ passes through the cooling roll 32, the laminated body 10 ′ is cooled and easily separated from the cooling roll 32. Therefore, the laminated body 10 ′ is pulled out from the cooling roll 32 without applying excessive force to the unevenness of the transparent film 13. Even if an excessive force is applied to the unevenness of the transparent film 13, the unevenness is reinforced by the ink layer, so that it is difficult to be crushed or deformed.

Note that the pressurizing means 34 shown in FIG. 3 does not have to be a type that uses a fluid pressure medium as in this example, or may not be a type that is divided into the front side 34a and the rear side 34b. Good.
Further, in the above description, the case where the surface film 14 is mirror-finished by using the mirror-finished pressing surfaces 33a and 33b is exemplified. However, the mirror-finishing may be performed as necessary and is not necessarily performed. It does not have to be.

According to the method for producing a decorative film of the present invention described above, an ink layer is previously formed on a base film, and a transparent film is arranged on the ink layer so that the uneven surface is in contact with each other to form a laminate. The laminated body is thermocompression bonded. At that time, since the ink layer is thermocompression bonded into the concave portions constituting the concave and convex portions on the surface of the transparent film, the concave and convex portions are reinforced by the ink layer. Therefore, it is possible to keep the concavo-convex shape well without causing the concavo-convex of the transparent film to be crushed or deformed in the thermocompression bonding step. As a result, the decorative film can be obtained in which the light that has passed through the surface film can be irregularly reflected by the unevenness of the transparent film and can exhibit excellent three-dimensional design.
Moreover, when the decorative film of the present invention thus obtained is integrated with a resin molded body by insert molding or the like to form a decorative molded body, the unevenness of the transparent film is not easily crushed or deformed. Therefore, the decorative film has processing suitability at the time of insert molding.

The decorative film of the present invention thus obtained is integrated with a resin molded body by insert molding or the like, and used, for example, as a decorative molded body 40 shown in FIG.
Specifically, the decorative film 10 is disposed in a cavity of a mold, a molten resin is injected into the cavity, and a resin molded body 41 made of the molten resin is formed on the surface of the decorative film 10 on the base film side. The decorative molded body 40 is obtained through an integral molding process for fusing and integrating the two.
Examples of the molten resin include ABS resin, PVC resin, PP resin, and PE resin.

The conditions (temperature and pressure) at the time of insert molding are not particularly limited, and may be set as appropriate depending on the type of molten resin.
Although temperature and pressure are applied at the time of insert molding, the unevenness of the transparent film 13 constituting the decorative film 10 is reinforced by the ink layer entering the recess, so that the unevenness of the transparent film 13 is crushed at the time of insert molding. Or difficult to deform. Therefore, the obtained decorative molded body 40 can exhibit excellent three-dimensional design properties.
Moreover, in the case of insert molding, molten resin is inject | poured in a cavity so that the surface by the side of the base film of a decorating film and molten resin may contact | connect. Unlike the decorative sheet described in Patent Document 1, the surface of the base film in contact with the molten resin has no irregularities, so that the molten resin can easily spread on the surface of the base film, A decorative molded body having excellent adhesion to the resin molded body is obtained.

In addition, as a method of manufacturing a decorative molded body, it is not limited to the method mentioned above, for example, producing a resin molded body previously and manufacturing this resin molded body and a decorative film by thermocompression bonding through an adhesive May be. Alternatively, a decorative molded body may be manufactured by a TOM molding method in which a resin molded body is prepared in advance and used instead of a mold.
The decorative molded body of the present invention thus obtained can be used for various applications such as home appliances, OA equipment, and building materials in addition to automobile interior and exterior parts.

Hereinafter, the present invention will be specifically described with reference to examples.
[Example 1]
The decorative film 10 of FIG. 1 was manufactured using the apparatus shown in FIGS. 2-3 and the film material shown below.
That is, the base film 11 and the transfer film 21 are supplied to the laminating apparatus 23 in a state where the ink layer formed on the transfer film 21 is in contact with the base film 11, and the ink layer is supplied to the base film 11. The film was transferred to the top to obtain a substrate film 11 ′ with an ink layer. The release film 21 ′ of the transfer film 21 was collected by a winder 25.
Subsequently, the base film 11 ′ with the ink layer was cooled by the cooling roll 24 and supplied to the thermocompression bonding means 30. Then, the transparent film 13 is arranged on the ink layer of the base film 11 ′ with the ink layer so that the uneven surface is in contact with the pressing surface 33a, 33b facing the endless metal belt 33. Further, the surface film 14 was disposed on the transparent film 13, and these (laminated body 10 ′) were heated by the endless metal belt 33 heated by the heating roll 31. Next, the pressing surfaces 33a and 33b are brought close to each other by the pressing means to sandwich the laminated body 10 ′, pressed and molded, and cooled by the cooling roll 32 to obtain the decorative film 10 shown in FIG. .
In addition, the various conditions of an apparatus and the manufacturing method of the decorative film 10 are as having described previously.
The obtained decorative film was able to express excellent three-dimensional design properties.

Next, after placing the obtained decorative film 10 in the cavity of the mold, the ABS resin is injected into the cavity so that the molten ABS resin contacts the base film 11 side of the decorative film 10, The decorative molded body in which the decorative film 10 was provided on the surface was manufactured.
The obtained decorative molded body was able to sufficiently express the three-dimensional design of the decorative film. Moreover, the decorative film 10 had processing suitability at the time of insert molding.

Here, the film material used in Example 1 is shown below.
1) Base film 11: ABS resin film (F975BR448) manufactured by Shin-Etsu Polymer Co., Ltd., thickness 0.36 mm.
2) Transparent film 13: PC / PET direct embossed film (DCP50HL-22) manufactured by Goyo Paper Industries Co., Ltd., thickness 0.05 mm, recess depth 2.7 μm.
3) Surface film 14: acrylic resin film (S001) manufactured by Sumitomo Chemical Co., Ltd., thickness 0.075 mm.
4) Transfer film 21: Metallic silver solid printing TP film (film in which metallic silver (ink layer) is printed on the entire surface of TP film (peeling film)) manufactured by Nippon Decor Co., Ltd., and the thickness of the ink layer is 5 μm.

[Comparative Example 1]
A decorative film and a decorative molded body were produced in the same manner as in Example 1 except that the transparent film 13 was not used. The obtained decorative film and decorative molded body did not exhibit three-dimensional moldability.

  10: decorative film, 10 ': laminate, 11: substrate film, 12: ink layer, 13: transparent film, 13a: uneven surface, 14: surface film, 15: pattern layer, 30: thermocompression bonding means, 31: heating roll, 32: cooling roll, 33: endless metal belt, 33a, 33b: pressing surface, 34: pressurizing means, 40: decorative molded body, 41: resin molded body.

Claims (6)

  An ink layer forming step for forming an ink layer on the base film, and a transparent film having one surface with an uneven surface on the base film on which the ink layer is formed are arranged so that the uneven surface is in contact with the ink layer. A laminated body, and a thermocompression bonding step of thermocompression bonding the laminated body.   The ink layer forming step is performed by transferring the ink layer onto a base film from a transfer film having a release film and an ink layer formed on the release film. The manufacturing method of the decoration film of description.   The method for producing a decorative film according to claim 1, wherein the thermocompression bonding step is performed by arranging a transparent surface film on a surface opposite to the uneven surface of the transparent film.   The method for producing a decorative film according to claim 3, wherein the surface film has a transparent pattern layer formed on the surface on the transparent film side.   The thermocompression bonding step includes a pair of heating rolls, a pair of cooling rolls provided on the rear side of the heating rolls, and the opposite surfaces of the laminated body that are wound around the same side of the heating rolls and the cooling rolls. A pair of endless metal belts that are pressing surfaces that sandwich and press and a pair of pressurizing units that act so that the pressing surfaces of the endless metal belts approach each other. The manufacturing method of the decorating film in any one of Claims 1-4 characterized by the above-mentioned.   The decorative film manufactured by the method according to any one of claims 1 to 5 is placed in a cavity of a mold, molten resin is injected into the cavity, and the base film side of the decorative film is placed. A method for producing a decorative molded body, comprising an integral molding step of fusing and integrating a resin molded body made of a molten resin on a surface.

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