JP2002036437A - Outside plate decorating film, its manufacturing method and method for using the same as well as decorating outside plate, its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an outside plate decorating film not suffering matting or blushing even by shaping a component to a complicated shape and a decorating outside plate using the decorating film. SOLUTION: The outside plate decorating film 1 comprises a guard film 2 of a first layer, a photosetting clear layer 3 of a second layer, a laminated structure of an adhesive colored layer 4 of a third layer so that the clear layer is a semicured state. The decorating outside plate is obtained by shaping the film 1 to an outside plate to be decorated, and then emitting an ultraviolet ray to cure the layer 3.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative film for an outer panel used instead of coating the outer panel of an industrial product such as an automobile, and more particularly to a decorative film which is excellent in appearance even when used on a curved surface having a large curvature. The present invention relates to a decorative film for an outer panel, which can reduce the cost required for the outer panel.

[0002]

2. Description of the Related Art A decorative film for an outer plate is a film which is attached to an outer plate instead of painting the outer plate of an automobile, and a conventional decorative film for an outer plate as shown in FIG. 4 is used. Was. FIG. 4 is a cross-sectional view showing a state in which a conventional outer panel decorative film is attached to the outer panel.

As shown in FIG. 4, the conventional decorative film for outer panel 100 has a laminated structure including a backing sheet 101 as a first layer, a colored layer 102 as a second layer, and a clear layer 103 as a third layer. Was. The backing sheet 101 is a film serving as a base of the outer-plate decorative film 100, and is made of the same type of material as a material of a component to be decorated, for example, a resin component such as a bumper or a garnish. The coloring layer 102 is a coloring layer containing a pigment, and the clear layer 103 is a transparent resin layer for protecting the coloring layer and providing gloss. Such an outer plate decorative film is formed into a component shape by in-mold molding or vacuum molding, and the backing sheet 101 is bonded to the outer plate 105 by heat-sealing.

[0004]

However, the above-mentioned conventional decorative film for an outer panel has the following problems. When shaping a conventional outer sheet decorative film into a part, heat and soften a flat sheet that has already been cured,
They were shaped into parts. Therefore, due to the thickness of the sheet and the layer configuration of having the backing sheet, abrupt changes in shape, such as whitening of the backing sheet and local elongation of the clear layer occur when shaped into a part having a convex portion, a deep drawing shape, or the like. There was something. The whitening of the backing sheet causes color unevenness, and the local elongation of the clear layer causes luster. Therefore, there was a problem that the conventional decorative film for outer plate tends to cause poor appearance.

[0005] In addition, since it is necessary to heat and mold the outer decorative film which has already been cured, the cost of parts increases. Furthermore, unless the material of the decorated outer plate is made of the same type as that of the backing sheet, a good adhesion state between the outer plate and the backing sheet cannot be obtained. Therefore, there is also a problem that the material of the component that can be decorated is limited to the same type as the backing sheet.

[0006] On the other hand, in the conventional coating such as spraying,
Dust may be attached during the drying of the paint, which may cause poor appearance. In this case, the outer plate cannot be regenerated and must be discarded.

Accordingly, the present invention solves the above problems and provides an outer plate decorative film which is excellent in appearance, has low manufacturing costs for decorative outer plates, and has less restrictions on parts materials. The aim is to provide a method. Another object of the present invention is to provide a decorative outer panel using the outer panel decorative film having the above-described features, and a method of manufacturing the same.

[0008]

In order to solve the above-mentioned problems, in the invention of claim 1, a guard film is adopted in place of the conventional backing sheet as the first layer, and a guard film and a second film are used in the first layer. The layer had a three-layer structure of a photocurable clear layer, the third layer had an adhesive layer, and the photocurable clear layer was configured to be in a semi-cured state.

With this configuration, since the light-cured clear layer is flexible at the time of shaping, local expansion of the light-cured clear layer does not occur, and defects such as gloss sink can be reduced. Further, since the adhesive coloring layer is applied to the decorative outer plate, a guard film is not required after the shaping is completed. Therefore, the material of the outer plate is not restricted by the material of the guard film. That is, by appropriately selecting the material of the adhesive coloring layer, the outer plate decorative film can be applied to various types of outer plates such as an iron plate, an aluminum plate, and a resin.

Further, since the decorative film of the present invention is flexible, it does not need to be heated at the time of shaping, and the energy consumption at the time of shaping the decorative film of the outer plate is reduced, leading to a reduction in manufacturing cost.

Next, according to the invention of claim 2, there is provided a method for manufacturing a decorative film for an outer panel according to claim 1, wherein a light-curable clear layer is laminated on the guard film, and then an adhesive coloring layer is laminated. .

By laminating the light-curable clear layer and the adhesive coloring layer on the basis of the guard film as described above, the outer plate decorative film according to claim 1 having the above-mentioned features can be obtained.

In the invention according to claim 3, in the method for using the decorative film for outer plate according to claim 1, the guard film, which protects the light-cured clear layer from being damaged during shaping, is provided.
After the photocuring of the photocurable clear layer is completed, the layer is peeled off before use of the product.

In this way, by using the decorative film for an outer plate according to the first aspect of the present invention, after the decoration of the outer plate is completed, the product is transferred to a customer's hand, and the outer plate is damaged before the product is used. There is no sticking. Further, by peeling off the guard film, the coloring of the decorative outer plate can be further improved.

According to a fourth aspect of the present invention, there is provided a decorative outer plate obtained by shaping the outer plate decorative film according to the first aspect on a decorative outer plate, and thereafter light-curing the outer plate decorative film. Was configured.

[0016] With this configuration, it is possible to perform the shaping in a soft state by making use of the features of the decorative film for an outer plate according to the first aspect, so that it is possible to prevent the clear layer from being glossy and to perform the shaping. A decorative outer panel having scratch resistance that can withstand use as an outer panel of an automobile or the like can be obtained by light curing after shaping.

According to a fifth aspect of the present invention, in the method for manufacturing a decorative outer panel, after the outer panel decorative film according to the first aspect is formed on the decorative outer panel, the photocurable clear layer is photocured. This is characterized in that a coating film is obtained by performing the above.

By manufacturing the decorative outer panel as described above, the outer panel decorative film is shaped in a flexible state and then light-cured, so that the decorative outer panel having no clear layer gloss or the like can be obtained. Obtainable.

It should be noted that the decorative film of the present invention can be used widely when it is desired to color the outer plate of an industrial product, and is not limited to the outer plate of an automobile, but can be used for various purposes such as motorcycles, ships, toys, and building materials. It can be used for outer panels.
Further, the outer plate does not necessarily mean only a plate-shaped part, but means an outer part of a part used for an appearance part, and also includes a thick part.

The decorated outer panel refers to a panel before the outer panel is colored, and corresponds to a white body in the case of an automobile body. Also, with decorative skins,
It means a colored outer plate after the decorative film is attached.

Further, the adhesive coloring layer referred to in the claims means not only a case of having a single solid color, but also a case of putting characters and other designs using a metallic color, a transparent color, and a plurality of colors. It is a meaning that includes.

The semi-cured state of the photocurable clear layer referred to in the claims is a state before cross-linking, and means a state in which the layer can be further cured by irradiating ultraviolet rays.

Forming a film means giving a film conforming to the shape of a part to a flat film.

[0024]

Next, an embodiment of the present invention will be described with reference to the drawings. First, a method for manufacturing the decorative film for outer plate of the present invention will be described. FIG. 1 is a cross-sectional view of the decorative film for outer plate of the present invention, FIG. 2 is a diagram showing a method of manufacturing the decorative film for outer plate of the present invention, (a) is a step of laminating a photocurable clear layer, (B) shows the step of laminating the adhesive coloring layer.

As the material of the photocurable clear layer 3, for example, a mixture of an acrylic polymer, an acrylic oligomer and an elastomer can be used. In this mixture, the compound of each component is kneaded, and the acrylic oligomer is dispersed in the acrylic polymer. The acrylic oligomer is excited by absorbing ultraviolet rays and polymerizes with an acrylic polymer to form an acrylic-based resin film.

The semi-cured mixture is extruded from the extruder 10 into a sheet and molded. The extruded photocurable resin sheet 3 a is further thinned by a rolling roll 11 to a thickness of 30 to 50 μm and laminated on the guard film 2. Thus far, the guard film 2 and the photocurable clear layer 3 in FIG. 1 are formed. Thereafter, the sheet on which the photocurable clear layer 3 is laminated is wound by the winding device 12. Note that the guard film 2 can be a film having good releasability from the photocurable clear layer 3 after photocuring and the adhesive coloring layer 4 when wound up. It can be used with a 50 μm polyethylene terephthalate film. The thickness of the guard film 2 can be set as appropriate,
If it is too thin, it is inconvenient to handle, and if it is too thick, shaping becomes difficult. Further, the thickness of the photocurable clear layer 3 can also be appropriately set according to the desired color, strength, and the like.

Next, the adhesive coloring layer 4 is applied to a film thickness of 20 to 30 μm by a coating device 13 such as a roll coater or a knife coater at a discharge rate of 100 g / m ² (FIG. 2).
(B)). The adhesive coloring layer 4 is a mixture in which a coloring agent that is a general pigment, an adhesive, and an adhesion promoter are dispersed. As the adhesive, for example, water-soluble nylon or acrylic emulsion can be used. Further, as the adhesion-imparting agent, an organic material containing an epoxy group or a urethane group can be used. The thickness of the adhesive coloring layer 4 can be appropriately set according to the desired color, adhesive strength, and the like.

In the state where the adhesive coloring layer is just applied, the film sticks when the film is sticky and rolled up. Therefore, the film is dried by the dryer 14 at 80 to 100 ° C. for 5 to 10 minutes. The sheet after drying is the third sheet of the present invention as shown in FIG.
It becomes the outer plate decorative film 1 of the layer. The sheet is wound by the winding device 15 and shipped.

Incidentally, all of the above steps can be manufactured by a general apparatus for manufacturing a conventional film.

Next, the step of attaching the decorative film for outer plate of the present invention to a component to be decorated will be described. 3A and 3B are diagrams showing a step of attaching the outer plate decorative film of the present invention to an injection-molded part, wherein FIG. 3A shows a step of vacuum forming the outer panel decorative film, FIG. 3B shows an injection molding step, and FIG. ) Light curing process,
(D) shows a peeling step.

In the present embodiment, an example of a step of forming the outer plate decorative film of the present invention on a resin injection molded part will be described. In FIG. 3A, the outer panel decorative film 1 is applied to the upper mold 21 with the guard film 2 facing upward, and attached to the upper mold 21 by vacuum forming. At this time, since the light-cured clear layer 3 of the outer-plate decorative film 1 is in a semi-cured state, the outer-plate decorative film 1 is easily deformed even in deep drawing as shown in FIG. be able to. Thereafter, the lower mold 22 is combined with the upper mold 21 and resin is injected from the gate 23 (FIG. 2B).

When the resin part 24 cools and hardens, the resin part 25 is taken out. In this state, the outer panel decorative film 1 is stuck to the resin portion 24. However, since the light-cured clear layer is soft as it is, it is hard to use it for parts requiring scratch resistance, such as automobile outer panels. Is inadequate.

Then, as shown in FIG. 3 (c), ultraviolet rays are applied to the resin component 25 by the ultraviolet irradiation device 26.
Then, the acrylic oligomer which is a photosensitizer is excited and radicalized. Then, the radical and the monomer combine to initiate photopolymerization to form a prepolymer. The polymer grows by repeating the bond between the radical and the monomer,
The polymerization is stopped by the recombination of the acrylic oligomer as the photosensitizer.

When the polymerization is stopped, the light-cured clear layer is sufficiently cured, and the resin component 25 becomes a decorative outer panel having scratch resistance. For this curing, for example, the ultraviolet irradiation conditions may be set to 450 to 550 mJ / cm ² in terms of the integrated light amount. When the irradiation amount is insufficient, the curing is insufficient, and when the irradiation amount is excessive, the coating film is rather deteriorated and energy is wasted.
After the light-cured clear layer is cured, the guard film 1 is peeled off to be ready for use as a product. Since the photo-curing process is an irreversible reaction, once it is cured, it does not soften again.

The embodiment of the present invention has been described above.
The present invention is not limited to the above embodiment. For example, in the above-described embodiment, a case has been described in which the outer plate decorative film of the present invention is formed on a resin injection-molded part, but the present invention can also be applied to a press-formed product of an iron plate or an aluminum plate. In this case, for example, the outer plate decorative film of the present invention may be previously laminated on an iron plate or the like before pressing, and the outer plate decorative film may be formed together with the iron plate during press forming. As another method, a decorative film for an outer plate may be pasted on one side of the mold in advance by vacuum forming, and then an iron plate or the like may be pressed and shaped.

In the above-described embodiment, the case where the decorative film of the present invention is applied to a resin component has been described. However, by appropriately adjusting the components of the adhesive coloring layer, it is possible to use any of iron plates, aluminum plates, resins, and the like. It is also possible to decorate the outer panel. For example, an adhesive agent having an epoxy group can be used for an iron plate or an aluminum plate, and an adhesive agent having a urethane group can be used for a resin-based outer plate. Even in the case of other materials, bonding can be performed by selecting a group suitable for an object to be bonded, or by using a multi-primer combined type adhesion imparting agent having a plurality of groups.

Although the conventional backing sheet is not used in the decorative film of the present invention, the decorative sheet of the present invention can be applied to a case where a component corresponding to the backing sheet is stuck on a part. Film can be used. In other words, it is conceivable that a member corresponding to the conventional backing sheet is coated on the performance of the component to be decorated, but in this case also, the material of the adhesive coloring layer is appropriately selected to be outside the scope of the present invention. A board decorative film can be used.

[0038]

As described in detail above, according to the present invention, even when used for a part having a large curvature and a complicated shape, a decorative film for an outer plate which does not cause whitening and luster and has good coloration. Can be provided (claim 1).

Further, by laminating a photocurable clear layer on the guard film and then laminating an adhesive coloring layer,
It is possible to produce a decorative film having a good coloration without whitening and glossiness (claim 2).

In addition, the guard film, which has protected the light-cured clear layer from being damaged during the shaping, is peeled off after the light-cured clear layer is completely light-cured and before use of the product. By using a decorative film, after the decoration of the outer panel is completed, the product can be delivered to the customer's hand, preventing the outer panel from being damaged before the product is used, and removing unnecessary layers. Color development can be improved (claim 3).

Further, by using the decorative film for outer plate according to claim 1 as a decorative outer plate, it is possible to provide a decorative outer plate having no whitening and luster, and having good color development. 4).

Further, after the decorative film for outer plate according to claim 1 of the present invention is formed on a decorative outer plate, the coating film is obtained by light-curing the photocurable clear layer to obtain a coating film. Because it is possible to obtain a decorative skin without coloring, and with good color development, it consumes less energy during manufacturing.
The cost of the product can be reduced (claim 5).

Further, according to the decorative film for outer plate of the present invention,
When decorating the outer plate, dust does not adhere during drying of the paint, and no defect occurs, as compared with paint such as spraying. Even if a defect occurs, the film can be peeled off and the outer plate can be reused before the photocuring, so that the yield of the paint can be improved.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a decorative film for an outer plate of the present invention.

FIGS. 2A and 2B are diagrams illustrating a process of manufacturing a decorative film for an outer plate according to the present invention, wherein FIG. 2A is a process of laminating a photocurable layer on a guard film, and FIG. Is shown.

FIG. 3 is a view for explaining a step of shaping the outer plate decorative film of the present invention into a resin part, wherein (a) is a step of vacuum forming the outer plate decorative film, (b) is an injection molding step, (C)
The photo-curing step and (d) are the peeling steps.

FIG. 4 is a cross-sectional view of an outer panel formed with a conventional outer panel decorative film.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Decorative film for outer plate, 2 ... Guard film, 3 ... Light-curing clear layer, 4 ... Adhesive coloring layer

Claims (5)

[Claims] 1. A laminated structure comprising a guard film as a first layer, a photocurable clear layer as a second layer, and an adhesive coloring layer as a third layer, wherein the photocurable clear layer is in a semi-cured state. Exterior decorative film. 2. The method according to claim 1, wherein a light-curable clear layer is laminated on the guard film, and then an adhesive coloring layer is laminated. Method of manufacturing decorative film. 3. The method for using a decorative film for an outer panel according to claim 1, wherein the guard film, which protects the light-curable clear layer from being damaged at the time of shaping, is replaced with a light-cured clear layer after the photocuring is completed. A method for using a decorative film for an outer plate, wherein the decorative film is peeled off before using the product. 4. A decorative outer panel obtained by forming the outer panel decorative film according to claim 1 on a decorative outer panel, and thereafter light-curing the outer panel decorative film. 5. A decorative outer panel, comprising: forming the outer panel decorative film according to claim 1 on a decorative outer panel, and then curing the photocurable clear layer with light. Manufacturing method.