JP2004249676A

JP2004249676A - Bright surface pattern structure and its manufacturing method

Info

Publication number: JP2004249676A
Application number: JP2003044758A
Authority: JP
Inventors: Eiji Kodama; 栄司児玉
Original assignee: Mitsubishi Plastics Inc
Current assignee: Mitsubishi Plastics Inc
Priority date: 2003-02-21
Filing date: 2003-02-21
Publication date: 2004-09-09
Anticipated expiration: 2023-02-21
Also published as: JP4391098B2

Abstract

<P>PROBLEM TO BE SOLVED: To provide a bright surface pattern structure capable of reducing the content of a bright material, making unnecessary for thickly forming a bright layer containing the bright material and developing excellent brightness. <P>SOLUTION: In the bright surface pattern structure obtained by laminating a bright pattern forming resin containing bright particles X on a base material 1 to form a bright pattern forming resin layer, unevenness 4 is formed on the surface of the bright pattern forming resin layer and the number of the bright particles X in the cross sections of protruded parts 4B of the unevenness 4 is made more than that of the bright particles X in the cross sections of the recessed parts 4A of the uneveness 4 to enhance the brightness of a pattern surface. The number of the bright particles in the cross sections of the protruded parts is increased by making the surface of the bright pattern forming resin layer uneven to collectively enhance the brightness of the protruded parts and the brightness of the pattern surface can be enhanced as compared with the bright pattern forming resin layer containing the same amount of the bright particles and having a flat surface. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

【０００１】
【発明の属する技術分野】
本発明は、基材表面に付与する表面模様構造に関し、詳しくは、光輝性を備えた表面模様構造及びその製造方法に関する。
【０００２】
【従来の技術】
光輝性を付与してなる表面模様構造或いはそのための樹脂組成物としては、例えば特許文献１（特公昭５９―４４２５５号公報）には、装飾層にパール顔料を所定量混入した変性ポリオレフィン樹脂を用い、着色層に着色したポリオレフィン樹脂を用い、被覆層に透明な熱可塑性樹脂を用いてなる多層構造成形品が開示されている。
【０００３】
特許文献２（特開昭５８−３７０４５号公報）には、ＡＢＳ樹脂とＡＳ樹脂の混合物１００重量部に、金属粉を０．５〜３０重量部添加混合することによって一様なメタリック調を付与した樹脂組成物が開示されている。
【０００４】
特許文献３（特開平６―１７１６３９号公報）には、樹脂製容器の容器壁で、その容器壁が外層および内層、または前記外層と前記内層を接着する中間層からなる多層構造の前記外層あるいは前記中間層のいずれか一層に粒径の小さな真珠光沢顔料を混入せしめたパール着色層を有する多層容器が開示されている。
【０００５】
特許文献４（特開２００１−３４１２４０）には、樹脂からなる第１層、および、光沢顔料を含む樹脂からなる第２層を有する多層構造樹脂成形品において、前記光沢顔料が、フレーク状ガラスの表面を、金属の層、または該フレーク状ガラスの屈折率よりも高い屈折率を有する金属酸化物の層で被覆してなる鱗片状粒子である光沢性外観を有する多層構造樹脂成形品が開示されている。
【０００６】
【特許文献１】
特公昭５９―４４２５５号公報
【特許文献２】
特開昭５８−３７０４５号公報
【特許文献３】
特開平６―１７１６３９号公報
【特許文献４】
特開２００１−３４１２４０号公報
【０００７】
【発明が解決しようとする課題】
基材表面に光輝性を付与するには、金属粉やパール顔料などの光輝材料を含む樹脂を基材表面等に塗工し、光輝性を備えた光輝性層を形成する必要がある。この際、好ましいメタリック感やパール感を得るためには、光輝材料の含有量を高めるか、或いは光輝性層を厚く塗る必要があった。
【０００８】
しかし、金属粉やパール顔料などの光輝材料はそれ自体価格が高いため、光輝材料の含有量を高めたり、光輝性層を厚く形成したりすることは、いずれも製造コストが高くなることを意味する。また、光輝材料を多く含有させると、塗工した樹脂の乾燥が悪くなり、ひっかき強度が低下するという問題も生じる。また、光輝性層を厚く塗るためには、シルク印刷等の印刷速度の遅い印刷方法で厚く塗工しなければならず、作業効率が低下するといった問題も発生する。
【０００９】
そこで本発明は、光輝性を備えた表面模様構造において、光輝材料の含有量が少なくて済み、しかも光輝材料を含んだ光輝性層を厚く形成する必要がなく、それでいて優れた光輝性を発揮する光輝性表面模様構造及びその製造方法を提供せんとするものである。
【００１０】
【課題を解決するための手段】
本発明は、光輝性粒子を含む光輝性模様形成樹脂を基材上に積層して光輝性模様形成樹脂層を形成してなる光輝性表面模様構造において、光輝性模様形成樹脂層の表面に凹凸を形成することにより、当該凹凸の凹部断面における光輝性粒子の粒子数よりも凸部断面における粒子数を多くして模様表面の光輝性を高めることを特徴とする光輝性表面模様構造を提案する。
【００１１】
光輝性模様形成樹脂層の光輝性は、断面における光輝性粒子の数に比例して高まるものと考えられる。本発明の光輝性表面模様構造では、光輝性粒子（光輝性材料を含む）の含有量が少なくても、また、光輝性粒子を含む光輝性模様形成樹脂層の平均厚さが小さくても、凸部断面における粒子数が多くなるからこの部分の光輝性を集中的に高めることができ、模様表面全体の光輝性を高めることができる。言い換えれば、同じ量の光輝性粒子を含み、表面平坦な光輝性模様形成樹脂層に比べ、模様表面の光輝性を高めることができる。
【００１２】
なお、本発明において、光輝性模様形成樹脂層表面の凹凸の程度は、微細凹凸したエンボス状程度であってもよい。ＪＩＳ−Ｂ０６５１に規定の触針式表面粗さ測定器を用い、触針２μｍ、荷重７０ｍｇ、測定長８ｍｍで測定した場合の値において、平均表面粗さ（Ｒａ）０．５以上、十点平均粗さ（Ｒｚ）０．５以上、最大高さ（Ｒｍａｘ）２μｍ以上のいずれかであるのが好ましい。これ以上に凹凸の程度が大きい場合、言い換えれば凸部の高さが大きい場合であればより一層好ましい光輝性を得ることができる。
【００１３】
上記構成を備えた光輝性表面模様構造としては、例えば、基材表面上に下地形成樹脂が積層して下地形成樹脂積層を形成し、当該下地形成樹脂積層上に、光輝性粒子を含み、かつ下地形成樹脂よりも表面張力が高い光輝性模様形成樹脂が積層して光輝性模様形成樹脂層を形成し、当該光輝性模様形成樹脂層の表面は微細凹凸したエンボス面部とされてなる構成を備えた光輝性表面模様構造を挙げることができる。
このような光輝性表面模様構造であれば、エンボス面部の微細凹凸における凸部断面の光輝性粒子の粒子数を多くすることができ、模様表面全体の光輝性を増大させることができる。
【００１４】
また、基材表面上に下地形成樹脂が部分的に積層し、当該基材表面上に下地形成樹脂積層部と、平面に見てこの下地形成樹脂積層部に囲まれるか或いは挟まれるかしてなる下地形成樹脂非積層部とを形成し、下地形成樹脂積層部及び下地形成樹脂非積層部上に、光輝性粒子を含み、かつ下地形成樹脂よりも表面張力が高い光輝性模様形成樹脂が積層して光輝性模様形成樹脂層を形成し、下地形成樹脂積層部に積層した光輝性模様形成樹脂層表面は凹凸したエンボス面部とされ、下地形成樹脂非積層部上に積層した光輝性模様形成樹脂層表面は断面が円弧状に盛り上がった丸凸部乃至丸凸条部とされてなる構成を備えた光輝性表面模様構造を挙げることができる。
このような光輝性表面模様構造では、エンボス面部の凸部並びに丸凸部乃至丸凸条部における断面の光輝性粒子の粒子数が、その他の部分における断面の粒子数よりも多くなり、模様表面全体の光輝性を増大させることができる。しかも、丸凸部乃至丸凸条部は、エンボス面部とも、単なる透明面部とも異なる異質の外観とすることができるから、丸凸部乃至丸凸条部、言い換えれば下地形成樹脂非積層部の大きさ、形状、配置等を各種変更することによって新たなデザインを基材表面に与えることができる。
【００１５】
上記の光輝性表面模様構造において、光輝性模様形成樹脂層の表面をエンボス面部とする方法としては、下地形成樹脂と光輝性模様形成樹脂とのハジキ現象を利用して樹脂表面を凹凸とする方法、下地形成樹脂と光輝性模様形成樹脂との表面張力の差を利用して樹脂表面を凹凸とする方法、光輝性模様形成樹脂にちぢみインキを用いる方法、複数種類の下地形成樹脂と光輝性模様形成樹脂との濡れ易さの違いにより凹凸を形成する方法、表面に凹凸面を備えた賦型フィルム、メッキ板或いはエンボスロールを基材表面に加圧して樹脂表面に凹凸を付する方法など、従来公知の各種方法を採用することが可能であり、また、下地形成樹脂非積層部の光輝性模様形成樹脂表面を丸凸部乃至丸凸条部とする方法も特に制限するものではないが、本発明は、下地形成樹脂と光輝性模様形成樹脂との表面張力差によって基材表面上にエンボス面部及び丸凸部乃至丸凸条部（レンズ状凸部乃至レンズ状凸条部）を形成する方法をより好ましいと考え、次のような製造方法を提案する。
【００１６】
即ち、本発明は、基材表面上に下地形成樹脂を積層させて下地形成樹脂積層部を形成し、当該下地形成樹脂積層部上に、光輝性粒子を含み、かつ下地形成樹脂よりも表面張力が高い光輝性模様形成樹脂をほぼ均一に塗布し、必要に応じて光輝性模様形成樹脂に対する硬化処理を行うことによって、光輝性模様形成樹脂層を形成すると共にその表面を凹凸させてエンボス面部とすることを特徴とする光輝性表面模様構造の製造方法を提案する。
【００１７】
また、基材表面上に下地形成樹脂を、積層しない部分を平面に見て囲むか或いは挟むかするように部分的に積層し、これら下地形成樹脂積層部及び下地形成樹脂非積層部上に、下地形成樹脂よりも表面張力が高く、かつ光輝性粒子を含む光輝性模様形成樹脂をほぼ均一に塗布し、必要に応じて光輝性模様形成樹脂に対する硬化処理を行うことにより、下地形成樹脂積層部上に積層する光輝性模様形成樹脂層の表面を凹凸させてエンボス面部とすると共に、下地形成樹脂積層部上の光輝性模様形成樹脂の一部を下地形成樹脂非積層部に移動させて集めて下地形成樹脂非積層部上に積層する光輝性模様形成樹脂層表面を断面が円弧状に盛り上がった丸凸部乃至丸凸条部とすることを特徴とする光輝性表面模様構造の製造方法提案する。
このような製造方法によれば、所定形状の下地形成樹脂非積層部を部分的に残して下地形成樹脂を基材表面上に積層し、光輝性模様形成樹脂をほぼ均一に塗布し、必要に応じて硬化処理を行うだけで、下地形成樹脂積層部上の光輝性模様形成樹脂層の表面をエンボス面部とし、かつ、下地形成樹脂非積層部上の光輝性模様形成樹脂層の表面を円弧状に盛り上がった丸凸部乃至丸凸条部とすることができ、基材表面上に光輝性を備えたエンボス面部と丸凸部乃至丸凸条部とを形成することができる。
しかも、下地形成樹脂非積層部（すなわち下地形成樹脂を積層しないで残す部分）の形状を変化させることで基材表面の模様を自在にデザインすることができ、また、下地形成樹脂と光輝性模様形成樹脂との表面張力差を種々変化させることでエンボス面部の凹凸の大きさ及び形状は勿論、丸凸部乃至丸凸条部の大きさ及び形状も自在に変えることができる。
【００１８】
なお、本発明において「透明樹脂」とは、無色透明及び有色透明の樹脂をいずれも包含する意であり、「表面が凹凸」とは、表面が平坦でなく、多数の凹部又は凸部を備えているという意味であり、微細な凹凸からなるエンボス面、多数の丸凸部乃至丸凸条部を備えた面などの状態を包含する。また、「光輝性粒子」とは、樹脂に配合することで当該樹脂に光輝性を当たることができる粒子全般を意味している。
【００１９】
【発明の実施の形態】
以下、本発明の実施形態について説明する。
なお、本実施形態では、基材１表面上にエンボス面部４と丸凸部乃至丸凸条部５とを備えた構造について説明するが、本発明の光輝性表面模様構造がこのような実施形態に制限されるものではない。例えば、エンボス面部４、丸凸部乃至丸凸条部５のいずれかを備えた構造も、本発明の光輝性表面模様構造に含まれる。
【００２０】
光輝性表面模様構造１０は、図１に示すように、基材１の表面上に下地形成樹脂２を部分的に（すなわち、基材１の全面ではない部分内に、部分的に非積層部２Ｂを残して）積層し、下地形成樹脂積層部２Ａ及び下地形成樹脂非積層部２Ｂ（この２Ｂ部分は基材１が露出している）上に、光輝性粒子Ｘを含む光輝性模様形成樹脂３を積層して光輝性模様形成樹脂層を形成し、この光輝性模様形成樹脂層の表面のうち、下地形成樹脂積層部２Ａ上の表面を微細凹凸したエンボス面部４とし、下地形成樹脂非積層部２Ｂ上の表面を断面が円弧状に盛り上がった丸凸部乃至丸凸条部５とし、基材１全体で見ると、基材１の表面上にエンボス面部４、丸凸部乃至丸凸条部５及び基材残存面６（基材１の表面のまま残した面部）を形成してある。
【００２１】
上記の構成において、微細凹凸したエンボス面部４を断面で見ると、図２（Ａ）に示すように、微細凹凸を構成する凹部４Ａより凸部４Ｂの方が厚いから、一定の密度で光輝性粒子Ｘが含んでいれば、凹部４Ａの断面における一定幅Ｌ内の光輝性粒子Ｘの粒子数よりも凸部４Ｂの断面における一定幅Ｌ内の光輝性粒子Ｘの粒子数の方が多くなっている。
また、仮に、図２（Ｂ）に示すように、同じ密度で光輝性粒子Ｘを含み、かつエンボス面部４における光輝性模様形成樹脂層の平均厚さと同じ厚さを備えた平坦な樹脂層３０を想定すると、平坦な樹脂層３０の断面における一定幅Ｌ内の光輝性粒子Ｘの粒子数よりも、凸部４Ｂの断面における一定幅Ｌ内の光輝性粒子Ｘの粒子数の方が多くなる。
さらにまた、丸凸部乃至丸凸条部５の断面における一定幅Ｌ内の光輝性粒子Ｘの粒子数が更に多くなることは明らかである。
光輝性粒子Ｘを含む光輝性模様形成樹脂層の光輝性は、断面における光輝性粒子Ｘの粒子数が多くなれば高まるから、光輝性模様形成樹脂層の表面に凸部４Ｂ或いは丸凸部乃至丸凸条部５を形成することによって、この部分で集中的に光輝性を高めて模様表面全体の光輝性を高めることができる。よって、光輝性粒子Ｘの含有量が少なくても、また、光輝性模様形成樹脂層の平均厚さが小さくても、模様表面全体の光輝性を高めることができる。
【００２２】
また、光輝性表面模様構造１０は、平面に見ると丸凸部乃至丸凸条部５がエンボス面部４に囲まれるか或いは挟まれるかの状態に形成されており、そのデザインは、下地形成樹脂２をどのように積層するか、言い換えれば、下地形成樹脂２を積層しないで残す部分、すなわち下地形成樹脂非積層部２Ｂの形状をどのようにデザインするかによって任意の模様を表現することができる。例えば、図３（Ａ）の如く、エンボス面部４内に適宜間隔をおいて球面状凸部を形成するようにしたり、図３（Ｂ）の如く、適宜間隔をおいて六角形状の凸部を蜂の巣状に形成し、凸部間をエンボス面部として形成するようにしたり、図３（Ｃ）の如く、エンボス面部４内に帯状の凸条部を適宜間隔をおいて形成すようにしたり、図３（Ｄ）の如く、エンボス面部４内に特殊デザイン（図では星形）の凸部乃至凸条部を形成するようにしたり、その他任意にデザインすることができる。
【００２３】
この光輝性表面模様構造１０において、エンボス面部４の平均表面粗さ（Ｒａ）は０．５〜５０μｍ（１０点の実測値１．９〜３．５μｍ）が好ましく、十点平均粗さ（Ｒｚ）は０．５〜５０μｍ（１０点の実測値１２〜２２μｍ）が好ましく、最大高さ（Ｒｍａｘ）は２〜５０μｍ（１０点の実測値１４〜２７．５μｍ）が好ましく、山数（Ｐｃ）は２〜５０μｍ（１０点の実測値１６〜３２μｍ）が好ましい（以上の数値は、いずれも触針２μｍ、荷重７０ｍｇにて測定した場合の値）。
また、エンボス面部４のＪＩＳＫ−７１０５による鏡面光沢度（６０°×６０°）は１〜８０（１０点の実測値１４〜５９）が好ましく、ＪＩＳＫ−７１０５による４５°光線反射率（全反射）は１〜５０％（１０点の実測値６．２〜２１．０％）が好ましく、ＪＩＳＫ−７１０５による４５°光線反射率（拡散反射）は１〜５０％（１０点の実測値４．９〜１７．８％）が好ましく、ＪＩＳＫ−７１０５による光線透過率（全透過）は５〜９８％（１０点の実測値１６．５〜９０．４％）が好ましく、ＪＩＳＫ−７１０５による光線透過率（拡散透過）は１〜８０％（１０点の実測値７．０〜３５．７％）が好ましく、ＪＩＳＫ−７１０５によるヘーズは１０〜９０％（１０点の実測値２５．６〜４３．０％）が好ましい。
【００２４】
なお、エンボス面部４、丸凸部乃至丸凸条部５及び基材残存面６上に保護層などその他の層を積層することも任意であるし、また、基材１の裏面の構造は任意である。
【００２５】
基材１は、その材質を制限するものではなく、例えば樹脂（プラスチック）、金属、紙、木材、ガラス、石材その他の材質を用いることが可能であるが、アート紙、コート紙、上質紙、ＯＣＲ紙、合成紙などの紙や、各種樹脂シート乃至フィルム等が好適である。中でも透明樹脂シート乃至フィルムは、意匠性の高い包装資材を提供できる点で特に好ましい。
【００２６】
透明樹脂シート乃至フィルムとしては、例えばポリエチレンテレフタレート、ポリプロピレン、ポリエチレン、ポリアクリル酸エステル、ポリエーテルケトン、ポリイミド、ポリカーボネート、ポリスルホン、ポリスチレン、ポリエーテル、ポリ乳酸、その他の非晶質樹脂からなるシート乃至フィルムを挙げることができる。中でも、成形性や耐折性などの点を考慮すると、ポリエチレンテレフタレート、ポリプロピレン、ポリスチレンなどが好ましく、その中でも特に透明性及び剛性等の点からポリエチレンテレフタレート（ＰＥＴ）、例えばアモルファスＰＥＴ（「Ａ−ＰＥＴ」とも言う。）などが好ましい。
【００２７】
基材１の表面は、フレーム処理、コロナ放電処理、薬品処理、プライマー処理等の表面処理を行い、下地形成樹脂２や光輝性模様形成樹脂３との付着性を高めるようにしてもよい。
【００２８】
下地形成樹脂２及び光輝性模様形成樹脂３は、両者のＪＩＳＫ−６７６８による表面張力の差が１０μＮ／ｃｍ以上、好ましくは２０μＮ／ｃｍ以上、中でも特に４０μＮ／ｃｍ以上とするのが好ましい。この際の上限値は、現在の技術水準においては現実的には４００μＮ／ｃｍ程度が上限であるが、理論的には上限値を定めるものではない。
表面張力差が１０μＮ／ｃｍ以上であれば、下地形成樹脂２上に模様形成樹脂３を均一に塗布するだけで自然にその表面を好適なエンボス面とすることができ、同時に自然に下地形成樹脂非積層部２Ｂ上に集めて円弧状に盛り上がった丸凸部乃至丸凸条部５を形成することができる。
【００２９】
下地形成樹脂２のＪＩＳＫ−６７６８による表面張力は、３２０μＮ／ｃｍ以下、中でも３００μＮ／ｃｍ以下であるのが好ましい。この際の下限値は、現在の技術水準においては現実的には２００μＮ／ｃｍ程度が下限であるが、理論的には下限値を定めるものではない。
また、下地形成樹脂２の接触角は７０〜９０°、中でも特に７５〜９０°であるのが好ましい。
【００３０】
下地形成樹脂２としては、基材１に付着可能であればその種類を限定するものではないが、透明樹脂を用いるのが好ましい。例えば、アクリル酸及びそのエステル，メタアクリル酸及びそのエステル，スチレン，エチレン，酢酸ビニール，塩化ビニール等のモノマーの少なくとも一種類以上を重合した樹脂、塩素化ポリプロピレン樹脂，塩化ゴム，飽和ポリエステル樹脂を単独又は２〜４種類混合したものをトルエン，キシレン，酢酸エチル，酢酸メチル，酢酸ｎプロピル，酢酸イソプロピル，酢酸ブチル，酢酸イソブチル，アセトン，キシレン，酢酸メチル，イソプロピルアルコール，エタノール等の溶剤に溶解した樹脂（ワニス）、水及びアルコールを単独又は混合した溶媒に溶解又は分散した樹脂（ワニス）に炭化水素化合物，シリコーン化合物，フッ素化合物等の撥油剤を添加した樹脂などを挙げることができる。中でも、基材表面に光沢を付与したり、耐磨耗性を向上させたりする等の目的で一般的に使用されているオーバープリントニス（ＯＰニス）が好ましい。
【００３１】
下地形成樹脂積層部２Ａにおける下地形成樹脂２の厚さは、特に制限するものではないが、一般的には０．２〜２０μｍとするのが好ましい。
【００３２】
他方、光輝性模様形成樹脂３は、上記下地形成樹脂２よりも表面張力が大きい樹脂を主材とし、光輝性粒子を含んでいる必要がある。
【００３３】
光輝性粒子は、光輝度反射性、光干渉性、虹彩性、ホログラム性、金属光沢性、真珠光沢性等の光学的性状を示す粒子であればよい。
その屈折率は１．５以上であるのが好ましい。ちなみに、ガラスの屈折率は通常１．５〜１．６程度、アナターゼ型二酸化チタンの屈折率は約２．５、ルチル型二酸化チタンの屈折率は約２．７である。
具体的には、マイカ（雲母）粒子やガラス粒子などの鉱物粒子、鱗片状アルミニウムなどの金属粒子、二酸化チタンなどの酸化金属、又はこれらを金属或いは金属酸化物で被覆した粒子など、パール顔料、フレーク顔料、アルミニウム顔料、ブロンズ顔料などの光輝性顔料に含める光輝性粒子などを用いることができる。
粒子形状は、球形状、だ円球形状、角柱状、丸柱状、フレーク状、鱗片状、不定形状など、所定の光学的性状を示せば任意である。また、粒径も任意であり、塗布性や流動性あるいは組成物中での均一分散性などを勘案して適宜選択するのが好ましい。
光輝性粒子の含有量は、特に制限するものはないが、主材となる樹脂に対して０．１〜５０重量％、好ましくは１〜３０重量％とすればよい。ただし、上述のように本発明によれば、光輝性粒子の含有量を減らしても好適な光輝性を付与することができる。
【００３４】
光輝性模様形成樹脂３の表面張力は、ＪＩＳＫ−６７６８による表面張力が、２４０μＮ／ｃｍ以上、中でも３００μＮ／ｃｍ以上であるのが好ましい。この際の上限値は、現在の技術水準においては現実的には２００μＮ／ｃｍ程度が下限であるが、理論的には上限値を定めるものではない。
また、光輝性模様形成樹脂３の接触角は１０〜８５°、中でも特に３０〜８０°であるのが好ましい。
なお、表面張力の調整は、シリコン系やアクリル系などの表面調整剤を使うこによっても行なうことができる。
光輝性模様形成樹脂３の厚さは、特に制限するものではないが、一般的には０．２〜２０μｍとするのが好ましい。
【００３５】
光輝性模様形成樹脂３の主材として用いる樹脂は、上記の表面張力を備えたものであれば適宜採用可能ではあるが、製造効率などの点からエネルギー線硬化型樹脂、すなわち、分子を重合乃至架橋し得るエネルギー量子を有する電磁波又は荷電粒子線、例えば可視光線、紫外線（近紫外線、真空紫外線等）Ｘ線、電子線、イオン線等の照射によって硬化し得る樹脂を好ましく用いることができる。
【００３６】
下地形成樹脂２及び模様形成樹脂３ともに、本発明の目的を阻害しない限り、通常使用されるその他の各種添加剤を配合することは任意である。
【００３７】
（製造方法）
以下、光輝性表面模様構造１０の製造方法について説明する。
【００３８】
先ず、基材１の表面内に、積層しない部分（非積層部２Ｂ）を残すように部分的に下地形成樹脂２を積層する。この際、基材１の表面全面若しくは所定の部分に、下地形成樹脂２を積層しない部分（非積層部２Ｂ）を下地形成樹脂積層部２Ａで囲むか或いは挟むかするように部分的に下地形成樹脂２を積層する。
【００３９】
次に、下地形成樹脂積層部２Ａ及び下地形成樹脂非積層部２Ｂ（この部分は基材１が露出している）上に、光輝性粒子を含む光輝性模様形成樹脂３をほぼ均一に塗布し、所定時間経過後必要に応じて光輝性模様形成樹脂硬化処理を行う。
これによって下地形成樹脂積層部２Ａ上の光輝性模様形成樹脂層表面は凹凸したエンボス面部４となり、同時に下地形成樹脂積層部２Ａ上の光輝性模様形成樹脂３の一部が自然に下地形成樹脂非積層部２Ｂに移動して集まり、下地形成樹脂非積層部２Ｂ上の光輝性模様形成樹脂層表面は断面が円弧状に盛り上がった丸凸部乃至丸凸条部５となる。よって、基材１の表面上には、エンボス面部４、丸凸部乃至丸凸条部５及び基材残存面６（基材１の表面のまま残した面部）が形成する。
【００４０】
下地形成樹脂２を基材１上に積層する方法としては、それぞれを押出成形する方法、下地形成樹脂２からなるフィルムを圧着ラミネートする方法、下地形成樹脂２を塗工する方法など様々な方法を採用することができるが、所定の非積層部２Ｂを残しながら下地形成樹脂２を積層する点を考慮すると、下地形成樹脂２を塗工する方法が好適である。具体的には、グラビアコート、グラビアリバースコート、グラビアオフセットコート、メイヤーバーコート、エアーナイフコート、スピンナーコート、ロールコート、リバースロールコート、キスコート、ホイラーコート、シルクスクリーンによるベタコート、フローコート、スプレーコート等の公知の塗工手段を用いることができ、中でも、所定形状の転写部を備えたロールを用いて樹脂を塗工する方法が好適である。
【００４１】
また、光輝性模様形成樹脂３を塗布する方法としては、下地形成樹脂２の塗工方法として挙げられた方法を採用することができる。この際、光輝性模様形成樹脂３は０．２〜２０μｍの厚さに塗布するのが好ましい。
【００４２】
なお、光輝性模様形成樹脂３は、下地形成樹脂２を充分に乾燥させた後塗布するようにしてもよいし、また、乾燥しないうちに塗布するようにしてもよい。
下地形成樹脂積層部２Ａの光輝性模様形成樹脂３の一部が自然に下地形成樹脂非積層部２Ｂに移動して集まるようにするには、光輝性模様形成樹脂を加温するか、又は紫外線照射するまでの時間をできるだけ長くする、すなわち、下地形成樹脂積層部２Ａの光輝性模様形成樹脂３の一部が自然に下地形成樹脂非積層部２Ｂに移動して集まる時間をおいて紫外線照射するようにするのが好ましい。
【００４３】
必要に応じて行う光輝性模様形成樹脂硬化処理は、光輝性模様形成樹脂３としてエネルギー線硬化型樹脂を用いる場合は、紫外線、γ線などのエネルギー線を照射可能な装置を用いてそれらを照射するようにすればよい。
【００４４】
このような方法によって光輝性表面模様構造を製造すれば、基材１上に非積層部２Ｂを残しながら下地形成樹脂２を積層し、光輝性模様形成樹脂３をほぼ均一に塗布し、必要に応じて光輝性模様形成樹脂硬化処理を行うだけで、下地形成樹脂積層部２Ａ上の光輝性模様形成樹脂層表面を凹凸したエンボス面部４とする一方、下地形成樹脂非積層部２Ｂ上の光輝性模様形成樹脂層表面を丸凸部乃至丸凸条部５とすることができる。そして、下地形成樹脂積層部２Ａ或いは下地形成樹脂非積層部２Ｂの形状を変化させることで自在にデザインすることができ、また、下地形成樹脂２と光輝性模様形成樹脂３の表面張力差を種々変化させることでエンボス面部４の凹凸の大きさ及び形状を変化させてその風合い等を変化させることができるし、更には丸凸部乃至丸凸条部５の大きさ及び形状を自在に変化させることができる。例えば、下地形成樹脂２と光輝性模様形成樹脂３の表面張力差を小さくすることにより、丸凸部乃至丸凸条部５の一つの大きさをより大きくすることができる。
【００４５】
（実施例１）
厚さ０．３ｍｍのアモルファスＰＥＴ（「Ａ−ＰＥＴ」ヘーズ０．８％）の表面に、図１及び図３（Ａ）に示すように、直径０．５ｍｍΦの円をピッチ０．７５ｍｍで残すように（すなわち非積層部２Ｂを形成するように）、下地形成樹脂としてＯＰニス（アクリル酸プレポリマー及びアクリル酸オリゴマーを含有するＯＰニス；大日本インキ化学工業製ダイキュアＲＴ−８、ＪＩＳＫ−６７６８による表面張力３００μＮ／ｃｍ以下、接触角８５°）を厚さ１μｍで塗工し、下地形成樹脂積層部２Ａ及び下地形成樹脂非積層部２Ｂ上に光輝性模様形成樹脂を略均一に厚さ３μｍに塗布し、塗布後２０ｍｍＳＥＣ後に紫外線照射装置で紫外線照射して模様付シートを得た。
この際、光輝性模様形成樹脂には、紫外線硬化樹脂インキ（アクリル酸プレポリマー及びアクリル酸オリゴマーを含有する紫外線硬化樹脂インキ；大日本インキ化学工業製「ダイキュアクリアＵＶ−１６０１ＥＭ」、ＪＩＳＫ−６７６８による表面張力３４０μＮ／ｃｍ、接触角７４°）に、メルク社製「イリオジン１５３（雲母）」を２０重量％配合したものを使用した。
【００４６】
得られた模様付シートの表面は、図３（Ａ）の如く、エンボス面部４内に適宜間隔をおいてレンズの如き球面状凸部５が形成され、パール感良好な模様付シートが得られた。
なお、エンボス面部４は、平均表面粗さＲａ３．５μｍ、光沢度（６０°）２４、表面の６０°グロス値２４、光線透過率１６．５％、ヘーズ４２．３％、光線反射率６．２％であった。
【００４７】
（実施例２）
厚さ０．３ｍｍのアモルファスＰＥＴ（「Ａ−ＰＥＴ」ヘーズ０．８％）の表面に、図１及び図３（Ａ）に示すように、直径０．５ｍｍΦの円をピッチ０．７５ｍｍで残すように（すなわち非積層部２Ｂを形成するように）、下地形成樹脂としてＯＰニス（アクリル酸プレポリマー及びアクリル酸オリゴマーを含有するＯＰニス；大日本インキ化学工業製ダイキュアＲＴ−８、ＪＩＳＫ−６７６８による表面張力３００μＮ／ｃｍ以下、接触角８５°）を厚さ１μｍで塗工し、下地形成樹脂積層部２Ａ及び下地形成樹脂非積層部２Ｂ上に光輝性模様形成樹脂を略均一に厚さ３μｍに塗布し、塗布後２０ｍｍＳＥＣ後に紫外線照射装置で紫外線照射して模様付シートを得た。
この際、光輝性模様形成樹脂には、紫外線硬化樹脂インキ（アクリル酸プレポリマー及びアクリル酸オリゴマーを含有する紫外線硬化樹脂インキ；大日本インキ化学工業製「ダイキュアクリアＵＶ−１６０１ＥＭ」、ＪＩＳＫ−６７６８による表面張力３４０μＮ／ｃｍ、接触角７４°）に、東洋インキ製シルバーペーストを１０重量％配合したものを使用した。
【００４８】
得られた模様付シートの表面は、実施例１同様、エンボス面部４内に適宜間隔をおいてレンズの如き球面状凸部５が形成され、メタリック感良好な模様付シートが得られた。
【００４９】
（実施例３）
厚さ０．３ｍｍのアモルファスＰＥＴ（「Ａ−ＰＥＴ」ヘーズ０．８％）の表面に、図１及び図３（Ａ）に示すように、直径０．５ｍｍΦの円をピッチ０．７５ｍｍで残すように（すなわち非積層部２Ｂを形成するように）、下地形成樹脂としてＯＰニス（アクリル酸プレポリマー及びアクリル酸オリゴマーを含有するＯＰニス；大日本インキ化学工業製ダイキュアＲＴ−８、ＪＩＳＫ−６７６８による表面張力３００μＮ／ｃｍ以下、接触角８５°）を厚さ１μｍで塗工し、下地形成樹脂積層部２Ａ及び下地形成樹脂非積層部２Ｂ上に光輝性模様形成樹脂を略均一に厚さ３μｍに塗布し、塗布後２０ｍｍＳＥＣ後に紫外線照射装置で紫外線照射して模様付シートを得た。
この際、光輝性模様形成樹脂には、紫外線硬化樹脂インキ（アクリル酸プレポリマー及びアクリル酸オリゴマーを含有する紫外線硬化樹脂インキ；大日本インキ化学工業製「ダイキュアクリアＵＶ−１６０１ＥＭ」、ＪＩＳＫ−６７６８による表面張力３４０μＮ／ｃｍ、接触角７４°）に、メルク社製「シラリックＴ６０−１０ＷＮＴクリスタルシルバー」を２０重量％配合したものを使用した。
【００５０】
得られた模様付シートの表面は、実施例１同様、エンボス面部４内に適宜間隔をおいてレンズの如き球面状凸部５が形成され、パール感良好な模様付シートが得られた。
【００５１】
（比較例１）
厚さ０．３ｍｍのアモルファスＰＥＴ（「Ａ−ＰＥＴ」ヘーズ０．８％）の表面に、下地形成樹脂を塗工せず、光輝性模様形成樹脂を略均一に厚さ３μｍに塗布し、塗布後２０ｍｍＳＥＣ後に紫外線照射装置で紫外線照射して模様付シートを得た。
この際、光輝性模様形成樹脂には、紫外線硬化樹脂インキ（アクリル酸プレポリマー及びアクリル酸オリゴマーを含有する紫外線硬化樹脂インキ；大日本インキ化学工業製「ダイキュアクリアＵＶ−１６０１ＥＭ」、ＪＩＳＫ−６７６８による表面張力３４０μＮ／ｃｍ、接触角７４°）に、東洋インキ製「シルバーペースト」を１０重量％配合したものを使用した。
【００５２】
得られた模様付シートの表面は、平坦で凹凸がなく、メタリック感が乏しく、灰色に見えた。
【００５３】
なお、本発明（実施例含む）において、鏡面光沢度は、ＪＩＳＫ−７１０５に従い、デジタル変角光度計（光源：標準光Ｃ）を用いて、標準光をワークの入射角６０°の方向から照射し、反射角６０°の方向で首記装置で反射した光を測定した値である。
本発明（実施例含む）において、表面粗さ（Ｒａ、Ｒｚ、Ｒｍａｘ及びＰｃ）は、ＪＩＳ−Ｂ０６５１に規定の触針式表面粗さ測定器を用い、触針２μｍ、荷重７０ｍｇ、測定長８ｍｍで測定した場合の値である。
本発明（実施例含む）において、接触角は、接触角計を使用し、試験液として蒸留水を用いて、滴下後３０秒後の値を測定した値である。
本発明（実施例含む）において、光線透過率（全透過、拡散透過及びヘーズ）は、ＪＩＳＫ−７１０５に従い、ヘーズメータを使用して測定した値である。
【図面の簡単な説明】
【図１】本発明の一実施形態に係る光輝性表面模様構造を備えたシート体の一例を示した断面図である。
【図２】本発明の光輝性表面模様構造における光輝性模様形成樹脂の表面状態を説明するための要部拡大断面図であり、（Ａ）は本発明の光輝性模様形成樹脂の表面状態、（Ｂ）は仮想の模様形成樹脂の表面状態である。
【図３】（Ａ）〜（Ｄ）のいずれも、本発明の光輝性表面模様構造のデザイン例を示した斜視図である。
【符号の説明】
１基材
２下地形成樹脂
２Ａ下地形成樹脂積層部
２Ｂ下地形成樹脂非積層部
３光輝性模様形成樹脂
４エンボス面部
５丸凸部乃至丸凸条部
６基材残存面
１０光輝性表面模様構造[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a surface pattern structure provided on a substrate surface, and more particularly, to a surface pattern structure having glitter and a method for manufacturing the same.
[0002]
[Prior art]
For example, Patent Document 1 (Japanese Patent Publication No. 59-44255) discloses a modified polyolefin resin in which a predetermined amount of a pearl pigment is mixed in a decorative layer as a surface pattern structure provided with glitter and a resin composition therefor. There is disclosed a molded article having a multilayer structure in which a colored polyolefin resin is used for a colored layer and a transparent thermoplastic resin is used for a coating layer.
[0003]
Patent Document 2 (JP-A-58-37045) discloses that a uniform metallic tone is imparted by adding and mixing 0.5 to 30 parts by weight of a metal powder to 100 parts by weight of a mixture of an ABS resin and an AS resin. The disclosed resin composition is disclosed.
[0004]
Patent Literature 3 (Japanese Patent Application Laid-Open No. 6-171639) discloses a container wall of a resin container, wherein the container wall has an outer layer and an inner layer, or the outer layer or a multilayer structure having an intermediate layer for bonding the outer layer and the inner layer. A multilayer container having a pearl coloring layer in which a pearlescent pigment having a small particle diameter is mixed in any one of the intermediate layers is disclosed.
[0005]
Patent Document 4 (Japanese Patent Application Laid-Open No. 2001-341240) discloses a multilayer resin molded article having a first layer made of a resin and a second layer made of a resin containing a gloss pigment, wherein the gloss pigment is made of flake glass. A multi-layer resin molded article having a glossy appearance, which is a flaky particle formed by coating the surface with a metal layer or a metal oxide layer having a refractive index higher than that of the flake glass, is disclosed. ing.
[0006]
[Patent Document 1]
JP-B-59-44255
[Patent Document 2]
JP-A-58-37045
[Patent Document 3]
JP-A-6-171639
[Patent Document 4]
JP 2001-341240 A
[0007]
[Problems to be solved by the invention]
In order to impart glitter to the surface of the substrate, it is necessary to apply a resin containing a glitter material such as metal powder or pearl pigment to the surface of the substrate or the like to form a glitter layer having glitter. In this case, in order to obtain a preferable metallic or pearly feeling, it was necessary to increase the content of the glittering material or to apply a thick glittering layer.
[0008]
However, since brilliant materials such as metal powder and pearl pigments are expensive in themselves, increasing the content of brilliant materials or forming a brilliant layer thicker means higher manufacturing costs. I do. Further, when a large amount of the glittering material is contained, drying of the applied resin becomes poor, and there is a problem that the scratching strength is reduced. Further, in order to apply the glittering layer thickly, it is necessary to apply thickly by a printing method having a low printing speed such as silk printing, which causes a problem that the working efficiency is reduced.
[0009]
Thus, the present invention provides a surface pattern structure having a brilliant property, in which the content of the brilliant material is small, and it is not necessary to form a thick brilliant layer containing the brilliant material, and yet the excellent brilliant property is exhibited. An object of the present invention is to provide a glittering surface pattern structure and a method for producing the same.
[0010]
[Means for Solving the Problems]
The present invention provides a glittering surface pattern structure formed by laminating a glittering pattern-forming resin containing glittering particles on a substrate, and forming a glittering pattern-forming resin layer on the surface of the glittering pattern-forming resin layer. By forming a luminous surface pattern structure, the number of particles in the convex section is increased more than the number of brilliant particles in the concave section of the concavo-convex to enhance the brilliancy of the pattern surface. .
[0011]
It is considered that the glitter of the glitter pattern forming resin layer increases in proportion to the number of glitter particles in the cross section. In the glittering surface pattern structure of the present invention, even if the content of the glittering particles (including the glittering material) is small, and the average thickness of the glittering pattern-forming resin layer containing the glittering particles is small, Since the number of particles in the cross section of the convex portion increases, the glitter of this portion can be intensively increased, and the glitter of the entire pattern surface can be enhanced. In other words, the glitter of the pattern surface can be enhanced as compared with a glitter pattern forming resin layer containing the same amount of glitter particles and having a flat surface.
[0012]
In the present invention, the degree of unevenness on the surface of the glittering pattern forming resin layer may be approximately embossed with minute unevenness. The average surface roughness (Ra) is 0.5 or more, and the ten-point average is the value measured with a stylus 2 μm, a load of 70 mg, and a measurement length of 8 mm using a stylus type surface roughness meter specified in JIS-B0651. It is preferable that the roughness (Rz) is 0.5 or more and the maximum height (Rmax) is 2 μm or more. If the degree of unevenness is larger than that, in other words, if the height of the convex portion is large, more preferable glitter can be obtained.
[0013]
As the glittering surface pattern structure having the above configuration, for example, an undercoating resin is laminated on the surface of the base material to form an undercoating resin laminate, and the undercoating resin laminate contains glitter particles, and A glitter pattern forming resin having a higher surface tension than the underlayer forming resin is laminated to form a glitter pattern forming resin layer, and the surface of the glitter pattern forming resin layer is provided with an embossed surface portion having fine irregularities. Brilliant surface pattern structure.
With such a brilliant surface pattern structure, the number of brilliant particles in the cross section of the convex portion in the fine unevenness of the embossed surface portion can be increased, and the brilliancy of the entire pattern surface can be increased.
[0014]
Further, the base forming resin is partially laminated on the surface of the base material, and the base forming resin laminated portion is formed on the base material surface. And a glitter pattern-forming resin containing glitter particles and having a higher surface tension than the primer resin is laminated on the laminate resin layer and the laminate resin non-laminate portion. The glittering pattern forming resin layer is formed by forming the glittering pattern forming resin layer, and the glittering pattern forming resin layer surface laminated on the underlayer forming resin laminated portion has an uneven embossed surface portion, and the glittering pattern forming resin laminated on the underlayer forming resin non-laminating portion. The surface of the layer may be a glittering surface pattern structure having a configuration in which a cross section is formed as a circular convex portion or a circular convex line portion which is raised in an arc shape.
In such a brilliant surface pattern structure, the number of brilliant particles in the cross section at the convex portion and the round convex portion or the round ridge portion of the embossed surface portion is larger than the number of particles at the cross section in other portions, and the pattern surface The overall glitter can be increased. In addition, since the round convex portion or the round convex line portion can have a different appearance from the embossed surface portion or the mere transparent surface portion, the size of the round convex portion or the round convex line portion, in other words, the size of the base-forming resin non-laminated portion is reduced. A new design can be given to the base material surface by variously changing the shape, arrangement, and the like.
[0015]
In the above-described glittering surface pattern structure, as a method of forming the surface of the glittering pattern forming resin layer as an embossed surface portion, a method of making the resin surface uneven by utilizing the repelling phenomenon of the base forming resin and the glittering pattern forming resin. , A method of making the resin surface uneven by utilizing the difference in surface tension between the base forming resin and the glitter pattern forming resin, a method of using fine ink for the glitter pattern forming resin, a plurality of types of base forming resin and the glitter pattern A method of forming unevenness due to the difference in wettability with the forming resin, a shaping film having an uneven surface on the surface, a method of applying unevenness to the resin surface by pressing a plating plate or an embossing roll on the substrate surface, Conventionally known various methods can be adopted, and the method of forming the glittering pattern forming resin surface of the underlayer forming resin non-laminated portion into a round convex portion or a round convex ridge portion is not particularly limited. Departure Is a method of forming an embossed surface portion and a round convex portion or a round convex line portion (lens-like convex portion or lens-like convex line portion) on a substrate surface by a surface tension difference between a base forming resin and a glitter pattern forming resin. Considering that it is more preferable, the following manufacturing method is proposed.
[0016]
That is, the present invention forms a base-forming resin laminate by laminating a base-forming resin on the surface of a base material, includes glittering particles on the base-forming resin laminate, and has a surface tension higher than that of the base-forming resin. By applying a highly brilliant pattern forming resin almost uniformly, and performing a curing treatment on the brilliant pattern forming resin as necessary, a brilliant pattern forming resin layer is formed and the surface thereof is made uneven to emboss the surface. A method of manufacturing a glittering surface pattern structure is proposed.
[0017]
Further, the base forming resin is partially laminated on the surface of the base material so as to enclose or sandwich the non-laminated portion in a plan view, and on the base forming resin laminated portion and the base forming resin non-laminated portion, By applying a glitter pattern forming resin having a higher surface tension than the base forming resin and containing glitter particles almost uniformly and performing a curing treatment on the glitter pattern forming resin as necessary, The surface of the glittering pattern forming resin layer to be laminated thereon is made uneven to form an embossed surface portion, and a part of the glittering pattern forming resin on the underlayer forming resin laminated portion is moved to the underlayer forming resin non-laminating portion and collected. A method for manufacturing a glittering surface pattern structure, characterized in that the glittering pattern forming resin layer laminated on the underlayer forming resin non-laminating portion is formed into a circular convex portion or a circular convex portion having a cross-sectionally protruding arc shape. .
According to such a manufacturing method, the base forming resin is laminated on the surface of the base material while partially leaving the base forming resin non-laminated portion of a predetermined shape, and the glittering pattern forming resin is applied substantially uniformly. The surface of the glittering pattern-forming resin layer on the base-forming resin-laminated portion is used as the embossed surface portion, and the surface of the glittering pattern-forming resin layer on the base-forming-resin non-laminated portion is formed in an arc shape only by performing the curing process in accordance with It is possible to form an embossed surface portion having a glittering property and a round convex portion or a round convex portion on the surface of the base material.
In addition, the pattern of the substrate surface can be freely designed by changing the shape of the non-laminated portion of the base-forming resin (that is, the portion left without laminating the base-forming resin). By variously changing the surface tension difference with the forming resin, not only the size and shape of the concavities and convexities on the embossed surface portion but also the size and shape of the round protrusions or the round protrusions can be freely changed.
[0018]
In the present invention, the “transparent resin” is intended to include both colorless and transparent resins, and the “surface is uneven” means that the surface is not flat and has many concave portions or convex portions. And includes a state such as an embossed surface formed of fine irregularities, a surface provided with a large number of round convex portions or round convex stripe portions, and the like. In addition, the term “brilliance particles” means all particles that can give brilliance to the resin when blended with the resin.
[0019]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described.
In the present embodiment, a structure in which an embossed surface portion 4 and a round convex portion or a round convex portion 5 are provided on the surface of the base material 1 will be described. It is not limited to. For example, a structure including any one of the embossed surface portion 4 and the round convex portion to the round convex stripe portion 5 is also included in the glittering surface pattern structure of the present invention.
[0020]
As shown in FIG. 1, the glittering surface pattern structure 10 is formed by partially coating the base forming resin 2 on the surface of the base material 1 (that is, partially in the non-full surface of the base material 1, 2B) and a glittering pattern forming resin containing glittering particles X on the base forming resin laminated portion 2A and the base forming resin non-laminating portion 2B (where the base material 1 is exposed in the 2B portion). 3 to form a glittering pattern forming resin layer, and among the surfaces of the glittering pattern forming resin layer, the surface on the base forming resin laminated portion 2A is made into an embossed surface portion 4 having fine irregularities. The surface on the portion 2B is a round convex portion or a round convex portion 5 whose section is raised in an arc shape, and when the substrate 1 is viewed as a whole, the embossed surface portion 4, the round convex portion or the round convex line on the surface of the substrate 1 A portion 5 and a substrate remaining surface 6 (a surface portion left as it is on the surface of the substrate 1) are formed.
[0021]
In the above configuration, when the embossed surface portion 4 having fine irregularities is viewed in a cross section, as shown in FIG. 2A, the convex portions 4B are thicker than the concave portions 4A forming the fine irregularities, so When the particles X are included, the number of the glittering particles X within the constant width L in the cross section of the convex portion 4B is larger than the number of the glitter particles X within the constant width L in the cross section of the concave portion 4A. ing.
Further, as shown in FIG. 2B, a flat resin layer 30 containing the glittering particles X at the same density and having the same thickness as the average thickness of the glittering pattern forming resin layer on the embossed surface portion 4. Is assumed, the number of glittering particles X within the constant width L in the cross section of the convex portion 4B is larger than the number of glittering particles X in the constant width L in the cross section of the flat resin layer 30. .
Further, it is clear that the number of glittering particles X within a certain width L in the cross section of the round convex portion or the round convex stripe portion 5 further increases.
The brilliancy of the brilliant pattern forming resin layer containing the brilliant particles X increases as the number of the brilliant particles X in the cross section increases, so that the surface of the brilliant pattern forming resin layer has a convex portion 4B or a round convex portion. By forming the round ridges 5, it is possible to intensively enhance the brilliancy at this portion and enhance the brilliancy of the entire pattern surface. Therefore, even if the content of the glitter particles X is small and the average thickness of the glitter pattern forming resin layer is small, the glitter of the entire pattern surface can be enhanced.
[0022]
Further, the glittering surface pattern structure 10 is formed such that a round convex portion or a round convex streak portion 5 is surrounded or sandwiched by the embossed surface portion 4 when viewed in a plane. 2 can be expressed by how to laminate the base-forming resin 2, in other words, how to design the shape of the portion where the base-forming resin 2 is left without being laminated, that is, the shape of the base-forming resin non-laminated portion 2 </ b> B. . For example, as shown in FIG. 3A, a spherical convex portion is formed in the embossed surface portion 4 at an appropriate interval, or a hexagonal convex portion is formed in the embossed surface portion 4 at an appropriate interval as shown in FIG. 3B. It is formed in a honeycomb shape, and between the convex portions is formed as an embossed surface portion. As shown in FIG. 3 (C), band-shaped convex ridges are formed in the embossed surface portion 4 at appropriate intervals. As shown in FIG. 3 (D), a specially designed (star-shaped in the figure) convex portion or ridge portion may be formed in the embossed surface portion 4, or any other design may be used.
[0023]
In this glittering surface pattern structure 10, the average surface roughness (Ra) of the embossed surface portion 4 is preferably 0.5 to 50 μm (actually measured values at ten points 1.9 to 3.5 μm), and the ten-point average roughness (Rz) ) Is preferably 0.5 to 50 μm (actually measured values at 10 points: 12 to 22 μm), the maximum height (Rmax) is preferably 2 to 50 μm (measured values at 10 points: 14 to 27.5 μm), and the number of peaks (Pc) Is preferably 2 to 50 μm (actual measured values at 10 points: 16 to 32 μm) (all of the above numerical values are values measured with a stylus of 2 μm and a load of 70 mg).
Further, the specular glossiness (60 ° × 60 °) of the embossed surface part 4 according to JIS K-7105 is preferably 1 to 80 (actually measured values of 14 points to 14 to 59), and the 45 ° light reflectance (total Reflection) is preferably 1 to 50% (actually measured values at 10 points 6.2 to 21.0%), and the 45 ° light reflectance (diffuse reflection) according to JIS K-7105 is 1 to 50% (actually measured values at 10 points). 4.9 to 17.8%), and the light transmittance (total transmission) according to JIS K-7105 is preferably 5 to 98% (actually measured values at 10 points 16.5 to 90.4%), and JIS K-7105. The light transmittance (diffuse transmission) according to JIS K is preferably 1 to 80% (measured value at 10 points: 7.0 to 35.7%), and the haze according to JIS K-7105 is 10 to 90% (actual value at 10 points: 25.6). ~ 43.0%) is preferred.
[0024]
In addition, it is optional to laminate another layer such as a protective layer on the embossed surface portion 4, the round convex portion or the round convex portion 5, and the substrate remaining surface 6, and the structure of the back surface of the substrate 1 is optional. It is.
[0025]
The material of the base material 1 is not limited. For example, resin (plastic), metal, paper, wood, glass, stone, and other materials can be used, but art paper, coated paper, woodfree paper, Paper such as OCR paper and synthetic paper, and various resin sheets or films are suitable. Above all, a transparent resin sheet or film is particularly preferable because it can provide a packaging material having high designability.
[0026]
Examples of the transparent resin sheet or film include a sheet or film made of, for example, polyethylene terephthalate, polypropylene, polyethylene, polyacrylate, polyetherketone, polyimide, polycarbonate, polysulfone, polystyrene, polyether, polylactic acid, and other amorphous resins. Can be mentioned. Among them, polyethylene terephthalate, polypropylene, polystyrene and the like are preferable in consideration of moldability and folding resistance. Among them, polyethylene terephthalate (PET), for example, amorphous PET (“A-PET”) is particularly preferable in terms of transparency and rigidity. And the like.).
[0027]
The surface of the base material 1 may be subjected to a surface treatment such as a frame treatment, a corona discharge treatment, a chemical treatment, a primer treatment, or the like, so as to enhance the adhesion to the base forming resin 2 or the glitter pattern forming resin 3.
[0028]
The difference between the surface tension of the undercoating resin 2 and that of the glittering pattern forming resin 3 according to JIS K-6768 is 10 μN / cm or more, preferably 20 μN / cm or more, and particularly preferably 40 μN / cm or more. At this time, the upper limit is practically about 400 μN / cm in the current technical level, but is not theoretically set.
If the surface tension difference is 10 μN / cm or more, the surface can be naturally formed into a suitable embossed surface simply by uniformly applying the pattern forming resin 3 on the base forming resin 2, and at the same time, the base forming resin can be naturally formed. It is possible to form a round convex portion or a round convex stripe portion 5 which is gathered on the non-laminated portion 2B and rises in an arc shape.
[0029]
The surface tension of the base-forming resin 2 according to JIS K-6768 is 320 μN / cm or less, and particularly preferably 300 μN / cm or less. At this time, the lower limit is practically about 200 μN / cm in the current technical level, but is not theoretically set.
Further, the contact angle of the base forming resin 2 is preferably 70 to 90 °, and particularly preferably 75 to 90 °.
[0030]
The kind of the base forming resin 2 is not limited as long as it can be attached to the base material 1, but it is preferable to use a transparent resin. For example, a resin obtained by polymerizing at least one kind of monomer such as acrylic acid and its ester, methacrylic acid and its ester, styrene, ethylene, vinyl acetate and vinyl chloride, chlorinated polypropylene resin, chlorinated rubber and saturated polyester resin alone Or a resin obtained by dissolving a mixture of 2 to 4 kinds in a solvent such as toluene, xylene, ethyl acetate, methyl acetate, n-propyl acetate, isopropyl acetate, butyl acetate, isobutyl acetate, acetone, xylene, methyl acetate, isopropyl alcohol, ethanol, etc. (Varnish), a resin in which water and an alcohol are dissolved or dispersed in a solvent alone or mixed, and a resin (varnish) to which an oil repellent such as a hydrocarbon compound, a silicone compound, a fluorine compound, or the like is added. Among them, an overprint varnish (OP varnish) generally used for the purpose of imparting gloss to the surface of a base material or improving abrasion resistance is preferred.
[0031]
The thickness of the base forming resin 2 in the base forming resin laminated portion 2A is not particularly limited, but is generally preferably 0.2 to 20 μm.
[0032]
On the other hand, the glittering pattern forming resin 3 is required to be mainly composed of a resin having a higher surface tension than the base forming resin 2 and to contain glittering particles.
[0033]
The brilliant particles may be particles exhibiting optical properties such as luminous reflectivity, light interference, iris, hologram, metallic luster, and pearl luster.
The refractive index is preferably 1.5 or more. Incidentally, the refractive index of glass is usually about 1.5 to 1.6, the refractive index of anatase type titanium dioxide is about 2.5, and the refractive index of rutile type titanium dioxide is about 2.7.
Specifically, pearl pigments such as mineral particles such as mica (mica) particles and glass particles, metal particles such as flaky aluminum, metal oxides such as titanium dioxide, or particles obtained by coating these with a metal or metal oxide, Glitter particles included in glitter pigments such as flake pigments, aluminum pigments, and bronze pigments can be used.
The particle shape is arbitrary as long as it exhibits a predetermined optical property such as a spherical shape, an elliptical spherical shape, a prismatic shape, a round pillar shape, a flake shape, a scale shape, and an irregular shape. The particle size is also arbitrary, and is preferably selected as appropriate in consideration of coatability, fluidity, uniform dispersibility in the composition, and the like.
The content of the glittering particles is not particularly limited, but may be 0.1 to 50% by weight, preferably 1 to 30% by weight based on the resin as the main material. However, as described above, according to the present invention, suitable glitter can be imparted even when the content of the glitter particles is reduced.
[0034]
Regarding the surface tension of the brilliant pattern forming resin 3, the surface tension according to JIS K-6768 is preferably 240 μN / cm or more, particularly preferably 300 μN / cm or more. At this time, the upper limit value is practically about 200 μN / cm in the current technical level, but is not theoretically set.
Further, the contact angle of the glitter pattern forming resin 3 is preferably 10 to 85 °, and particularly preferably 30 to 80 °.
The surface tension can also be adjusted by using a silicon-based or acrylic-based surface conditioner.
The thickness of the glitter pattern forming resin 3 is not particularly limited, but is generally preferably 0.2 to 20 μm.
[0035]
The resin used as the main material of the glittering pattern forming resin 3 can be appropriately adopted as long as it has the above-mentioned surface tension. However, from the viewpoint of production efficiency and the like, an energy ray-curable resin, that is, polymerizing or A resin that can be cured by irradiation with an electromagnetic wave or a charged particle beam having an energy quantum that can be crosslinked, for example, visible light, ultraviolet (near ultraviolet, vacuum ultraviolet, or the like) X-ray, electron beam, ion beam, or the like can be preferably used.
[0036]
As long as the object of the present invention is not impaired, the base forming resin 2 and the pattern forming resin 3 may optionally contain various other commonly used additives.
[0037]
(Production method)
Hereinafter, a method for manufacturing the glittering surface pattern structure 10 will be described.
[0038]
First, the base forming resin 2 is partially laminated on the surface of the base material 1 so as to leave a non-laminated portion (non-laminated portion 2B). At this time, on the entire surface of the base material 1 or on a predetermined portion, a portion where the base forming resin 2 is not laminated (the non-laminated portion 2B) is partially surrounded or sandwiched by the base forming resin laminated portion 2A. The resin 2 is laminated.
[0039]
Next, a glittering pattern forming resin 3 containing glittering particles is applied substantially uniformly on the underlayer forming resin laminated portion 2A and the underlayer forming resin non-laminating portion 2B (where the substrate 1 is exposed). After the elapse of a predetermined time, a glittering pattern forming resin curing treatment is performed as necessary.
As a result, the surface of the glittering pattern forming resin layer on the base forming resin laminated portion 2A becomes the embossed surface portion 4 which is uneven, and at the same time, a part of the glittering pattern forming resin 3 on the base forming resin laminated portion 2A naturally becomes uncoated with the base forming resin. The glittering pattern forming resin layer surface on the base-forming resin non-laminating portion 2B moves to and gathers in the laminating portion 2B, and becomes a round convex portion or a round convex streak portion 5 whose cross section rises in an arc shape. Therefore, on the surface of the substrate 1, the embossed surface portion 4, the round convex portion or the round convex portion 5, and the substrate remaining surface 6 (the surface portion left as it is on the surface of the substrate 1) are formed.
[0040]
As a method of laminating the base forming resin 2 on the base material 1, there are various methods such as a method of extruding each, a method of laminating a film made of the base forming resin 2, a method of applying the base forming resin 2, and the like. Although it can be adopted, a method of applying the base forming resin 2 is preferable in consideration of the fact that the base forming resin 2 is stacked while leaving a predetermined non-laminated portion 2B. Specifically, gravure coat, gravure reverse coat, gravure offset coat, meyer bar coat, air knife coat, spinner coat, roll coat, reverse roll coat, kiss coat, wheeler coat, solid coat by silk screen, flow coat, spray coat, etc. The known coating means can be used, and among them, a method of coating the resin using a roll having a transfer portion of a predetermined shape is preferable.
[0041]
In addition, as a method of applying the glitter pattern forming resin 3, the method described as a method of applying the base forming resin 2 can be employed. At this time, it is preferable to apply the glitter pattern forming resin 3 to a thickness of 0.2 to 20 μm.
[0042]
Note that the glitter pattern forming resin 3 may be applied after the base forming resin 2 is sufficiently dried, or may be applied before drying.
In order for a part of the glittering pattern forming resin 3 of the base forming resin laminated portion 2A to naturally move and gather in the base forming resin non-laminating portion 2B, the glittering pattern forming resin is heated or ultraviolet rays are used. Make the time until irradiation as long as possible, that is, irradiate with ultraviolet light at a time during which a part of the glittering pattern forming resin 3 of the base forming resin laminated portion 2A naturally moves to the base forming resin non-laminated portion 2B and gathers. It is preferable to do so.
[0043]
The glitter pattern forming resin curing treatment to be performed as necessary is performed by using an apparatus capable of irradiating energy rays such as ultraviolet rays and γ rays when an energy ray-curable resin is used as the glitter pattern forming resin 3. What should I do?
[0044]
When the glittering surface pattern structure is manufactured by such a method, the base forming resin 2 is laminated while leaving the non-laminated portion 2B on the base material 1, and the glittering pattern forming resin 3 is applied substantially uniformly. In response to this, only the glitter pattern forming resin curing treatment is performed to form the embossed surface portion 4 with the uneven surface of the glitter pattern forming resin layer on the underlying resin layered portion 2A, while the glitter on the non-layered resin forming portion 2B. The surface of the pattern-forming resin layer can be a round convex portion or a round convex stripe portion 5. By changing the shape of the base-forming resin laminated portion 2A or the base-forming resin non-laminated portion 2B, it is possible to design freely, and the surface tension difference between the base-forming resin 2 and the glittering pattern-forming resin 3 can be variously changed. By changing the shape, the size and shape of the concavities and convexities of the embossed surface portion 4 can be changed to change the texture and the like, and further, the size and shape of the round convex portion or the round convex portion 5 can be freely changed. be able to. For example, by reducing the surface tension difference between the base forming resin 2 and the glittering pattern forming resin 3, the size of one of the round protrusions or the round protrusions 5 can be further increased.
[0045]
(Example 1)
As shown in FIG. 1 and FIG. 3A, a circle having a diameter of 0.5 mmΦ is left at a pitch of 0.75 mm on the surface of amorphous PET having a thickness of 0.3 mm (“A-PET” haze 0.8%). (That is, so as to form the non-laminated portion 2B), an OP varnish (OP varnish containing an acrylic acid prepolymer and an acrylic acid oligomer; Daicure RT-8, JIS K-, manufactured by Dainippon Ink and Chemicals, Inc.) as a base-forming resin A surface tension of 300 μN / cm or less with a contact angle of 6768, and a contact angle of 85 °) is applied at a thickness of 1 μm, and the glittering pattern forming resin is formed on the base forming resin laminated portion 2A and the base forming resin non-laminated portion 2B in a substantially uniform thickness. It was applied to a thickness of 3 μm, and after 20 mm SEC after the application, ultraviolet irradiation was performed by an ultraviolet irradiation apparatus to obtain a patterned sheet.
At this time, the glittering pattern forming resin includes an ultraviolet-curable resin ink (an ultraviolet-curable resin ink containing an acrylic acid prepolymer and an acrylic acid oligomer; "Die Cure Clear UV-1601EM" manufactured by Dainippon Ink and Chemicals, JIS K- A material obtained by blending 20% by weight of “Iliodin 153 (mica)” manufactured by Merck with a surface tension of 340 μN / cm according to 6768 and a contact angle of 74 ° was used.
[0046]
On the surface of the obtained patterned sheet, as shown in FIG. 3A, a spherical convex portion 5 such as a lens is formed at an appropriate interval in the embossed surface portion 4, and a patterned sheet having a good pearly feeling can be obtained. Was.
The embossed surface portion 4 has an average surface roughness Ra of 3.5 μm, a glossiness (60 °) of 24, a surface gloss value of 24, a light transmittance of 16.5%, a haze of 42.3%, and a light reflectance of 6. 2%.
[0047]
(Example 2)
As shown in FIG. 1 and FIG. 3A, a circle having a diameter of 0.5 mmΦ is left at a pitch of 0.75 mm on the surface of amorphous PET having a thickness of 0.3 mm (“A-PET” haze 0.8%). (That is, so as to form the non-laminated portion 2B), an OP varnish (OP varnish containing an acrylic acid prepolymer and an acrylic acid oligomer; Daicure RT-8, JIS K-, manufactured by Dainippon Ink and Chemicals, Inc.) as a base-forming resin A surface tension of 300 μN / cm or less with a contact angle of 6768, and a contact angle of 85 °) is applied at a thickness of 1 μm, and the glittering pattern forming resin is formed on the base forming resin laminated portion 2A and the base forming resin non-laminated portion 2B in a substantially uniform thickness. It was applied to a thickness of 3 μm, and after 20 mm SEC after the application, ultraviolet irradiation was performed by an ultraviolet irradiation apparatus to obtain a patterned sheet.
In this case, the glittering pattern forming resin includes an ultraviolet-curable resin ink (an ultraviolet-curable resin ink containing an acrylic acid prepolymer and an acrylic acid oligomer; "Die Cure Clear UV-1601EM" manufactured by Dainippon Ink and Chemicals, JIS K- A material obtained by blending 10% by weight of a silver paste made by Toyo Ink with a surface tension of 6768 (340 μN / cm, contact angle 74 °) was used.
[0048]
As in Example 1, the surface of the obtained patterned sheet was formed with a spherical convex portion 5 such as a lens at an appropriate interval in the embossed surface portion 4, and a patterned sheet having a good metallic feeling was obtained.
[0049]
(Example 3)
As shown in FIG. 1 and FIG. 3A, a circle having a diameter of 0.5 mmΦ is left at a pitch of 0.75 mm on the surface of amorphous PET having a thickness of 0.3 mm (“A-PET” haze 0.8%). (That is, so as to form the non-laminated portion 2B), an OP varnish (OP varnish containing an acrylic acid prepolymer and an acrylic acid oligomer; Daicure RT-8, JIS K-, manufactured by Dainippon Ink and Chemicals, Inc.) as a base-forming resin A surface tension of 300 μN / cm or less with a contact angle of 6768, and a contact angle of 85 °) is applied at a thickness of 1 μm, and the glittering pattern forming resin is formed on the base forming resin laminated portion 2A and the base forming resin non-laminated portion 2B in a substantially uniform thickness. It was applied to a thickness of 3 μm, and after 20 mm SEC after the application, ultraviolet irradiation was performed by an ultraviolet irradiation apparatus to obtain a patterned sheet.
In this case, the glittering pattern forming resin includes an ultraviolet-curable resin ink (an ultraviolet-curable resin ink containing an acrylic acid prepolymer and an acrylic acid oligomer; "Die Cure Clear UV-1601EM" manufactured by Dainippon Ink and Chemicals, JIS K- A material obtained by blending 20 wt% of "Silalic T60-10 WNT Crystal Silver" manufactured by Merck Ltd. with a surface tension of 340 μN / cm according to 6768 and a contact angle of 74 ° was used.
[0050]
As in Example 1, the surface of the obtained patterned sheet was formed with a spherical convex portion 5 such as a lens at an appropriate interval in the embossed surface portion 4, and a patterned sheet having a good pearly feeling was obtained.
[0051]
(Comparative Example 1)
Applying a glitter pattern forming resin to the surface of a 0.3 mm thick amorphous PET (“A-PET” haze 0.8%) almost uniformly to a thickness of 3 μm without coating a base forming resin, and applying the coating. After 20 mm SEC, ultraviolet irradiation was performed with an ultraviolet irradiation device to obtain a patterned sheet.
In this case, the glittering pattern forming resin includes an ultraviolet-curable resin ink (an ultraviolet-curable resin ink containing an acrylic acid prepolymer and an acrylic acid oligomer; "Die Cure Clear UV-1601EM" manufactured by Dainippon Ink and Chemicals, JIS K- A surface tension of 340 μN / cm according to 6768 and a contact angle of 74 °) mixed with 10% by weight of “Silver paste” manufactured by Toyo Ink was used.
[0052]
The surface of the obtained patterned sheet was flat, had no unevenness, had a poor metallic feeling, and appeared gray.
[0053]
In the present invention (including examples), the specular gloss is measured in accordance with JIS K-7105 by using a digital variable-angle photometer (light source: standard light C) from the direction of the incident angle of the workpiece of 60 °. This is a value obtained by measuring the light irradiated and reflected by the inscription device in the direction of the reflection angle of 60 °.
In the present invention (including examples), the surface roughness (Ra, Rz, Rmax, and Pc) was measured using a stylus type surface roughness measuring instrument prescribed in JIS-B0651, a stylus 2 μm, a load 70 mg, and a measurement length 8 mm. It is a value when measured by.
In the present invention (including Examples), the contact angle is a value obtained by measuring a value 30 seconds after the addition using a contact angle meter and distilled water as a test liquid.
In the present invention (including Examples), the light transmittance (total transmission, diffuse transmission and haze) is a value measured using a haze meter according to JIS K-7105.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing an example of a sheet body having a glittering surface pattern structure according to an embodiment of the present invention.
FIG. 2 is an enlarged sectional view of a main part for explaining the surface state of a glitter pattern forming resin in the glitter surface pattern structure of the present invention, wherein (A) is a surface state of the glitter pattern forming resin of the present invention; (B) is a surface state of the virtual pattern forming resin.
3 (A) to 3 (D) are perspective views showing design examples of the glittering surface pattern structure of the present invention.
[Explanation of symbols]
1 Substrate
2 Base forming resin
2A Underlayer resin layer
2B Non-laminated part of base forming resin
3 Bright pattern forming resin
4 Embossed surface
5 Round ridge or round ridge
6 Substrate remaining surface
10 Bright surface pattern structure

Claims

In a glittering surface pattern structure formed by laminating a glittering pattern forming resin containing a glittering particle on a substrate to form a glittering pattern forming resin layer,
By forming irregularities on the surface of the glittering pattern forming resin layer, the number of particles in the convex section is larger than the number of glittering particles in the concave section of the irregularity, thereby enhancing the glitter of the pattern surface. Brilliant surface pattern structure.

An undercoating resin is laminated on the surface of the base material to form an undercoating resin laminate, and on the undercoating resin laminate, a glittering pattern forming resin containing glitter particles and having a higher surface tension than the undercoating resin is formed. A glittering surface pattern structure having a configuration in which a glittering pattern forming resin layer is formed by laminating, and the surface of the glittering pattern forming resin layer is an embossed surface portion having fine irregularities.

An underlayer formed by partially laminating the underlayer forming resin on the surface of the base material, and being surrounded or sandwiched by the underlayer forming resin laminate portion in plan view on the base material surface Forming a forming resin non-lamination part,
On the underlayer-forming resin laminated portion and the underlayer-forming resin non-laminating portion, a glittering pattern-forming resin containing glittering particles and having a higher surface tension than the underlayer-forming resin is laminated to form a glittering pattern-forming resin layer, The surface of the glittering pattern-forming resin layer laminated on the base-forming resin laminated portion has an uneven embossed surface portion, and the surface of the glittering pattern-forming resin layer laminated on the non-laminating portion of the foundation-forming resin has a round section with a cross-section protruding in an arc shape. A brilliant surface pattern structure having a configuration formed of a convex part or a round convex part.

A base forming resin is laminated on the surface of the base material to form a base forming resin laminated portion. On the base forming resin laminated portion, a brilliant pattern including glitter particles and having a higher surface tension than the base forming resin is formed. By applying the resin almost uniformly and performing a curing treatment on the glittering pattern forming resin as necessary, a glittering pattern forming resin layer is formed and its surface is made uneven to form an embossed surface portion. A method for producing a glittering surface pattern structure.

On the surface of the base material, the base forming resin is partially laminated so as to enclose or sandwich the non-laminated portion in plan view, and the base forming resin is formed on the base forming resin laminated portion and the base forming resin non-laminated portion. The surface tension is higher than the resin, and the glittering pattern forming resin containing glittering particles is applied almost uniformly, and if necessary, a curing treatment is performed on the glittering pattern forming resin, so that the glittering pattern forming resin is cured. The surface of the glittering pattern forming resin layer to be laminated is made uneven to form an embossed surface portion, and a portion of the glittering pattern forming resin on the underlayer forming resin laminated portion is moved to the underlayer forming resin non-laminating portion and collected to form the underlayer. A method for producing a glittering surface pattern structure, characterized in that the glittering pattern forming resin layer surface to be laminated on the resin non-laminated portion is a circular convex portion or a circular convex portion whose cross section is raised in an arc shape.