JP2009241368A - Resin molded product using hard coat film - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a resin molded product which is shaped by using a hard coat film, has a sufficient hard coat property, and does not cause a crack. <P>SOLUTION: The resin molded product is made by integrally shaping the hard coat film having a hard coat layer on one surface of a base film and a resin molding material into one body. At least one surface of the base film of the hard coat film is subjected to sand blast treatment, and there is formed on the sand blast-treated surface the hard coat layer formed of at least an ionizing radiation-curable resin composition. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to various resin molded products such as an operation unit (keypad unit) of a device such as a touch panel, a mobile phone, a game machine, a sound player, and a notebook computer, and in particular, a resin molding material and a hard coat film are integrated. It relates to resin molded products.

  Conventionally, as a method of patterning the surface of various molded products made of resin, etc., or providing a hard coat layer, a mold is made of a resin molding material and a hard coat film in which a printed layer or a hard coat layer is formed on a base film. There is a method of integrally molding (insert molding).

As such a hard coat film for insert molding, for example, a hard coat film having a metal deposition layer or a printing layer on one side of a base film such as a polyester film and a hard coat layer on the other side has been proposed. (Patent Document 1, Patent Document 2)
Japanese Patent Laying-Open No. 2005-288720 (Claim 1) Japanese Patent Laying-Open No. 2005-305786 (Claim 1)

  In general, a hard coat layer used for the purpose of protecting the surface of a resin molded product is required to have a hard coat property. For example, the hard coat layer is required to have a hardness of H or higher in pencil hardness and a load of 300 g or higher in a steel wool test. For this reason, the hard coat layer is composed of a curable resin excellent in hard coat properties such as an ionizing radiation curable resin. However, when a hard coat film formed with such a hard coat layer is used for insert molding, the surface of the molded product generally has curved surfaces, corners, etc., and thus the hard coat layer is likely to be cracked, whitened or cracked during molding.

  In order to solve this problem, it is conceivable to add a thermoplastic resin to the resin component constituting the hard coat layer to enhance flexibility. However, in that case, the surface hardness is lowered by increasing the flexibility, and cannot withstand the load of the steel wool test as described above.

  Accordingly, an object of the present invention is to provide a resin molded product having an excellent aesthetic appearance that does not cause cracks, whitening, or cracks in the hard coat layer when it is integrally molded with a hard coat film while having sufficient surface hardness.

  In order to solve the above problems, the present inventor has conducted extensive research on the hard coat layer and the base film of the hard coat film at the time of insert molding. The present inventors have found that a hard coat film excellent in followability (flexibility) to curved surfaces, corners, etc. can be obtained while having the properties.

  That is, the resin molded product of the present invention is a hard coat layer formed from at least an ionizing radiation curable resin composition on a surface of a base film that has been sandblasted on at least one surface. A hard coat film provided with a resin molding material is integrated by molding, and the hard coat layer is provided on the surface.

  Further, the resin molded product of the present invention is characterized in that the arithmetic average roughness Ra (JIS B0601: 2001) of the surface of the base film subjected to sandblasting is 0.4 μm or more and 1.0 μm or less. To do.

  In the resin molded product of the present invention, for example, the resin molding material is one selected from an acrylic resin and a polycarbonate resin.

  The resin molded product of the present invention is characterized in that at least one layer including a metal vapor deposition layer, a printing layer, and an adhesive layer is formed between the resin molding material and the hard coat layer. .

  The hard coat film of the present invention includes a hard coat layer formed of at least an ionizing radiation curable resin composition on a surface of a base film that has been sand blasted on at least one surface. It is characterized by that.

  Further, the hard coat film of the present invention is characterized in that the arithmetic average roughness Ra (JIS B0601: 2001) of the surface of the base film subjected to the sandblasting treatment is 0.4 μm or more and 1.0 μm or less. To do.

  In addition, the hard coat film of the present invention is characterized in that the value of the bending resistance test measured by a cylindrical mandrel method (JIS K5600-5-1: 1999) is 6 mm or less.

  Further, the hard coat film of the present invention is characterized in that the hard coat layer does not cause scratches when steel wool # 0000 with a load of 300 g is reciprocated 10 times.

  The hard coat film of the present invention is characterized in that the hard coat layer has a thickness of 1 μm to 10 μm.

  The hard coat film of the present invention is characterized in that at least one layer including a metal vapor deposition layer, a printing layer and an adhesive layer is formed on the other surface of the substrate film.

  According to the present invention, the hard coat layer is sufficient by providing the hard coat film with the hard coat layer on the surface subjected to the sand blast treatment of the base film subjected to the sand blast treatment on at least one surface. It is possible to obtain a resin molded product that has a hard coat property and an excellent aesthetic appearance that does not cause cracking, whitening, or cracking during molding.

  Hereinafter, embodiments of the resin molded product and the hard coat film of the present invention will be described.

  The resin molded product of the present invention is obtained by molding a hard coat film having a hard coat layer and a resin molding material on a surface of the base film that has been sand blasted on at least one surface. It is integrated and has a hard coat layer on the surface. The resin molding material may be an injectable resin, and for example, thermoplastic resins such as acrylic resin, polycarbonate resin, ABS resin, and AS resin, and thermosetting resins are used.

  The hard coat film of the present invention is composed of a base film subjected to sandblasting and a hard coat layer as a basic structure, and the hard coat layer is formed on the surface of the resin molded product of the present invention by molding. Become a layer.

  As the base film, those having excellent transparency, heat resistance and mechanical strength are preferable. Specifically, polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polycarbonate, polyethylene, polypropylene, polystyrene, triacetyl cellulose. Acryl, polyvinyl chloride, norbornene compounds and the like. In particular, from the viewpoint of good dimensional stability due to heat, it is preferable to use a biaxially stretched polyethylene terephthalate film.

  The base film is subjected to sandblasting on at least one surface. Sand blasting is a process in which sand with high hardness such as silica sand (shot material) is struck against the surface of the film with a high-speed rotary blade, or mixed with water and struck against the surface of the film with a high-pressure pump. It is to physically scrape the surface.

  The hard coat film of the present invention is roughened by subjecting the above-mentioned base film to such a sandblast treatment. Here, the substrate film can be roughened by embossing or coating with a binder resin added with a matting agent (hereinafter referred to as chemical matting), but in the present invention, the sandblasting is performed. There is a need to.

  When the surface of the base film is roughened, the surface area of the base film is increased. Therefore, when the hard coat layer is coated on the upper layer, the contact area between the base film and the hard coat layer is increased. Adhesiveness is improved. Further, when the roughening method is a sandblasting process, the shot material is struck against the base film, so that the surface has a concavity and depression shape. If a hard coat layer is coated on such a surface, a coating film is formed on the surface with a concave shape that rises up, so that the coating film is formed on a surface with a concave shape or a convex shape that does not rise up. It is considered that the adhesion is increased. The reason why cracking, whitening, and cracking during molding in the hard coat film can be suppressed by such sandblasting treatment is not clear, but as described above, the unique surface shape generated by sandblasting treatment, that is, the concavo-convex concave shape Therefore, it is considered to be an effect obtained by forming a coating film.

  For example, if the surface is roughened by embossing, it is embossed by applying heat, so it is possible to create a concave surface, but it is possible to create a concavo-convex concave shape like sandblasting. Can not. As a result, when a pressure is applied to the curved surface or corner of the resin molding material, a crack or the like is generated. Therefore, the roughening by the embossing process cannot suppress the occurrence of cracks, whitening, and cracks during molding. In addition, when one surface of the base film is concave, the other surface is convex and does not become a flat surface. Therefore, when a metal treatment layer or printing layer described later is provided or in close contact with the resin molding material Inconvenience may occur.

  Further, for example, when the surface is roughened by chemical mat treatment, even if the kind and size of the matting agent and the thickness of the mat layer are appropriately selected, it is not possible to form a raised concave shape like sandblast treatment. As a result, when a pressure is applied to the curved surface or corner of the resin molding material, a crack or the like is generated. Therefore, the roughening by the chemical mat treatment cannot suppress the occurrence of cracks, whitening, and cracks during molding. In addition, since the adhesiveness varies depending on the type of binder resin selected, the design becomes complicated.

  For example, when an easy adhesion treatment layer is provided, the adhesion between the base film and the hard coat layer can be improved, but the occurrence of cracks, whitening, and cracks during molding cannot be suppressed.

  The shape of the roughened surface changes conditions such as shot material type (hardness), size, spray amount, speed at which it strikes the base film, time, and the distance between the device and the base film. Can be changed by doing. As an example, for example, the condition of processing the surface of polyethylene terephthalate to an arithmetic average roughness Ra (JIS B0601: 2001) of about 0.5 μm is as follows: shot material type: silica sand, shot material size: average particle size 200 μm, injection amount: 2.0 to 2.5 l / sec, peripheral speed: 40 to 50 m / sec, processing time: 30 to 60 sec, distance between apparatus and film: 430 mm.

  The arithmetic average roughness Ra (JIS B0601: 2001) of the surface subjected to sandblasting treatment of such a base film is preferably 0.4 μm or more, more preferably 0.5 μm or more as a lower limit, preferably as an upper limit. Is 1.0 μm or less, more preferably 0.7 μm. By making Ra 0.4 μm or more, cracks, whitening and cracking can be made difficult to occur during molding, and by making it Ra 1.0 μm or less, it is possible to prevent the transparency from being lowered unnecessarily.

  The surface of the base film that has been sandblasted and the other surface may be subjected to easy adhesion treatment such as plasma treatment, corona discharge treatment, far ultraviolet irradiation treatment, and formation of an undercoat easy adhesion layer. Moreover, when sandblasting is performed also on the other surface of the base film, a unique texture can be imparted to the decorative layer composed of a metal vapor-deposited layer and a printed layer described later.

  Further, the thickness of the base film is not particularly limited and is appropriately selected depending on the applied material, but is generally 20 μm to 200 μm, preferably 50 μm to 150 μm. By setting the thickness to 20 μm or more, the physical strength of the base film can be improved, and the sandblasting can be easily performed. Further, by setting the thickness to 200 μm or less, it can be easily integrated by molding with a resin molding material.

  Next, the hard coat layer will be described. The hard coat layer is formed from at least an ionizing radiation curable resin composition. As the ionizing radiation curable resin composition, a photo cationic polymerizable resin capable of crosslinking and curing by irradiation with ionizing radiation (ultraviolet ray or electron beam), or a photo polymerizable prepolymer capable of photo radical polymerization is used. be able to.

  Examples of the cationic photopolymerizable resin include bisphenol-based epoxy resins, novolak-type epoxy resins, alicyclic epoxy resins, aliphatic epoxy resins, and other epoxy-based resins, vinyl ether-based resins, and the like.

  As the photopolymerizable prepolymer capable of photoradical polymerization, an acrylic prepolymer having two or more acryloyl groups in one molecule and having a three-dimensional network structure by crosslinking and curing is particularly preferably used. As the acrylic prepolymer, urethane acrylate, polyester acrylate, epoxy acrylate, melamine acrylate, polyfluoroalkyl acrylate, silicone acrylate and the like can be used, and can be appropriately selected according to the type and use of the base film. From the viewpoint of imparting crack resistance while maintaining hard coat properties, a polyfunctional oligomer having a dendrimer structure and having three or more (meth) acrylate functional groups may be used together with the photopolymerizable prepolymer. Good. These acrylic prepolymers can be used alone, but it is preferable to add a photopolymerizable monomer in order to impart various performances such as improvement of cross-linking curability and adjustment of curing shrinkage.

  As photopolymerizable monomers, monofunctional acrylic monomers such as 2-ethylhexyl acrylate, 2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate, butoxyethyl acrylate, 1,6-hexanediol diacrylate, neopentyl glycol diacrylate, diethylene glycol One kind of bifunctional acrylic monomer such as diacrylate, polyethylene glycol diacrylate, hydroxypivalate ester neopentyl glycol diacrylate, etc., or polyfunctional acrylic monomer such as dipentaerythritol hexaacrylate, trimethylpropane triacrylate, pentaerythritol triacrylate or the like Two or more are used.

  Further, from the viewpoint of imparting crack resistance while maintaining hard coat properties, a photopolymerizable monomer having a cyclo ring in the molecule in addition to the polymerizable reactive group may be used as the photopolymerizable monomer.

  In addition, when such a hard coat layer is used after being cured by ultraviolet irradiation, in addition to the above-mentioned photopolymerizable prepolymer and photopolymerizable monomer, a photopolymerization initiator, a photopolymerization accelerator, and ultraviolet sensitization. It is preferable to use an additive such as an agent.

  As photopolymerization initiators, photocationic polymerization initiators such as onium salts, sulfonic acid esters, organometallic complexes, acetophenone, benzophenone, Michler ketone, benzoin, benzylmethyl ketal, benzoylbenzoate, α-acyloxime esters, thioxanthones, etc. Photoradical polymerization initiators.

  Further, the photopolymerization accelerator can reduce the polymerization obstacle due to air at the time of curing and increase the curing speed. For example, p-dimethylaminobenzoic acid isoamyl ester, p-dimethylaminobenzoic acid ethyl ester, and the like. can give. Examples of the ultraviolet sensitizer include n-butylamine, triethylamine, and tri-n-butylphosphine.

  As the resin component, in addition to the ionizing radiation curable resin composition as described above, other resins such as thermoplastic resins and thermosetting resins may be added as long as the effects of the present invention are not impaired. Also good. Specifically, a resin such as acrylic, polyester, polystyrene, polyvinyl acetate, polyurethane, and cellulose acetate can be added as long as it is about 30% by weight or less of the resin component constituting the hard coat layer.

  In addition, the hard coat layer has a matting agent, lubricant, colorant, pigment, dye, fluorescent whitening agent, flame retardant, antibacterial agent, antifungal agent, antistatic agent, as long as the effect of the present invention is not impaired. Various additives such as ultraviolet absorbers, light stabilizers, heat stabilizers, antioxidants, plasticizers, leveling agents, flow regulators, antifoaming agents, dispersants, storage stabilizers, crosslinking agents, silane coupling agents, etc. May be added.

  The value of the bending resistance test of the hard coat film of the present invention varies depending on the thickness of the hard coat layer and the type and thickness of the base film, but is preferably adjusted to 6 mm or less, more preferably 5 mm or less. Is desirable. When the bending resistance test value is adjusted to a predetermined value or less, the crack resistance of the hard coat layer can be improved. In addition, the value of a bending resistance test is a value measured by the cylindrical mandrel method based on JIS K5600-5-1: 1999.

  Further, it is desirable that such a hard coat layer is adjusted so as not to be damaged when steel wool # 0000 is reciprocated 10 times with a load of 300 g, preferably 500 g. By adjusting in this way, it is possible to ensure the necessary hard coat properties.

  Further, it is desirable that the hard coat layer has a pencil scratch value (pencil hardness) adjusted to H or higher, more preferably 2H or higher, and further preferably 3H or higher. When the pencil scratch value is adjusted to a predetermined value or more, it is possible to effectively prevent the surface of the hard coat layer from being damaged. The pencil scratch value is a value measured by a method based on JIS K5400: 1990.

  The thickness of such a hard coat layer is preferably 1 μm to 10 μm, more preferably 2 μm to 7 μm. By setting the thickness to 1 μm or more, the hard coat property can be easily obtained. This is because if the thickness of the hard coat layer exceeds 10 μm, cracks, whitening, and cracks are likely to occur depending on the shape.

  The hard coat layer as described above is formed on the surface of the base film that has been sandblasted on at least one surface as described above, and the ionizing radiation curable resin composition described above and, if necessary, the surface. The coating material for the hard coat layer is prepared by mixing the additive material and the diluting solvent added in this manner, and a conventionally known coating method such as a bar coater, die coater, blade coater, spin coater, roll coater, gravure coater, flow. It is formed by coating with a coater, spray, screen printing or the like, drying as required, and curing the ionizing radiation curable resin composition by irradiation with ionizing radiation.

  As a method of irradiating with ionizing radiation, ultraviolet rays in a wavelength region of 100 nm to 400 nm, preferably 200 nm to 400 nm, emitted from an ultrahigh pressure mercury lamp, a high pressure mercury lamp, a low pressure mercury lamp, a carbon arc, a metal halide lamp, etc. are irradiated or scanned. The irradiation can be performed by irradiating an electron beam having a wavelength region of 100 nm or less emitted from a type or curtain type electron beam accelerator.

  The basic configuration of the hard coat film of the present invention is a configuration in which a hard coat layer is provided on the surface of the base film that has been subjected to the sand blast treatment on at least one surface, and further the base material. The metal vapor deposition layer and printing layer for decorating a resin molded product may be provided in the surface on the opposite side to the surface in which the hard-coat layer of the film was provided. FIG. 1 shows an example of the structure of a typical hard coat film used in the insert molding method.

  In the illustrated hard coat film 10, a hard coat layer 12 is formed on the surface of the base film 11 that has been subjected to the sand blast treatment 16 on at least one surface, and the metal deposition layer 13 is formed on the other surface. And a decorative layer composed of the printed layer 14 and an adhesive layer 15 are formed in this order. In the figure, the decorative layer is formed by forming the metal vapor-deposited layer 13 on the base film 11 and forming the printed layer 14 thereon, but the configuration of the decorative layer is not limited to that shown in the drawing, but various It can be set as this structure. For example, after forming a desired character or pattern on the base film 11 by a known printing method, silk screen method, gravure method, ink jet method or the like, the metal vapor deposition layer 13 may be formed thereon. In some cases, the printing layer 14 is omitted and the metal vapor deposition layer 13 is formed directly on the base film 11 or only the printing layer 14 is not present. When providing the printing layer 14, you may provide the receiving layer for receiving printing ink in the surface in which the printing layer 14 of the base film 11 is provided.

  The metal vapor-deposited layer 13 is formed of a metal such as aluminum, nickel, gold, platinum, chromium, iron, copper, tin, indium, silver, titanium, lead, or zinc, or an alloy or compound thereof by a known method, for example, It can be formed by vapor deposition by a vacuum vapor deposition method, a sputtering method, an ion plating method or the like.

  The adhesive layer 15 is a layer used for enhancing the adhesion between the resin molded product material and the decorative layer made of the metal vapor-deposited layer 13 or the printing layer 14. Depending on the resin molding material, polyurethane, polyacrylic, Adhesives such as polyester, epoxy, polyvinyl acetate, vinyl chloride / vinyl acetate copolymer, and cellulose can be appropriately used.

  Next, an example of a method for producing a resin molded product using the hard coat film of the present invention will be described.

First, when the hard coat film of the present invention is made into a resin molded product, the hard coat layer is arranged so as to be on the outer side and pressed to be molded into a desired shape. Next, the molded hard coat film is placed in a molding die, and a resin (resin molding material) that has been heated and fluidized between the dies is poured. The resin (resin molding material) is cured and integrated with the hard coat film to obtain the resin molded product of the present invention. The molding conditions (temperature, pressure, time) are appropriately selected according to the type of resin molding material, the shape of the resin molded product, and the like. Generally, the mold clamping pressure is calculated by the resin molded product projection area × in-mold resin pressure. As an example, when the resin to be injection-molded (resin molding material) is ABS resin and the resin molded product dimension (L × W × H) is 60 × 80 × 2 (mm ³ ), the mold clamping pressure is 60 t, the mold temperature is 60 The resin temperature is 250 ° C., and the injection speed is 60 mm / second.

  The resin molded product of the present invention uses a hard coat film provided with a hard coat layer on the surface of the base film that has been sand blasted on at least one surface. No cracking, whitening, or cracking occurs during press working and molding with a metal mold, and it has excellent aesthetics and excellent hard coat properties.

  Examples of the present invention will be described below. “Part” and “%” are based on weight unless otherwise specified.

[Example 1]
Arithmetic average roughness Ra (JIS B0601: 2001) is set to 0.3 μm on one surface of a polyethylene terephthalate film (Lumirror T60: Toray Industries, Inc.) having a thickness of 125 μm as a base film using a rotary vane type jet device. Sandblast treatment (type of shot material: silica sand, size of shot material: average particle size 200 μm, injection amount: 1.5 to 2.0 l / sec, peripheral speed: 40 to 50 m / sec, treatment time: 30 to 60 sec The distance between the apparatus and the film: 430 mm).

Next, a hard coat layer coating solution having the following composition was applied to the surface of the base film that had been sandblasted by the bar coater method, dried at 90 ° C. for 1 minute, and then irradiated with ultraviolet light with a high-pressure mercury lamp ( A hard coat film of Example 1 having a hard coat layer with an irradiation amount of 400 mJ / cm ² ) and a thickness of about 5 μm was obtained.

<The coating liquid for hard-coat layers of Example 1>
17 parts of photopolymerizable prepolymer / photopolymerizable monomer (solid content: 100%) (Beamset 575: Arakawa Chemical Industries)
・ Photopolymerizable monomer having a cyclo ring (solid content: 100%) 3 parts (SR368: Sartomer)
・ 0.4 parts of photopolymerization initiator (Irgacure 651: Ciba Japan)
・ Propylene glycol monomethyl ether 30 parts

[Example 2]
One surface of the same base film as in Example 1 was subjected to sandblasting so that the arithmetic average roughness Ra (JIS B0601: 2001) was 0.4 μm (type of shot material: silica sand, shot material (Size: average particle size 200 μm, injection amount: 1.8 to 2.3 l / sec, peripheral speed: 35 to 45 m / sec, processing time: 30 to 60 sec, distance between apparatus and film: 430 mm). Next, a hard coat layer was formed on the surface of the base film that had been sandblasted in the same manner as in Example 1 to obtain a hard coat film of Example 2.

[Example 3]
One surface of the same base film as in Example 1 was subjected to sandblasting so that the arithmetic average roughness Ra (JIS B0601: 2001) was 0.5 μm (type of shot material: silica sand, shot material (Size: average particle size 200 μm, injection amount: 2.0 to 2.5 l / sec, peripheral speed: 40 to 50 m / sec, processing time: 30 to 60 sec, distance between apparatus and film: 430 mm). Next, a hard coat layer was formed on the surface of the base film that had been sandblasted in the same manner as in Example 1 to obtain a hard coat film of Example 3.

[Example 4]
One surface of the same base film as in Example 1 was subjected to sandblasting so that the arithmetic average roughness Ra (JIS B0601: 2001) was 0.7 μm (treated twice under the conditions of Example 3). Performed). Next, a hard coat layer was formed on the surface of the base film that had been sandblasted in the same manner as in Example 1 to obtain a hard coat film of Example 4.

[Comparative Example 1]
A hard coat layer was formed in the same manner as in Example 1 except that the sandblast treatment was not performed with the same base film as in Example 1, and a hard coat film of Comparative Example 1 was obtained.

[Comparative Example 2]
Instead of the base film of Example 1, a film subjected to chemical mat treatment (chemical mat PW: Kimoto Co., thickness 125 μm) having an arithmetic average roughness Ra (JIS B0601: 2001) of 1.0 μm was subjected to sandblast treatment. A hard coat layer was formed in the same manner as in Example 1 on the surface that was not subjected to chemical matting, and a hard coat film of Comparative Example 2 was obtained.

[Comparative Example 3]
The base film similar to that in Example 1 was not subjected to sandblasting, and a hard coat layer coating solution having the following composition was applied to one surface of the base film, dried, and then irradiated with ultraviolet light using a high-pressure mercury lamp. A hard coat film of Comparative Example 3 having a hard coat layer having a thickness of 5.5 μm was obtained.

<Coating liquid for hard coat layer of Comparative Example 3>
・ Photopolymerizable prepolymer / photopolymerizable monomer (solid content 100%) 12 parts (Beamset 575: Arakawa Chemical Industries)
・ 20 parts of thermoplastic acrylic resin (solid content 40%) (Acridic A195: Dainippon Ink and Chemicals)
・ 0.4 parts of photopolymerization initiator (Irgacure 651: Ciba Japan)
・ 33 parts of propylene glycol monomethyl ether

  About the hard coat film obtained by the Example and the comparative example, it evaluated as follows about adhesiveness, a hard-coat property, and crack resistance. The results are shown in Table 1.

(1) Evaluation of adhesiveness First, a cross cut method based on JIS K5600-5-6: 1999 is used to cut the hard coat layer so that 100 squares with a gap interval of 1 mm are formed. Next, the cellophane adhesive tape based on JISZ1522 was affixed on the surface in which the cut | interruption was made, and the state of the coating film after peeling was observed visually. As a result, the case where peeling did not occur at all was evaluated as “◯”, the case where peeling slightly occurred was evaluated as “Δ”, and the case where all peeling occurred was evaluated as “x”.

(2) Evaluation of hard coat properties (2) -1. Steel wool resistance (SW resistance)
The surface of the hard coat layer was rubbed 10 times with steel wool # 0000 with a load of 500 g, and the presence or absence of scratches on the surface was visually observed. Next, with respect to those which were damaged by a load of 500 g, 10 reciprocations were rubbed with steel wool in the same manner as described above at a load of 300 g, and the presence or absence of scratches on the surface was visually observed. As a result, “◎” indicates that no damage was caused by a load of 500 g, “◯” indicates that no damage was caused by a load of 300 g, and “×” indicates that the damage was clearly damaged by a load of 300 g. .

(2) -2. Pencil Hardness The pencil scratch value on the hard coat layer surface was measured by a method based on JIS K5400: 1990. The measured value obtained was 3H or more as “◎”, 2H or more but less than 3H as “◯”, H or more but less than 2H as “Δ”, and less than H as “X”. evaluated.

(3) Crack resistance Based on the bending resistance (cylindrical mandrel method) according to JIS K5600-5-1: 1999, the hard coat layer was folded back and wrapped around an iron bar having a diameter of about 5 mm. It was visually observed whether or not a crack occurred in the wound hard coat layer. Next, about the thing in which the crack was confirmed with the iron bar about 5 mm in diameter, it wound around the iron bar about 6 mm in diameter similarly to the above, and visually observed whether the hard-coat layer produced a crack. As a result, “◎” indicates that no crack was found on the iron bar having a diameter of about 5 mm, “◯” indicates that no crack was found on the iron bar having a diameter of about 6 mm, and cracks were confirmed on the iron bar having a diameter of about 6 mm. Things were evaluated as “x”.

  As can be seen from the results shown in Table 1, a hard coat layer formed of an ionizing radiation curable resin composition is formed on the surface of the base film that has been sandblasted on one surface. Examples 1-4 which are the hard coat films provided were excellent in hard coat properties and crack resistance. Particularly, Examples 2 to 4 in which the arithmetic average roughness Ra of the surface subjected to the sandblasting treatment of the base film was 0.4 μm or more and 1.0 μm or less are the most excellent in crack resistance, In the bending resistance test by the cylindrical mandrel method, even an iron bar having a diameter of about 5 mm did not crack.

  On the other hand, Comparative Example 1, which is a hard coat film using a base film that has not been subjected to sandblasting, has excellent hard coat properties but is inferior to Examples 1 to 4 in crack resistance. In the bending resistance test by the shape mandrel method, even an iron bar having a diameter of about 6 mm generated cracks. Also, the adhesion between the hard coat layer and the substrate was low.

  Moreover, although the hard-coat film which is a hard coat film using what was not subjected to sandblasting as a base film and was subjected to chemical matting is excellent in hard coat properties, the crack resistance is higher than those in Examples 1 to 4. However, even in an iron bar having a diameter of about 6 mm in a bending resistance test by a cylindrical mandrel method, a crack was generated.

  Further, Comparative Example 3 which is a hard coat film obtained by adding a thermoplastic resin to the hard coat layer using a base film that has not been sandblasted has improved crack resistance, but at the same time has hard coat properties. Decreased.

[Example 5, Comparative Examples 4, 5]
When the hard coat films obtained in Example 3 and Comparative Examples 1 and 3 were each formed into a resin molded product, they were incorporated into an injection mold so that the hard coat layer would be on the outside, and formed into a three-dimensional shape by vacuum molding. After molding, the melted acrylic resin was filled in a mold, the mold was cooled, and an acrylic resin molded product cured integrally with the hard coat film was taken out.

  About these resin molded products, the edge part (curved surface and corner | angular part) of the resin molded product surface was observed visually. Moreover, the same evaluation as the hard coat film mentioned above was performed about the hard coat property (steel wool resistance) of the surface.

  As a result, for the resin molded product using the hard coat film of Example 3 (Example 5), there was no occurrence of cracking or whitening at the edge portion, and the hard coat property (steel wool resistance) was also described above. Good results similar to the film were obtained.

  In contrast, for the resin molded product using the hard coat film of Comparative Example 1 (Comparative Example 4), good results were obtained for the hard coat properties, but cracking and whitening were confirmed at the edge portion. It was.

  Further, for the resin molded product using the hard coat film of Comparative Example 3 (Comparative Example 5), there was no occurrence of cracks or whitening at the edge portion, but for the hard coat properties, the hard coat film of Example 3 was used. It was inferior to the resin molded product used (Example 5).

  ADVANTAGE OF THE INVENTION According to this invention, it is a resin molded product using a hard-coat film, Comprising: The generation | occurrence | production of the crack at the time of shaping | molding, whitening, and the resin molded product excellent in hard-coat property are provided.

The figure which shows an example of the structure of the hard coat film to which this invention is applied

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 ... Hard coat film 11 ... Base film 12 ... Hard coat layer 13 ... Metal vapor deposition layer 14 ... Print layer 15 ... Adhesive layer 16 ... Sandblasting surface

Claims (10)

  A hard coat film having a hard coat layer formed of at least an ionizing radiation curable resin composition on a surface subjected to a sand blast treatment of a base film subjected to a sand blast treatment on at least one surface, and resin molding A resin molded product, which is formed by integrating a material with a molding and has the hard coat layer on the surface.   2. The resin molded product according to claim 1, wherein an arithmetic average roughness Ra (JIS B0601: 2001) of a surface of the base film on which sandblasting is performed is 0.4 μm or more and 1.0 μm or less. Characteristic resin molded product.   3. The resin molded product according to claim 1, wherein the resin molded material is one selected from an acrylic resin and a polycarbonate resin.   4. The resin molded product according to claim 1, wherein at least one layer including a metal vapor deposition layer, a printing layer, and an adhesive layer is formed between the resin molding material and the hard coat layer. 5. A resin molded product characterized by   A hard coat characterized by comprising a hard coat layer formed of at least an ionizing radiation curable resin composition on a surface of a base film that has been subjected to a sand blast treatment on at least one surface. the film.   The hard coat film according to claim 5, wherein the arithmetic average roughness Ra (JIS B0601: 2001) of the surface of the base film on which the sandblast treatment has been performed is 0.4 μm or more and 1.0 μm or less. Features a hard coat film.   The hard coat film according to claim 5 or 6, wherein a value of a flex resistance test measured by a method based on a cylindrical mandrel method (JIS K5600-5-1: 1999) is 6 mm or less. Hard coat film.   8. The hard coat film according to claim 7, wherein the hard coat layer does not cause scratches when steel wool # 0000 with a load of 300 g is reciprocated 10 times.   The hard coat film according to claim 5, wherein the hard coat layer has a thickness of 1 μm to 10 μm.   10. The hard coat film according to claim 5, wherein at least one layer including a metal vapor-deposited layer, a printed layer, and an adhesive layer is formed on the other surface of the base film. Features a hard coat film.

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