JP2012081406A - Method for manufacturing cover film and film for cover film - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a cover film to which a stamping process can be applied without generating cracks or fissure marks (milkiness), regardless of the material and layer thickness of a constituent material.SOLUTION: This method for manufacturing a cover film comprises the following processes: a coat layer forming process (P2) which forms a coat layer 3A like a fluid on a base sheet 2A, a first curing process (P3) which prevents the coat layer 3A from laminating on a corresponding member, when the base sheet 2A on which the coat layer 3A is formed, is wound in the form of a roll and also, which cures the coat layer 3A at a first hardness which cracks the coat layer 3A, when the base sheet 2A is blanked using a blade 4, a blanking process (P4) which forms a film (6) including the base sheet 2A and the coat layer 3A to the desired shape by blanking process after the first curing process(P3), and a second curing process (P5) which cures the coat layer 3A which is through with the blanking process (P4), at a second hardness which is higher than the first hardness.

Description

  The present invention relates to a method for producing a cover film formed by forming a hard coat layer on a transparent substrate sheet. Moreover, this invention relates to the film for cover films used for the manufacturing method of the cover film.

  2. Description of the Related Art Conventionally, a cover film is widely provided on the display surface of various electronic device products such as a mobile phone, a flat panel display, and a touch panel. This is mainly for preventing the display surface of the electronic device from being scratched or preventing dust, dust, etc. from adhering to the display surface.

  As a method for producing such a cover film, there is conventionally a method disclosed as “a method for producing a resin laminated sheet” in paragraph [0004] of Patent Document 1. This conventional method is a method in which a hard coat layer is formed on a substrate sheet made of an acrylic resin sheet or the like, and then the substrate and the hard coat layer are formed into a desired outer shape by cutting. In this conventional method, it takes a long time to process a desired outer shape by cutting. That is, the productivity of the cutting process was extremely low. Also, the processing cost was very high.

  Further, in the paragraph [0007] of Patent Document 1, when a punching process is used instead of a cutting process as a method for forming a conventional general resin laminated sheet into a desired shape, the sheet is cracked. It is described that. The process of punching a resin laminated sheet is also disclosed in the paragraphs [0005] and [0018] of Patent Document 2.

  And in the [0009] paragraph of patent document 1, the manufacturing method of the resin laminated sheet which prevented generation | occurrence | production of such a crack is disclosed. Specifically, an intervening layer is provided between the base sheet and the hard coat layer, the material of the base sheet and the intervening layer is specified, and the thickness of the intervening layer and the thickness of the entire resin laminated sheet as a product By specifying both thicknesses, punching workability when performing a punching process using a tool is improved. And thereby, the improvement of the productivity of a resin lamination sheet is intended. However, in this method, the material and thickness of the constituent material of the sheet must be limited, and the versatility is poor and is not practical.

  A technique related to the present invention is disclosed in Patent Document 3. This technique relates to a method of manufacturing an insert decorative article as a cover film using a so-called insert molding technique. As shown in FIG. 12, the cover film manufacturing method is easy to understand. As shown in FIG. 12, an insert molding sheet including an overcoat layer is formed (steps P501 to P504), and the sheet is formed by drawing before the overcoat layer is cured. Is formed into a three-dimensional shape (process P505), the sheet after the drawing process is placed in a mold, and injection molding is performed (process P506 to P508), and an adhesive integrated molded product obtained by injection molding The overcoat layer, which is a constituent element, is irradiated with UV (ultraviolet rays) and cured to produce a cover film having a hard coat layer (step P509). The relationship between this prior art and the present invention will be described later.

JP 2008-049623 A Japanese Patent No. 4192128 JP 2004-082565 A

The present invention has been made in view of the above problems, and is a cover film to which a punching process can be applied without generating cracks and crack marks (white turbidity) regardless of the material and layer thickness of the constituent materials. It aims at providing the manufacturing method of.
Another object is to provide a film for a cover film that is suitable for carrying out such a method for producing a cover film.

  The method for producing a cover film according to the present invention includes (1) a coat layer forming step of forming a coat layer in a fluid state on the substrate sheet, and (2) winding the substrate sheet on which the coat layer is formed in a roll shape. A first curing step of curing the coating layer to a first hardness that is a hardness that does not cause the coating layer to crack when the coating layer is not attached to a facing member and is punched with a blade; 3) a punching process for forming a film including the base sheet and the coat layer into a desired shape by a punching process after the first curing process; and (4) the first coating layer after the punching process. And a second curing step of curing to a second hardness higher than the hardness.

  In the above configuration, the “blade” is, for example, a well-known big blade, that is, an engraving blade. The cross-sectional shape of the big blade is, for example, an acute cross-sectional shape as shown in FIG.

  As the “base sheet”, any material can be selected and used as long as it is transparent and suitable for punching. “Transparent” means, for example, a state where the light transmittance is 70 to 95%. As such a material, for example, PET (polyethylene terephthalate) can be used.

  “Punching” is a process of cutting a sheet member into a predetermined shape using a blade tool such as a big blade, that is, an engraving blade, etc., using a rotary punching process using a rotary blade or a blade tool that moves up and down. Flat punching can be used.

  Generally, when a coat layer is initially formed on a base sheet, the coat layer is in a fluid state, for example, a liquid, so that it is sticky or flows and is inconvenient to handle. In the present invention, the first curing step allows the coating layer to be cured to the first hardness that does not stick to the opposing member, so that the coating layer does not stick to a human hand, but can be stuck even when wound in a roll. It does not occur and is easy to handle.

  Further, even after being cured to the first hardness, the first hardness is a hardness that does not cause cracks in the coating layer when it is punched with a blade. When the film is formed into a desired shape by punching, no cracks or crack marks (white turbidity) are generated in the film.

  A hard coat layer can be formed on the surface layer by curing the coat layer by irradiating the coat layer with radiation after the punching process. In this way, it is possible to produce a cover film that is hardly damaged. In addition, the production efficiency is very high because it is not a cutting process or a laser process but a punching process. Furthermore, since it is not necessary to limit the material, thickness, etc. of the base sheet and the coating layer to specific ones, it is extremely versatile and practical.

  In Patent Document 3, before the coating layer is cured, the sheet including the coating layer is drawn, the processed sheet material is injection-molded, and the coating layer is subjected to UV after the injection-molding process. An insert molding method is disclosed in which a colored article as a cover film that can function as a protective cover is produced by irradiating and curing the coating layer. This method is a technique in which a drawing process is performed while the coat layer is soft, and the coat layer is cured after the drawing process to obtain a desired hardness. It is also possible to think that this is related to the present invention in which the coat layer is subsequently cured to obtain the desired hardness.

  However, the technique disclosed in Patent Document 3 is a device for forming a three-dimensional shape (three-dimensional shape) by drawing, whereas the present invention is based on a punching process that is unrelated to the molding of the three-dimensional shape. It is related to the formation of the outer shape, and in that sense, they handle completely different technologies.

  In the present invention, the first hardness of the coat layer in the first curing step and the second hardness of the coat layer in the second curing step can be adjusted by the ratio of the components of the material forming the coat layer.

  In the method for manufacturing a cover film according to the present invention, the first hardness is preferably a hardness of less than 2H pencil hardness.

  The pencil hardness is a hardness defined by JIS. The pencil hardness nH (in general, n is an integer) is a value when the object is scratched when the object is rubbed with a pencil of hardness nH, and the pencil with a hardness less than that is not damaged. It is hardness. For example, when the object is rubbed with a pencil having a hardness of 2H and scratched with a pencil having a hardness less than that, the pencil hardness of the object is 2H.

  If the coat layer has a pencil hardness of less than 2H, when the base sheet on which the coat layer is formed is wound into a roll, the coat layer does not stick to the opposing member, and when it is punched with a blade, It is possible to realize a state in which cracks (that is, cracks and crack marks (white turbidity) do not enter).

  Generally, the pencil hardness is expressed as an integer such as 1H, 2H, 3H, 4H,. In the present invention, “pencil hardness less than 2H” does not mean that only “1H”, which is an integer value less than “2H”, is an arbitrary stepless continuous lower than pencil hardness “2H”. Hardness is an index.

  In the cover film manufacturing method according to the present invention, the second hardness is preferably a pencil hardness of 2H or more. If the coat layer has a pencil hardness of 2H or more, the coat layer can be a hard coat layer that is hardly scratched.

  In the cover film manufacturing method according to the present invention, the coat layer is preferably formed of a resin obtained by mixing a thermosetting resin and a radiation curable resin, and the first curing step is performed by heating. It is preferable that the second curing step is performed by curing the radiation curable resin by radiation irradiation. With this configuration, the first curing and the second curing of the coat layer can be accurately realized.

  Note that “radiation” refers to electromagnetic waves such as radio waves, microwaves, infrared rays, visible rays, ultraviolet rays (UV), X-rays and gamma rays, or particle rays such as alpha rays, beta rays, neutron rays and electron rays. As the radiation curable resin, any material can be selected and used as necessary. Examples of such materials include acrylate compounds and methacrylate compounds.

  The cover film manufacturing method according to the present invention includes (1) a printing layer on the substrate sheet or the coating layer using a thermosetting ink after the first curing step and before the punching step. A printing layer forming step to be formed; and (2) a printing layer curing step of curing the printing layer by heating after the printing layer forming step and before the punching step, (3) In the punching process, the film including the base sheet, the coat layer, and the print layer can be punched. This method for producing a cover film is suitable when printing is performed using a thermosetting ink.

  The method for producing a cover film according to the present invention includes: (1) a printing layer is formed on the base sheet or the coat layer using a radiation curable ink after the first curing step and before the punching step. A printing layer forming step to be formed; (2) a printing layer curing step in which the printing layer is cured by radiation irradiation after the printing layer forming step and before the punching step; and (3) the printing layer forming step. And a radiation absorbing layer forming step of forming a radiation absorbing layer between the coat layer and the printed layer. This method for producing a cover film is suitable when printing is performed using a radiation curable ink.

  In the method for manufacturing a cover film according to the present invention, (1) the base sheet can be formed of a resin containing a radiation absorber. In this case, the manufacturing method includes (2) after the first curing step. A printing layer forming step of forming a printing layer on the base sheet or the coating layer using a radiation curable ink before the punching step; and (3) the punching process after the printing layer forming step. Before the step, a printing layer curing step of curing the printed layer by radiation irradiation can be included. This method of manufacturing the cover film is also suitable when printing is performed using a radiation curable ink.

  The method for producing a cover film according to the present invention includes (1) a second coat layer forming step of forming a second coat layer in a fluid state on the base sheet opposite to the side on which the coat layer is formed; ) A second coating layer curing step for curing the second coating layer to a third hardness that can prevent bending of the base sheet and when the second coating layer is punched with a blade; It is desirable to have

  In the present invention, the coating layer undergoes shrinkage due to cross-linking curing after curing, and the shrinkage may cause the substrate film to curl, that is, bend. In this regard, in the aspect of the present invention, the second coat layer is provided on the base sheet opposite to the side on which the coat layer is formed, and the second coat layer has a third hardness, that is, the base sheet can be prevented from bending. Curing of the base sheet can be prevented by curing.

  The third hardness is preferably less than the pencil hardness 2H. This hardness can prevent the curling from occurring when a coating layer is provided on the surface side of the base sheet. And it can prevent that a crack, ie, a crack, and a crack mark (white turbidity) enter at the time of a punching process.

  The method for producing a cover film according to the present invention includes: (1) a printing layer is formed on the base sheet or the coat layer using a radiation curable ink after the first curing step and before the punching step. A printing layer forming step to be formed; (2) a printing layer curing step in which the printing layer is cured by radiation irradiation after the printing layer forming step and before the punching step; and (3) the printing layer forming step. And a radiation absorbing layer forming step of forming a radiation absorbing layer between the coat layer and the printed layer.

  This cover film manufacturing method is suitable when printing is performed using a radiation curable ink in the case of providing a second coating layer for preventing curling on the opposite side of the coating layer.

  In the method for producing a cover film according to the present invention, (1) the second coat layer can be formed of a resin containing a radiation absorber. And this manufacturing method is (2) The printing layer which forms a printing layer on the said base sheet or the said coating layer using a radiation curable ink after the said 1st hardening process and before the said punching process process. And (3) a printing layer curing step of curing the printing layer by radiation irradiation after the printing layer forming step and before the punching step.

  This cover film manufacturing method is suitable when printing is performed using a radiation curable ink in the case of providing a second coating layer for preventing curling on the opposite side of the coating layer.

  In this invention, the 3rd hardness of the 2nd coating layer in a 2nd coating layer hardening process can be adjusted with the ratio of the component of the material which forms a 2nd coating layer.

  The film for a cover film according to the present invention is a film for a cover film having a base sheet and a coat layer laminated on the base sheet, and the coat layer includes a thermosetting resin and a radiation curable resin. The coat layer is formed of a resin, and the thermosetting resin is cured by heating, and the radiation curable resin is uncured.

  According to this cover film film, the coating layer is thermally cured (first cured) to a first hardness (for example, a hardness of less than 2H pencil hardness), and no stickiness or sticking occurs. Easy to handle. Specifically, it is easy to wind the film into a roll. This winding facilitates the conveyance of the film.

  Further, the first curing of the coat layer by heat curing is performed when the base sheet on which the coat layer is formed is rolled into a roll shape and the coat layer does not stick to the opposing member and is punched with a blade. The first hardness, which is a hardness that does not cause cracks in the coating layer, can be suppressed. In this way, the film that is prepared in an easy-to-handle state such as a roll after the first curing is carried to the punching process, and when the punching process is performed, the film is desired without causing cracks in the coat layer. It can be punched into a cover film of the shape. Since no crack occurs in the coat layer, a cover film having a beautiful appearance can be produced.

  Further, since the coating layer contains a radiation curable resin in addition to the thermosetting resin, after the above punching process is completed, the radiation curable resin is irradiated with radiation to be cured (second curing). Can do. And by this hardening, desired 2nd hardness (for example, the hardness of pencil hardness 2H or more) can be provided to a coat layer, As a result, the cover film provided with the hard-coat property which does not get a crack easily. Can be manufactured.

(Method for manufacturing cover film)
Generally, when a coat layer is formed on a base sheet, the coat layer is in a fluid state, for example, a liquid, so that it is sticky or flows and is inconvenient to handle. In the method for producing a cover film according to the present invention, the first curing step allows the coating layer to be cured to a first hardness that does not adhere to the opposing member. Even if it is wound around, sticking does not occur and handling becomes easy.

  Further, even after being cured to the first hardness, the first hardness is a hardness that does not cause cracks in the coating layer when it is punched with a blade. When the film is formed into a desired shape by punching, no cracks or crack marks (white turbidity) are generated in the film.

  A hard coat layer can be formed on the surface layer by curing the coat layer by irradiating the coat layer with radiation after the punching process. In this way, it is possible to produce a cover film that is hardly damaged. In addition, the production efficiency is very high because it is not a cutting process or a laser process but a punching process. Furthermore, since it is not necessary to limit the material, thickness, etc. of the base sheet and the coating layer to specific ones, it is extremely versatile and practical.

(Film for cover film)
According to the film for a cover film according to the present invention, the coating layer is heat-cured (first curing), and the film is easy to handle because no stickiness or sticking occurs. Specifically, it is easy to wind the film into a roll. This winding facilitates the conveyance of the film.

  Further, the first curing of the coat layer by heat curing is performed when the base sheet on which the coat layer is formed is rolled into a roll shape and the coat layer does not stick to the opposing member and is punched with a blade. The first hardness, which is a hardness that does not cause cracks in the coating layer, can be suppressed. In this way, the film that is prepared in an easy-to-handle state such as a roll after the first curing is carried to the punching process, and when the punching process is performed, the film is desired without causing cracks in the coat layer. It can be punched into a cover film of the shape. Since no crack occurs in the coat layer, a cover film having a beautiful appearance can be produced.

  Further, since the coating layer contains a radiation curable resin in addition to the thermosetting resin, after the above punching process is completed, the radiation curable resin is irradiated with radiation to be cured (second curing). Can do. And by this hardening, desired 2nd hardness (for example, the hardness of pencil hardness 2H or more) can be provided to a coat layer, As a result, the cover film provided with the hard-coat property which does not get a crack easily. Can be manufactured.

It is process drawing which shows one Embodiment of the manufacturing method of the cover film which concerns on this invention. It is a perspective view which shows one embodiment of each of the base sheet used by this invention, and the cover film manufactured by this invention. It is process drawing which shows other embodiment of the manufacturing method of the cover film which concerns on this invention. It is a perspective view which shows other embodiment of each of the base sheet used by this invention, and the cover film manufactured by this invention. It is process drawing which shows other embodiment of the manufacturing method of the cover film which concerns on this invention. It is process drawing which shows other embodiment of the manufacturing method of the cover film which concerns on this invention. It is process drawing which shows other embodiment of the manufacturing method of the cover film which concerns on this invention. It is process drawing which shows other embodiment of the manufacturing method of the cover film which concerns on this invention. It is process drawing which shows other embodiment of the manufacturing method of the cover film which concerns on this invention. It is process drawing which shows other embodiment of the manufacturing method of the cover film which concerns on this invention. It is a figure which shows the specific example of the shape of the blade used by this invention. It is process drawing which shows an example of the manufacturing method of the conventional cover film.

  Hereinafter, the present invention will be described based on embodiments. Of course, the present invention is not limited to this embodiment. In the following description, the drawings are referred to. In the drawings, the components may be shown in different ratios from the actual ones in order to show the characteristic parts in an easy-to-understand manner.

(First embodiment)
FIG. 1 shows an embodiment of a method for producing a cover film according to the present invention. This embodiment is a manufacturing method suitable for manufacturing, for example, a rectangular cover film 1 as shown in FIG. The cover film 1 is attached to, for example, a display surface of a mobile phone, a display surface of a PDA (Personal Digital Assistant or Personal Data Assistance), a surface of a touch panel provided on the display surface of the PDA, and the like. Used to protect.

  In the manufacturing method of the present embodiment, a base sheet 2A is prepared in FIG. 1 (step P1). The base sheet 2A is provided as a roll-shaped sheet having a wide width W, for example, as shown in FIG. 2 A of roll-shaped base sheets are mainly formed with resin which has transparent PET (polyethylene terephthalate) as a main component.

  Next, the coat layer 3A is laminated, for example, applied on the main surface, which is the display-side surface of the base sheet 2A, to form the film 6 (step P2). The coat layer 3A is formed of a transparent resin. The coat layer 3A is formed of a resin including a thermosetting resin and a radiation curable resin. As the resin forming the coat layer 3A, for example, an acrylate compound, a methacrylate compound, or the like is used. As a coating method, a known method such as a laminating method, a roll coating method, or a spray coating method can be adopted. The coated layer 3A in the applied state is liquid, that is, fluid, and the hardness thereof is, for example, a pencil hardness of 1H or less.

  Next, in the first curing step P3, the film 6 is heated and the coat layer 3A is dried, that is, cured to the first hardness. For example, the coat layer 3A having a pencil hardness of 1H or less is cured to an appropriate first hardness of less than the pencil hardness 2H. Specifically, the first hardness is determined when the base sheet 2A on which the coat layer 3A is formed is rolled into a roll shape so that the coat layer 3A does not stick to the opposing member and is punched with a blade. The hardness is such that cracks, that is, cracks, crack marks (white turbidity), etc. do not enter 3A.

  The film 6 on which the coating layer 3A is first cured is conveyed to a punching processing place after being easily carried by being wound up. Since the first cured coat layer 3A does not flow and does not stick, it can be easily wound into a roll. The film 6 conveyed to the punching processing place is punched (that is, punched) using the blade tool 4 in the punching process P4. As the blade tool 4, for example, a big blade, that is, an engraving blade is used.

In FIG. 1 and each drawing to be described below, the “solid line” drawn between each process indicates that the film to be processed is continuously processed in each process at the same place or continuously on the same transport line. It shows that it receives processing automatically. On the other hand, the “broken line” drawn between each process indicates that the processing object is transported from one process processing place to another process processing place.
Of course, in actual work, the embodiment of each process can be in any form other than the form shown by the “solid line” and “broken line” shown in the figure.

  A plurality of cover films 1 having a predetermined shape (rectangular shape in the present embodiment) as shown in FIG. 2B are simultaneously formed by the punching process in the process P4. The cover film 1 includes a rectangular base sheet 2 after punching and a coat layer 3 having the same shape adhered thereto. Since the coating layer 3A has a pencil hardness of less than 2H, which is a soft hardness at the time of punching, cracks, scratches, and crack marks (white turbidity) do not occur even when the tool 4 is punched, and the appearance is beautiful. Finished.

  Next, the coating layer 3 of the cover film 1 after the punching process is irradiated with radiation, for example, UV rays (ultraviolet rays) (process P5). By this UV irradiation, the coat layer 3 is cured to the second hardness. The second hardness is, for example, an appropriate hardness value of pencil hardness 2H or higher, for example, pencil hardness 3H, pencil hardness 4H, or a hardness value in the vicinity thereof.

  By this second hardness step, the hard coat layer 3 that is hard to be damaged is formed. Thereafter, the cover film 1 is attached to an object such as a display surface of an electronic device such as a mobile phone after an adhesive layer (for example, a double-sided adhesive) is formed on the back side of the base sheet 2. Thereby, the display surface of an electronic device etc. is protected from a damage | wound, dust, etc.

  In the present embodiment, when the cover film 1 is finished to the outer shape of FIG. 2B, it is possible to realize not only an individual processing method such as cutting or laser processing but also a blanking process that can form a large number of pieces at once. Therefore, it is very advantageous practically. Since many pieces are taken, the manufacturing cost is reduced. And although it is the manufacturing method of the hard coat film which employ | adopted the punching process, it can prevent that a crack, a damage | wound, a crack mark (white turbidity), etc. generate | occur | produce in a film.

  The process diagram shown in FIG. 1 shows essential process elements of the present invention, and other process elements may be added as needed in addition to the illustrated process elements.

(Second Embodiment)
FIG. 3 shows another embodiment of the method for producing a cover film according to the present invention. This embodiment is a manufacturing method suitable for manufacturing, for example, a cover film 11 having a rectangular shape as shown in FIG. 4B and provided with a printing layer 7 (in this embodiment, a frame region indicated by diagonal lines). . In the following description, the points common to the descriptions in the embodiments so far will be omitted as appropriate.

  In the present embodiment, the processes from the base sheet preparation process P11 to the first curing process P13 are the same as the processes from the base sheet preparation process P1 to the first curing process P3 in the embodiment of FIG. The film 6 after the first curing step (P13) is transported to a pre-printing processing place after being easily carried by being wound up.

  In the pre-printing process P14, the roll-shaped base sheet 2A shown in FIG. 4A is cut into a shape suitable for the printing process, for example, a slit shape or a sheet shape. Since the coat layer 3A is in the first hardness state, this cutting can also be performed easily and accurately.

  After completion of the pretreatment, a printing process is performed using a thermosetting ink in the printing layer forming step P15. By this printing process, as shown in FIG. 4B, a print layer 7 having a predetermined pattern (in this embodiment, a rectangular frame pattern) is formed on the back surface (the back surface of the main surface) of the cover film 11. . At this time, a character, a logo, etc. may be printed. Printing can be performed using a known printing method such as an offset printing method, a gravure printing method, or a screen printing method.

  Next, in the printing layer curing step P16, the film 6 is heated and the printing layer 7 is cured. Thereafter, the film 6 is carried to the punching process P17. Then, a punching process is performed on the film 6 using the blade tool 4. Thereby, as shown in FIG.4 (b), the cover film 11 in which the printing layer 7 was formed in the predetermined shape (this embodiment rectangular shape) is formed. The cover film 11 includes a rectangular base sheet 2 after punching and a coat layer 3 having the same shape adhered thereto. Since the coating layer 3A has a pencil hardness of less than 2H, which is a soft hardness at the time of punching, cracks, scratches, and crack marks (white turbidity) do not occur even when the tool 4 is punched, and the appearance is beautiful. Finished.

  Next, in the second curing step P18, the coating layer 3 of the cover film 11 after the punching process is irradiated with radiation, for example, UV rays (ultraviolet rays). By this UV irradiation, the coat layer 3 is cured to the second hardness. The second hardness is, for example, an appropriate hardness value of pencil hardness 2H or higher, for example, pencil hardness 3H, pencil hardness 4H, or a hardness value in the vicinity thereof. By this second curing, the hard coat layer 3 that is hardly damaged is formed.

(Third embodiment)
FIG. 5 shows still another embodiment of the method for manufacturing a cover film according to the present invention. This embodiment is also a manufacturing method suitable for manufacturing a cover film 11 having a rectangular shape as shown in FIG. 4B and provided with a printing layer 7 (frame region indicated by oblique lines), for example. In the following description, the points common to the descriptions in the embodiments so far will be omitted as appropriate.

  In the present embodiment, the processes from the base sheet preparation process P21 to the first curing process P23 are the same as the processes from the base sheet preparation process P1 to the first curing process P3 in the embodiment of FIG. In the present embodiment, thereafter, in the radiation absorbing layer forming step P24, the radiation absorbing layer 8A is formed on the back surface of the base sheet 2A opposite to the main surface on which the coat layer 3A is formed. In the present embodiment, the radiation absorbing layer 8A is a layer that absorbs UV (ultraviolet) rays that are radiation and blocks its progress.

  Thereafter, the film 6 is transported to a pre-printing processing place after being easily carried by winding it. In the pre-printing process P25, the roll-shaped substrate sheet 2A shown in FIG. 4A is cut into a shape suitable for the printing process, for example, a slit shape or a sheet shape. Since the coat layer 3A is in the first hardness state, this cutting can also be performed easily and accurately.

  After completion of the pretreatment, a printing process is performed using a radiation curable ink (in this embodiment, a UV ray curable ink) in the printing layer forming step P26, and as shown in FIG. A printed layer 7 having a predetermined pattern (in this embodiment, a rectangular frame pattern) is formed on the back surface (the surface on the back side of the main surface). At this time, a character, a logo, etc. may be printed. The printing at this time can be performed using a known printing method such as an offset printing method, a gravure printing method, a screen printing method, or the like.

  Thereafter, in the printing layer curing step P27, the printing layer 7 is irradiated with UV rays, which are radiation, and the printing layer 7 is cured. At this time, since the radiation absorbing layer 8A is provided on the display surface side of the printing layer 7, the radiation at this time is absorbed by the radiation absorbing layer 8A and does not reach the coating layer 3A. The layer 3A maintains the state of the first hardness (less than pencil hardness 2H).

  Thereafter, the film 6 is carried to the punching process P28. Then, a punching process is performed on the film 6 using the blade tool 4. Thereby, as shown in FIG.4 (b), the cover film 11 in which the printing layer 7 was formed in the predetermined shape (this embodiment rectangular shape) is formed. The cover film 11 includes a rectangular base sheet 2 after punching and a coat layer 3 having the same shape adhered thereto. Since the coat layer 3A has a first hardness which is soft at the time of punching, cracks, scratches and crack marks (white turbidity) do not occur even when punching is performed using the tool 4, and the appearance is beautiful. Finished.

  Next, in the second curing step P29, the coating layer 3 of the cover film 11 after the punching process is irradiated with UV rays that are radiation. By this UV irradiation, the coat layer 3 is cured to the second hardness. The second hardness is, for example, an appropriate hardness value of pencil hardness 2H or higher, for example, pencil hardness 3H, pencil hardness 4H, or a hardness value in the vicinity thereof. By this second curing, the hard coat layer 3 that is hardly damaged is formed.

(Fourth embodiment)
FIG. 6 shows still another embodiment of the method for producing a cover film according to the present invention. This embodiment is also a manufacturing method suitable for manufacturing a cover film 11 having a rectangular shape as shown in FIG. 4B and provided with a printing layer 7 (frame region indicated by oblique lines), for example. In the following description, the points common to the descriptions in the embodiments so far will be omitted as appropriate.

  In the embodiment shown in FIG. 5, the coating layer 3A is formed on the main surface of the base sheet 2A in step P22, and the radiation absorbing layer 8A is formed on the back surface of the base sheet 2A in step P24. On the other hand, in this embodiment, the radiation absorbing layer 8A was first formed on the main surface of the base sheet 2A in step P32, and then the coating layer 3A was formed on the radiation absorbing layer 8A in step P33. The subsequent steps are the same as those in the embodiment of FIG.

  Also in this embodiment, the printing layer 7 is cured by irradiating the printing layer 7 with UV rays, which are radiation, in the process P37. At this time, since the radiation absorbing layer 8A is provided on the display surface side of the printing layer 7, the radiation at this time is absorbed by the radiation absorbing layer 8A and does not reach the coating layer 3A. The layer 3A maintains the second hardening (less than 2H pencil hardness) state applied in the process P34.

  Therefore, even if the punching process is performed using the tool 4 in the process P38, the coat layer 3A is not cracked, scratched or cracked (white turbidity), and is finished in a beautiful appearance. Next, the coating layer 3 of the cover film 11 after the punching process is irradiated with UV rays that are radiation. By this UV irradiation, the coat layer 3 is cured to the second hardness. The second hardness is, for example, an appropriate hardness value of pencil hardness 2H or higher, for example, pencil hardness 3H, pencil hardness 4H, or a hardness value in the vicinity thereof. By this second curing, the hard coat layer 3 that is hardly damaged is formed.

(Fifth embodiment)
FIG. 7 shows still another embodiment of the method for manufacturing a cover film according to the present invention. This embodiment is also a manufacturing method suitable for manufacturing a cover film 11 having a rectangular shape as shown in FIG. 4B and provided with a printing layer 7 (frame region indicated by oblique lines), for example. In the following description, the points common to the descriptions in the embodiments so far will be omitted as appropriate.

  In the manufacturing method of the present embodiment, the base sheet 2B is prepared in step P41 of FIG. The base sheet 2B is provided as a roll sheet having a wide width W as shown in FIG. 4A, for example. The roll-shaped substrate sheet 2B is formed of a resin whose main component is a resin obtained by kneading a radiation absorber into transparent PET (polyethylene terephthalate).

  Next, the coat layer 3A is laminated, for example, applied on the main surface which is the display side surface of the base sheet 2B. The coat layer 3A is formed of a transparent resin including both a thermosetting resin and a radiation curable resin. As a coating method, a known method such as a laminating method, a roll coating method, or a spray coating method can be adopted.

  In the first curing step P43, the coat layer 3A is heated and dried, and the coat layer 3A having a pencil hardness of 1H or less is cured to a first hardness of less than the pencil hardness 2H. Specifically, the first hardness is determined when the base sheet 2B on which the coat layer 3A is formed is rolled into a roll shape when the coat layer 3A is not attached to the opposing member and is punched with a blade. The hardness is such that cracks, that is, cracks, crack marks (white turbidity), etc. do not enter 3A. By this first curing, the film 6 is in a state in which the coating layer 3A is not sticky, and is easy to handle for the operator.

  Next, in the pre-printing process P44, the roll-shaped base sheet 2B of FIG. 4A is cut into a shape suitable for the printing process, for example, a slit shape or a sheet shape. Since the coat layer 3A is in the soft first hardness state, this cutting can be easily performed.

  After completion of the pretreatment, a printing process is performed in step P45, and as shown in FIG. 4B, a predetermined pattern (in this embodiment, a rectangular frame) is formed on the back surface (the back surface of the main surface) of the cover film 11. (Print pattern 7) is formed. At this time, a character, a logo, etc. may be printed. Printing at this time is performed using radiation curable ink (for example, UV curable ink). Printing can be performed using a known printing method such as an offset printing method, a gravure printing method, or a screen printing method.

  Thereafter, in the printing layer curing step P46, the printing layer 7 is irradiated with UV rays as radiation, and the printing layer 7 is cured. At this time, since the radiation absorber is kneaded inside the base sheet 2B, the radiation at this time is absorbed by the radiation absorber and does not reach the coat layer 3A. The state of the first hardness is maintained.

  Thereafter, the film 6 is carried to the punching process P47. Then, a punching process is performed on the film 6 using the blade tool 4. Thereby, as shown in FIG.4 (b), the cover film 11 in which the printing layer 7 was formed in the predetermined shape (this embodiment rectangular shape) is formed. The cover film 11 includes a rectangular base sheet 2 after punching and a coat layer 3 having the same shape adhered thereto. Since the coating layer 3A has a first hardness (less than 2H pencil hardness) that is soft at the time of punching, cracks, scratches, and crack marks (white turbidity) are not generated even if the tool 4 is punched. It is finished with a beautiful appearance.

  Next, the coating layer 3 of the cover film 11 after the punching process is irradiated with UV rays that are radiation. By this UV irradiation, the coating layer 3 has a second hardness, that is, an appropriate hardness value of pencil hardness 2H or higher, for example, a pencil hardness 3H, a pencil hardness 4H, or a hardness value in the vicinity thereof. By this second curing, the hard coat layer 3 that is hardly damaged is formed.

(Sixth embodiment)
FIG. 8 shows still another embodiment of the method for manufacturing a cover film according to the present invention. This embodiment is a manufacturing method suitable for manufacturing, for example, a cover film 1 having a rectangular shape as shown in FIG. In the following description, the points common to the descriptions in the embodiments so far will be omitted as appropriate.

  In the manufacturing method of this embodiment, the base sheet 2A is prepared in FIG. The base sheet 2A is provided as a roll-shaped sheet having a wide width W, for example, as shown in FIG. The roll-shaped substrate sheet 2A is formed of a resin mainly composed of transparent PET (polyethylene terephthalate).

  Next, the first coat layer 3A is laminated, for example, applied on the main surface which is the display-side surface of the base sheet 2A. The first coat layer 3A is formed of a transparent resin including both a thermosetting resin and a radiation curable resin. As a coating method, a known method such as a laminating method, a roll coating method, or a spray coating method can be adopted.

  After the first coat layer 3A is formed, heat is applied to the first coat layer 3A, and the first coat layer 3A is changed from a hardness of pencil hardness 1H or less to a first hardness of less than pencil hardness 2H. Cured. Specifically, the first hardness is determined when the base sheet 2A on which the coat layer 3A is formed is rolled into a roll shape so that the coat layer 3A does not stick to the opposing member and is punched with a blade. The hardness is such that cracks, that is, cracks, crack marks (white turbidity), etc. do not enter 3A. By this first curing, the film 6 is in a state in which the coating layer 3A is not sticky, and is easy to handle for the operator.

  Next, in step P54, the second coat layer 3B is applied to the back surface of the base sheet 2A, and in step P55, heat is applied to the second coat layer 3B to bring the second coat layer 3B to the third hardness. Harden. When the coating layer 3A is formed on the surface of the base sheet 2A and cured, the base sheet 2A may be curled, that is, bent. The reason why the second coat layer 3B is formed on the back surface of the base sheet 2A in this embodiment is to prevent the base sheet 2A from curling as such.

Therefore, the third hardness given to the second coat layer 3B is sufficient to prevent the base sheet 2A from curling, that is, bending. Further, considering that the blanking process is performed in the blanking process P56 described later, the third hardness is a hardness that does not cause cracks in the second coat layer 3B when the blanking process is performed with a blade. From the above circumstances, the third hardness is more appropriately an appropriate value less than the pencil hardness 2H.
The second coat layer 3B may be formed of a radiation curable resin (process P54) and cured to the third hardness upon receiving radiation (process P55).

  After the coating layer 3A on the main surface side is cured to the first hardness and the coating layer 3B on the back surface side is cured to the third hardness, the long film 6 is wound up to make it easy to carry, The film 6 is conveyed to the punching process P56.

  With respect to the film 6 conveyed to the punching process P56, the punching process is performed using the blade tool 4. Thereby, as shown in FIG.2 (b), the cover film 1 of a predetermined shape (this embodiment rectangular shape) is formed. The cover film 1 includes a rectangular base sheet 2 after the punching process, and coat layers 3-1 and 3-2 having the same shape adhered thereto. Since the coating layers 3A and 3B have the first hardness and the third hardness, which are soft, respectively, at the time of the punching process in the process P56, even if the punching process is performed using the tool 4, cracks, scratches, crack marks (white turbidity) ) Does not occur, and it has a beautiful appearance.

  Next, the coating layer 3-1 of the cover film 1 after the punching process is irradiated with UV rays that are radiation. By this UV irradiation, the coat layer 3-1 is cured to the second hardness, that is, the pencil hardness 3H, 4H or a value in the vicinity thereof. Thereby, the hard coat layer 3 </ b> A that hardly scratches or the like is formed on the surface side of the base sheet 2 </ b> A.

  Since the coating layer 3-2 on the opposite side is not a coating layer located on the front surface side, the hardness does not necessarily have to be as high as that of the coating layer 3-1 on the front surface side. The layer 3-2 is not subjected to further curing treatment in the process P57. However, if necessary, the hardness may be further increased by irradiating the back coat layer 3-2 with radiation.

(Seventh embodiment)
FIG. 9 shows still another embodiment of the method for manufacturing a cover film according to the present invention. This embodiment is a manufacturing method suitable for manufacturing, for example, a cover film 11 having a rectangular shape as shown in FIG. In the following description, the points common to the descriptions in the embodiments so far will be omitted as appropriate.

  In this embodiment, the process from the base sheet preparation process P61 to the second coat layer curing process P65 is the same as the process from the base sheet preparation process P51 to the second coat layer curing process P55 in the embodiment of FIG. In the present embodiment, after that, in the radiation absorbing layer forming step P66, the radiation absorbing layer 8A is formed on the back surface of the base sheet 2A opposite to the main surface on which the coat layer 3A is formed. In the present embodiment, the radiation absorbing layer 8A is a layer that absorbs UV (ultraviolet) rays that are radiation and blocks its progress.

  Thereafter, the film 6 is transported to a pre-printing processing place after being easily carried by winding it. In the pre-printing process P67, the roll-shaped substrate sheet 2A shown in FIG. 4A is cut into a shape suitable for the printing process, for example, a slit shape or a sheet shape. Since the coat layer 3A is in the first hardness state, this cutting can also be performed easily and accurately.

  After completion of the pretreatment, a printing process is performed using a radiation curable ink (in this embodiment, a UV ray curable ink) in the printing layer forming step P68, and as shown in FIG. A printed layer 7 having a predetermined pattern (in this embodiment, a rectangular frame pattern) is formed on the back surface (the surface on the back side of the main surface). At this time, a character, a logo, etc. may be printed. The printing at this time can be performed using a known printing method, for example, an offset printing method, a gravure printing method, a screen printing method, or the like.

  Thereafter, in the printing layer curing step P69, the printing layer 7 is irradiated with UV rays that are radiation, and the printing layer 7 is cured. At this time, since the radiation absorbing layer 8A is provided on the display surface side of the printing layer 7, the radiation at this time is absorbed by the radiation absorbing layer 8A and does not reach the coating layer 3A. The layer 3A maintains the state of the first hardness (less than pencil hardness 2H).

  Thereafter, the film 6 is carried to the punching process P70. Then, a punching process is performed on the film 6 using the blade tool 4. Thereby, as shown in FIG.4 (b), the cover film 11 in which the printing layer 7 was formed in the predetermined shape (this embodiment rectangular shape) is formed. The cover film 11 includes a rectangular base sheet 2 after the punching process and coat layers 3-1 and 3-2 having the same shape adhered thereto. Since the coating layers 3A and 3B at the time of the punching process 70 are the first hardness and the third hardness, which are soft at the time of the punching process, respectively, even if the punching process is performed using the tool 4, cracks and scratches are caused. No crack marks (white turbidity) are generated, and the appearance is beautiful.

  Next, in the second curing step P71, the coating layer 3-1 of the cover film 11 after the punching process is irradiated with UV rays that are radiation. By this UV irradiation, the coat layer 3-1 is cured to the second hardness. The second hardness is, for example, an appropriate hardness value of pencil hardness 2H or higher, for example, pencil hardness 3H, pencil hardness 4H, or a hardness value in the vicinity thereof. By this second curing, the hard coat layer 3 that is hardly damaged is formed.

(Eighth embodiment)
FIG. 10 shows still another embodiment of the method for producing a cover film according to the present invention. This embodiment is a manufacturing method suitable for manufacturing, for example, a cover film 11 having a rectangular shape as shown in FIG. In the following description, the points common to the descriptions in the embodiments so far will be omitted as appropriate.

  In the embodiment shown in FIG. 8, the second coat layer 3B formed of a transparent resin including both the thermosetting resin and the radiation curable resin is applied to the back surface of the base sheet 2A in Step P54. On the other hand, in this embodiment, in the process P84, the second coat layer 3B formed of a transparent resin in which a radiation absorbent is further kneaded into a resin including both a thermosetting resin and a radiation curable resin. Was applied.

  Next, in step P85, heat is applied to the second coat layer 3B to cure the second coat layer 3B to the third hardness. The third hardness is sufficient to prevent the base sheet 2A from curling, that is, bending. Further, considering that the blanking process is performed in the blanking process P89 described later, the third hardness is a hardness that does not cause cracks in the second coat layer 3B when the blanking process is performed with a blade. From the above circumstances, the third hardness is more appropriately an appropriate value less than the pencil hardness 2H.

  Next, in the pre-printing process P86, the roll-shaped substrate sheet 2A in FIG. 4A is cut into a shape suitable for the printing process, for example, a slit shape or a sheet shape. At this time, since the coating layers 3A and 3B have the first hardness and the third hardness, which are soft hardnesses, respectively, this cutting can be easily performed.

  After the completion of the pretreatment, a printing process is performed in step P87, and as shown in FIG. 4B, a predetermined pattern (in this embodiment, a rectangular frame) is formed on the back surface (the back surface of the main surface) of the cover film 11. (Print pattern 7) is formed. At this time, a character, a logo, etc. may be printed. Printing at this time is performed using UV curable ink which is radiation curable ink. Printing can be performed using a known printing method such as an offset printing method, a gravure printing method, or a screen printing method.

  Thereafter, the printing layer 7 is irradiated with UV rays, which are radiation, and the printing layer 7 is cured. At this time, since the radiation absorber is kneaded inside the second coat layer 3B, the radiation at this time is absorbed by the radiation absorber and does not reach the first coat layer 3A. Therefore, the first coat layer 3A maintains the first hardness which is a soft state.

  Thereafter, the film 6 is transported to the punching process P89. Then, a punching process (that is, a punching process) is performed on the film 6 using the blade tool 4. As a result, as shown in FIG. 4B, a plurality of cover films 11 on which the printing layer 7 is formed in a predetermined shape (rectangular shape in the present embodiment) are simultaneously formed. The cover film 11 includes the rectangular base sheet 2 after the punching process, and the first coat layer 3-1 and the second coat layer 3-2 having the same shape adhered thereto. At the time of the punching process P89, the first coat layer 3A and the second coat layer 3B have the first hardness and the third hardness, which are soft hardnesses respectively. No cracks, scratches, crack marks (white turbidity) are generated, and a beautiful appearance is achieved.

  Next, in the second curing step P90, the coating layer 3-1 of the cover film 11 after the punching process is irradiated with UV rays that are radiation. By this UV irradiation, the coat layer 3-1 is cured to the second hardness. The second hardness is, for example, an appropriate hardness value of pencil hardness 2H or higher, for example, pencil hardness 3H, pencil hardness 4H, or a hardness value in the vicinity thereof. By this second curing, a hard coat layer 3-1 that is hardly damaged is formed.

(Other embodiments)
The present invention has been described with reference to the preferred embodiments. However, the present invention is not limited to the embodiments, and various modifications can be made within the scope of the invention described in the claims.

  For example, the outer shape of the film formed by punching is not limited to the rectangular shape as shown in FIGS. 2B and 4B, and can be any outer shape as necessary. Further, the pattern of the print layer 7, that is, the pattern is not limited to the frame shape as shown in FIG. 4B, and can be an arbitrary pattern as necessary.

1. 1. cover film, Base sheet, 2A. Base sheet before punching, 2B. A radiation absorber kneaded sheet, 3,3-1,3-2. Coat layer, 3A. Coating layer before punching, 3B. Second coat layer, 4. Blade tool, 6. Film, 7. Printed layer, 8. Radiation absorbing layer, 8A. 10. radiation absorbing layer before punching; Cover film

Claims (14)

A coating layer forming step of forming a coating layer in a fluid state on the base sheet;
When the base sheet on which the coating layer is formed is rolled up, the coating layer does not stick to a facing member and has a hardness that prevents the coating layer from cracking when it is punched with a blade. A first curing step for curing the coat layer to a hardness;
After the first curing step, a punching process for forming a film including the base sheet and the coat layer into a desired shape by punching;
A second curing step of curing the coat layer after the punching step to a second hardness higher than the first hardness;
The manufacturing method of the cover film characterized by having.   The method for manufacturing a cover film according to claim 1, wherein the first hardness is a hardness less than a pencil hardness of 2H.   The method for manufacturing a cover film according to claim 1 or 2, wherein the second hardness is a hardness of pencil hardness 2H or more. The coat layer is formed of a resin obtained by mixing a thermosetting resin and a radiation curable resin,
The first curing step is performed by curing the thermosetting resin by heating,
The method for producing a cover film according to any one of claims 1 to 3, wherein the second curing step is performed by curing the radiation curable resin by radiation irradiation. A printing layer forming step of forming a printing layer on the substrate sheet or the coating layer using a thermosetting ink after the first curing step and before the punching step;
A printing layer curing step for curing the printing layer by heating after the printing layer forming step and before the punching step,
5. The method of manufacturing a cover film according to claim 1, wherein in the punching process, a punching process is performed on the film including the base sheet, the coat layer, and the print layer. . A printing layer forming step of forming a printing layer on the substrate sheet or the coating layer using a radiation curable ink after the first curing step and before the punching step;
A printing layer curing step for curing the printing layer by radiation irradiation after the printing layer forming step and before the punching step,
A step performed before the printed layer forming step, wherein a radiation absorbing layer forming step of forming a radiation absorbing layer between the coat layer and the printed layer; and
The method for producing a cover film according to any one of claims 1 to 4, wherein: The base sheet is formed of a resin containing a radiation absorber,
A printing layer forming step of forming a printing layer on the substrate sheet or the coating layer using a radiation curable ink after the first curing step and before the punching step;
A printing layer curing step for curing the printing layer by radiation irradiation after the printing layer forming step and before the punching step,
The method for producing a cover film according to any one of claims 1 to 4, wherein: A second coat layer forming step of forming a second coat layer in a fluid state on the base sheet opposite to the side on which the coat layer is formed;
A second coating layer curing step of curing the second coating layer to a third hardness that can prevent bending of the base sheet and that does not crack in the second coating layer when being punched with a blade;
The method for producing a cover film according to any one of claims 1 to 7, wherein: A printing layer forming step of forming a printing layer on the substrate sheet or the coating layer using a radiation curable ink after the first curing step and before the punching step;
A printing layer curing step for curing the printing layer by radiation irradiation after the printing layer forming step and before the punching step,
A step performed before the printed layer forming step, wherein a radiation absorbing layer forming step of forming a radiation absorbing layer between the coat layer and the printed layer; and
The method for producing a cover film according to claim 8, comprising: The second coat layer is formed of a resin containing a radiation absorber,
A printing layer forming step of forming a printing layer on the substrate sheet or the coating layer using a radiation curable ink after the first curing step and before the punching step;
A printing layer curing step for curing the printing layer by radiation irradiation after the printing layer forming step and before the punching step,
The method for producing a cover film according to claim 8, comprising:   The method for producing a cover film according to any one of claims 8 to 9, wherein the third hardness is less than a pencil hardness of 2H.   The method for manufacturing a cover film according to any one of claims 1 to 11, wherein the first hardness and the second hardness of the coat layer are determined by a material component of the coat layer.   The radiation is electromagnetic waves such as radio waves, microwaves, infrared rays, visible rays, ultraviolet rays (UV), X-rays and gamma rays, or particle rays such as alpha rays, beta rays, neutron rays and electron rays. The method for producing a cover film according to any one of claims 1 to 12, characterized in that: A film for a cover film having a base sheet and a coat layer laminated on the base sheet,
The coat layer is formed of a resin including a thermosetting resin and a radiation curable resin,
The film for a cover film, wherein the thermosetting resin is cured by heating, and the radiation curable resin is uncured.

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