JP2013059889A - Hard coat transfer foil, molding using the transfer foil, and manufacturing method of hard coat transfer foil - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a hard coat transfer foil that can improve surface hardness of a transferred object, a molding using the transfer foil, and a manufacturing method of the hard coat transfer foil.SOLUTION: The hard coat transfer foil 12 at least includes: a support film 1; a release layer 2 formed on one surface of the support film 1; a surface protection layer 3 formed on a surface of an opposite side of a surface of the release layer 2 touching the support film 1 and having an acryloyl group or a methacryloyl group; and an adhesive layer 8 formed on an opposite side of a surface of the protection layer 3 touching the release layer 2, wherein a film layer 6 is formed between the surface protection layer 3 and the adhesive layer 8.

Description

  The present invention relates to a transfer foil having a scratch-preventing surface protective layer, that is, a hard coat transfer foil, a molded product using the transfer foil, and a method for producing the hard coat transfer foil.

  Conventionally, as a transfer foil obtained after transferring a surface excellent in scratch resistance, chemical resistance, etc., a surface protective layer made of an ultraviolet curable resin has been provided on the release surface of the release film. There has been proposed a transfer foil having a pattern layer, an adhesive layer and the like provided thereon (see Patent Document 1). The decorative transfer foil having such a scratch-resistant surface protective layer is often used for the purpose of protecting the surface of a soft plastic typified by a polycarbonate resin.

Japanese Patent No. 2538479

However, when a transfer foil having a surface protective layer on a soft material such as polycarbonate resin is transferred, the base is soft, so dent marks and cracks are likely to occur, and no matter how much the hardness of the surface protective layer material is improved, the transferred material is transferred. Often, the surface hardness of objects did not increase. This has been a problem.
Further, when various decorations are applied to the transfer foil, the transfer foil causes a partial peeling, which is inconvenient in printing.

The present invention has been intensively studied in order to solve the above-described problems, and includes a hard coat transfer foil that can improve the surface hardness of an object to be transferred, a molded product using the transfer foil, and a hard coat transfer foil. It is an object to provide a manufacturing method.
One aspect of the present invention for solving the above problems is a support film, a release layer formed on one surface of the support film, and a surface of the release layer in contact with the support film. At least a surface protective layer containing an acryloyl group or a methacryloyl group formed on the surface on the opposite side, and an adhesive layer formed on the side of the surface protective layer opposite to the surface in contact with the release layer The hard coat transfer foil according to claim 1, wherein a film layer is formed between the surface protective layer and the adhesive layer.

  According to the above aspect, the film layer is formed between the surface protective layer and the adhesive layer. For this reason, if it is a hard coat transfer foil according to the above aspect, even if the transfer object is recessed by external force (that is, when the underlying resin is soft), the film layer serves as a reinforcing material. By transferring this transfer foil, the object to be transferred can be prevented from being recessed. As a result, the surface hardness of the transfer object can be improved.

In another aspect of the present invention, the film layer may be thinner than the support film.
According to the said aspect, the thickness of a support film is thicker than the thickness of a film layer. For this reason, if it is a hard coat transfer foil which concerns on the said aspect, when a film insert molding is carried out, since a support film can protect a film layer, the ratio by which a film layer is fractured can be made small.

In another aspect of the present invention, the film layer may be cut into a predetermined dimension.
According to the above aspect, the film layer is cut into predetermined dimensions. For this reason, if it is the hard coat transfer foil which concerns on the said aspect, the excess transfer foil transcribe | transferred to the edge part of a molded article can be cut off easily.

Moreover, as another aspect of this invention, the said film layer is a film layer by which the predetermined | prescribed decoration was given to the surface, and it was manufactured by bonding the said film layer and the said surface protective layer Also good.
According to the above aspect, since the film layer and the surface protective layer are bonded together, the process is compared with the case where the transfer foil is manufactured by sequentially laminating the film layer, the decorative layer, and the like on the surface protective layer. Loss due to loss can be reduced.

In another aspect of the present invention, the film layer may be a multilayer film formed by laminating a plurality of materials having different refractive indexes.
According to the above aspect, the film layer is a multilayer film formed by laminating a plurality of materials having different refractive indexes. For this reason, if it is the hard coat transfer foil which concerns on the said aspect, since the color shift is carried out by changing the viewing angle, the design property can be improved.

Another aspect of the present invention is a molded article in which the hard coat transfer foil of the above aspect is transferred by injection molding or heat transfer.
According to the said aspect, injection molding or heat transfer is performed using the hard coat transfer foil mentioned above. For this reason, if it is a molded article which concerns on the said aspect, the surface hardness will improve.

  In another aspect of the present invention, a step of forming a release layer on one surface of the support film, and a surface of the release layer formed opposite to the surface on which the support film is formed are provided. , A step of forming a surface protective layer containing an acryloyl group or a methacryloyl group, a step of bonding a film layer different from the above layers and the surface protective layer with a primer layer interposed therebetween, and the bonded film And a step of forming an adhesive layer on the side of the layer opposite to the side where the primer layer is formed.

  According to the above aspect, a film layer can be formed between the surface protective layer and the adhesive layer. For this reason, in the case of the hard coat transfer foil manufactured in the above mode, the film layer serves as a reinforcing material even when the transfer object is recessed by an external force (that is, when the underlying resin is soft). Therefore, it can suppress that a to-be-transferred object dents by transferring this transfer foil. For this reason, the hard coat transfer foil which improved the surface hardness of the to-be-transferred object can be manufactured.

  Moreover, according to the said aspect, the film layer is formed between the surface protective layer and the contact bonding layer by bonding a film layer and a surface protective layer on both sides of a primer layer. For this reason, if it is the manufacturing method of the hard-coat transfer foil which concerns on the said aspect, compared with the case where a film layer, a decoration layer, etc. are laminated | stacked sequentially on a surface protective layer, the loss by process loss is produced. Can be produced.

  According to the present invention, it is possible to easily improve the surface hardness of an object to be transferred as compared with a transfer foil having a conventional surface protective layer. In addition, it is possible to easily realize a decorative expression that has been difficult to process with a decorative transfer foil.

Sectional drawing of the hard coat transfer foil which concerns on embodiment of this invention. Explanatory drawing of a half cut process.

(Hard coat transfer foil)
Hereinafter, a hard coat transfer foil according to an embodiment of the present invention will be described in detail with reference to FIGS. 1 and 2. In each figure, the same reference numerals are given to components that exhibit the same or similar functions, and duplicate descriptions are omitted.
FIG. 1 is a cross-sectional view of a hard coat transfer foil 12 according to an embodiment of the present invention. As shown in FIG. 1, the transfer foil 12 includes a support film 1, a release layer 2, a surface protective layer 3, a primer layer 4, a first decorative layer 5, a film layer 6, and a second additive. It is a laminate having a decorative layer 7 and an adhesive layer 8. Here, the release layer 2 is formed on one surface of the support film 1. And the surface protective layer 3 is formed in the surface on the opposite side to the surface in which the support film 1 was formed of the mold release layer 2. As shown in FIG. The primer layer 4 is formed on the surface of the surface protective layer 3 opposite to the surface on which the release layer 2 is formed. And the 1st decoration layer 5 is formed in the surface on the opposite side to the surface in which the surface protective layer 3 was formed of the primer layer 4. As shown in FIG. The film layer 6 is formed on the surface of the first decorative layer 5 opposite to the surface on which the primer layer 4 is formed. And the 2nd decorating layer 7 is formed in the surface on the opposite side to the surface in which the 1st decorating layer 5 of the film layer 6 was formed. The adhesive layer 8 is formed on the surface of the second decorative layer 7 opposite to the surface on which the film layer 6 is formed.
In addition, when there is no need, the 1st decorating layer 5 and the 2nd decorating layer 7 can also be abbreviate | omitted. Hereinafter, each layer of the hard coat transfer foil 12 will be described.

  As the base film 1, for example, a base such as a polyethylene terephthalate film, a polyethylene naphthalate film, a polypropylene film, a polyethylene film, a triacetyl cellulose film, a polycarbonate film, a nylon film, a cellophane film, or an acrylic film can be used. The usable film thickness is 25 μm to 150 μm, and preferably 38 μm to 50 μm.

  The release layer 2 is most preferably peelable from the surface protective layer 3 described later, but is preferably a curable resin since heat resistance, solvent resistance and stretchability are also required. For this reason, as the release layer 2, for example, a cured product such as a melamine resin, a polyolefin resin, a urethane resin, or cellulose acetate can be used. Although there is no restriction | limiting in particular in the thickness of the mold release layer 2, 0.1 micrometer-3 micrometers are optimal.

  The surface protective layer 3 is preferably made of a resin that is in a tack-free state before transfer and can be crosslinked by irradiating ultraviolet rays or electron beams after being transferred to the transfer object. The reason for crosslinking after transfer is that the transfer foil 12 is often used in injection molding or heat transfer. However, if the transfer foil 12 is crosslinked in advance, cracks tend to occur during transfer stretching, resulting in poor appearance. There are mainly the following three methods for realizing tack-free properties before transfer. As the first method, a polymer acrylate or methacrylate is used. As the second method, a tack-free method is achieved by slightly curing with a crosslinking system such as isocyanate / polyol resin or epoxy resin / amines. The third method is a method of slightly irradiating ultraviolet rays or an electron beam to make it a semi-cured state.

  In the present embodiment, the ultraviolet curable resin refers to a resin that is cured by ultraviolet rays (UV). A typical resin that undergoes radical polymerization reaction is an acrylic resin having an acryloyl group or a methacryloyl group in the molecule. For example, an epoxy acrylate, urethane acrylate, polyester acrylate, polyol acrylate oligomer, polymer and monofunctional Bifunctional or polyfunctional polymerizable (meth) acrylic monomers such as tetrahydrofurfuryl acrylate, 2-hydroxyethyl acrylate, 2-hydroxy-3-phenoxypropyl acrylate, polyethylene glycol diacrylate, polypropylene glycol diacrylate, trimethylolpropane triacrylate , Pentaerythritol triacrylate, pentaerythritol tetraacrylate and other monomers, oligomers, polymers, etc. It is a mixture. In the present embodiment, these resins can be used. Among them, urethane acrylate or acrylic acrylate having a molecular weight of about 5000 to 300000 is preferable in order to realize tack-free only by solvent drying. When curing with an electron beam, the resin is cured and crosslinked only with the above resin, but in order to perform crosslinking and curing with ultraviolet rays, it is necessary to add an ultraviolet polymerization initiator in an amount of 0.5 to 10% by weight. In order to improve various physical properties, a leveling agent, wax, silica fine particles and the like may be added.

The thickness of the surface protective layer 3 is optimally 3 μm to 10 μm.
The primer layer 4 is a layer for maintaining adhesion between the surface protective layer 3 and the first decorative layer 5 or the film layer 6, and is a polyol resin such as polyester polyol or acrylic polyol and / or a hydroxyl group-containing vinyl acetate resin. A resin comprising a hydroxyl group-containing resin and a polyisocyanate is preferred.

The thickness of the primer layer 4 is not particularly limited, but 0.5 μm to 10 μm is optimal.
The first decorative layer 5 and the second decorative layer 7 are not particularly different in material, but as a decoration technique that can be adopted in this embodiment, not only general printing with color inks, but also pearl and fluorescent , Special printing such as mirror, retro-reflection, magnetic printing, embossing to form uneven structure (various lens effects and holograms) by heat and ultraviolet rays, vacuum deposition or sputtering of aluminum, silver, chromium, titanium oxide, zinc sulfide, etc. It is possible to employ a thin film forming technique to be formed.

The material costs of the first decorative layer 5 and the second decorative layer 7 are often high, and the formation of the surface protective layer 3 is often expensive. For this reason, when the decoration layer is laminated | stacked in order on the support film 1 with which the surface protective layer 3 was laminated | stacked, the loss by a process loss may become large. Therefore, the surface protective layer 3 is formed in advance on the support film 1 with the release layer 2 interposed therebetween, and the first decorative layer 5 and the second decorative layer 7 are formed in advance on the second film, respectively. The method of bonding each other with the layer 4 is a desirable manufacturing method in this embodiment.
The film layer 6 is preferably a film having a relatively high hardness. For example, a substrate such as a polyethylene terephthalate film, a polyethylene naphthalate film, a triacetyl cellulose film, a cellophane film, or an acrylic film is optimal.

Moreover, as the thickness of the film layer 6, when it is thick, the foil cutting property is deteriorated, and when it is thin, the effect of improving the surface hardness is small. Therefore, it is preferably between 3 μm and 25 μm, and the optimum region is 12 μm to 16 μm. Thus, the film layer 6 is thinner than the support film 1.
Further, in order to improve the design, it is possible to substitute a film in which several hundred layers are alternately stacked by coextrusion of materials having different refractive indexes (for example, polyethylene terephthalate and polyethylene naphthalate). This laminated film has high design properties because the color shift is caused by changing the metallic luster and viewing angle. However, in conventional film insert molding (a molding method in which this film is inserted into a molding die and integrally molded), the film on which the design has been applied is broken and cannot be used. On the other hand, in the case of this embodiment, since it is protected by the thick support film 1, such a thin highly designable film can be used.

  As the adhesive layer 8, a known heat-sealable adhesive or pressure-sensitive adhesive can be used. For example, vinyl acetate resin, ethylene vinyl acetate copolymer resin, vinyl chloride resin, acrylic resin, butyral resin, epoxy resin, polyester resin, polyurethane resin, acrylic adhesive, rubber adhesive, silicon adhesive, urethane Examples include adhesives. The thickness of the adhesive layer is optimally in the range of 0.5 μm to 10 μm.

  Here, when the transfer foil 12 according to this embodiment is used in in-mold molding (a method in which the transfer foil is inserted into a mold and transferred simultaneously with molding) or heat transfer, burrs become a problem. Sometimes. When the film layer 6 is thin, there is often no problem. For this reason, as shown in FIG. 2 before the transfer, by performing a predetermined cut (half cut) with a half punching die (corrosion blade 9) or the like in advance, by forming the half cut groove 13 in the transfer foil 12, It is possible to eliminate the generation of burrs.

Moreover, the transfer foil which does not include the film layer 6 can easily cut off the excess transfer foil transferred to the end of the molded product. On the other hand, the transfer foil including the film layer 6 has improved mechanical strength due to the film layer 6 as compared with the transfer foil not including the film layer 6. For this reason, the excess transfer foil transferred to the end of the molded product cannot be easily separated. Therefore, for example, by inserting a half-cut groove 13 having a shape that matches the outer shape of the molded product, even if the transfer foil includes the film layer 6, an extra transfer foil transferred to the end of the molded product can be used. Can be easily separated.
FIG. 2 is a diagram showing a state in which the half-cut groove 13 is put in the transfer foil 12. Hereinafter, the process of putting the half cut groove 13 in the transfer foil 12 will be briefly described.

  As shown in FIG. 2, a magnet cylinder 10 is disposed on the adhesive foil 8 side of the transfer foil 12, and a pedestal roll 11 is disposed on the support film 1 side of the transfer foil 12. The transfer foil 12 is sandwiched between the magnet cylinder 10 and the pedestal roll 11 from both sides of the transfer foil 12. Corrosion blades 9 are arranged in a predetermined shape on the outer peripheral surface of the magnet cylinder 10, and the magnet cylinder 10 and the pedestal roll 11 are rotatable as indicated by arrows in the drawing. As a result, when the magnet cylinder 10 and the pedestal roll 11 rotate, the transfer foil 12 moves in the direction indicated by the arrow, and a half-cut groove 13 is formed on the adhesive layer 8 side of the transfer foil 12.

  As described above, according to the hard coat transfer foil 12 according to the present embodiment, the film layer 6 is formed between the surface protective layer 3 and the adhesive layer 8. For this reason, in the case of the hard coat transfer foil 12 according to the present embodiment, the film layer 6 serves as a reinforcing material even when the transfer object is recessed by an external force (that is, when the underlying resin is soft). Therefore, the transfer object 12 can be prevented from being recessed by transferring the transfer foil 12. As a result, the surface hardness of the transfer object can be improved.

(Method for producing hard coat transfer foil)
Next, a method for manufacturing the hard coat transfer foil 12 according to this embodiment will be briefly described.
First, the release layer 2 is formed on one surface of the support film 1. Next, a surface protective layer 3 containing an acryloyl group or a methacryloyl group is formed on the surface of the release layer 2 opposite to the surface on which the support film 1 is formed. Next, the film layer 6 different from the above layers and the surface protective layer 3 are bonded with the primer layer 4 interposed therebetween. Next, the adhesive layer 8 is formed on the side of the film layer 6 opposite to the side on which the primer layer 4 is formed. By doing so, the hard coat transfer foil 12 according to the present embodiment can be manufactured.

  As described above, according to the method for manufacturing the hard coat transfer foil 12 according to the present embodiment, the film layer 6 can be formed between the surface protective layer 3 and the adhesive layer 8. For this reason, in the case of the hard coat transfer foil 12 manufactured in this embodiment, the film layer 6 serves as a reinforcing material even when the transfer object is recessed by an external force. By doing so, it is possible to suppress the object to be transferred from being recessed. For this reason, the hard coat transfer foil 12 with improved surface hardness of the transfer object can be produced.

On the support film 1, a biaxially stretched polyester film (G440E50 manufactured by Mitsubishi Plastics) with a thickness of 50 μm, an acrylic melamine resin (Tesfine manufactured by Hitachi Chemical Polymer) with a thickness of Dry 0.2 μm is formed by a gravure method. Got. Here, “Dry 0.2 μm thickness” means that the thickness becomes 0.2 μm when dried. Similarly, “Dry OO μm thickness” described below means that the thickness becomes OO μm when dried.
Subsequently, a surface protective layer 3 was formed on the release layer 2 by applying a tack-free UV curable resin (RC29-117 manufactured by DIC) with a dry thickness of 5 μm by a reverse gravure method.

Next, predetermined | prescribed color printing was given to the 13-micrometer-thick multilayer film (Teijin DuPont spectrofilm No13) which is the film layer 6, and the 1st decorating layer 5 and the 2nd decorating layer 7 were formed.
Next, the primer layer 4 (adhesion layer) was formed on the first decorative layer 5. As primer layer 4, polyester polyol / isocyanate ink (TM-595 manufactured by Toyo Ink Co., Ltd.) was applied with a dry thickness of 2 μm by the gravure method, and then thermally laminated at 100 ° C. with surface protective layer 3 described above.
Subsequently, an ink obtained by dissolving a polyester resin (Byron 200) in toluene and methyl ethyl ketone was applied on the second decorative layer 7 to a dry thickness of 1 μm by a gravure method to form an adhesive layer 8.

Next, the corroded blade 9 having a predetermined design was half-cut into a predetermined size by a rotary die method to obtain a hard coat transfer foil 12 of the present embodiment.
Subsequently, the hard coat transfer foil 12 was set inside a mold of an injection molding machine, and injection molding was performed with a polycarbonate resin to obtain a molded product to which the transfer foil 12 of this embodiment was transferred.

Comparative example

On the support film 1, a biaxially stretched polyester film (G440E50 manufactured by Mitsubishi Plastics) with a thickness of 50 μm, an acrylic melamine resin (Tesfine manufactured by Hitachi Chemical Polymer) with a thickness of Dry 0.2 μm is formed by a gravure method. Got.
Subsequently, a surface-protecting layer 3 was formed by applying a tack-free UV-curable resin (RC29-117 manufactured by DIC) at a dry thickness of 5 μm by a reverse gravure method.

Next, as a primer layer 4 (adhesion layer), a polyester polyol / isocyanate ink (TM-595 manufactured by Toyo Ink Co., Ltd.) was applied with a dry thickness of 2 μm by a gravure method, and predetermined color printing was performed to form a decorative layer.
Subsequently, an ink prepared by dissolving a polyester resin (Byron 200) in toluene and methyl ethyl ketone as the adhesive layer 8 was applied on the decorative layer by dry 1 μm thickness by gravure method to obtain a transfer foil according to the comparative example. As described above, the transfer foil according to the comparative example has the same structure as the transfer foil of the example except that the film layer 6 is not included.
Subsequently, the hard coat transfer foil was set inside a mold of an injection molding machine, and injection molding was performed with a polycarbonate resin, to obtain a molded product on which the transfer foil was transferred.

(Evaluation)
When the molded products obtained in Examples and Comparative Examples were evaluated for hardness by a pencil hardness test (JIS K5600-5-4), the molded products of the Examples were H, and the molded products of the Comparative Examples were HB. In the hardness evaluation, “H” means that the hardness is higher than “HB”.
In addition, the molded product of the example had a bluish metallic luster and had an appearance with excellent design.

  The transfer foil obtained according to the present invention can be used for preventing scratches and decorating panel members used for home appliances, housing equipment, office equipment, automobile parts and the like.

DESCRIPTION OF SYMBOLS 1 ... Support film, 2 ... Release layer, 3 ... Surface protective layer, 4 ... Primer layer 5 ... 1st decoration layer, 6 ... Film layer, 7 ... 2nd decoration layer, 8 ... Adhesion layer 9 ... Corrosion blade 10 ... Magnetic cylinder, 11 ... Pedestal roll,
12 ... transfer foil (cut object), 13 ... half-cut groove

Claims (7)

A support film;
A release layer formed on one side of the support film;
A surface protective layer containing an acryloyl group or a methacryloyl group formed on the surface of the release layer opposite to the surface in contact with the support film;
In the hard coat transfer foil including at least an adhesive layer formed on the side of the surface protective layer opposite to the surface in contact with the release layer,
A hard coat transfer foil, wherein a film layer is formed between the surface protective layer and the adhesive layer.   The hard coat transfer foil according to claim 1, wherein the film layer is thinner than the support film.   The hard coat transfer foil according to claim 1 or 2, wherein the film layer is cut into a predetermined dimension. The film layer is a film layer with a predetermined decoration on the surface,
The hard coat transfer foil according to any one of claims 1 to 3, wherein the hard coat transfer foil is produced by bonding the film layer and the surface protective layer.   The hard coat transfer foil according to any one of claims 1 to 4, wherein the film layer is a multilayer film formed by laminating a plurality of materials having different refractive indexes.   A molded product, wherein the hard coat transfer foil according to any one of claims 1 to 5 is transferred by injection molding or heat transfer. Forming a release layer on one side of the support film;
Forming a surface protective layer containing an acryloyl group or a methacryloyl group on the surface of the release layer formed on the side opposite to the surface on which the support film is formed;
A step of laminating a film layer different from the above layers and the surface protective layer with a primer layer interposed therebetween,
The manufacturing method of the hard-coat transfer foil characterized by including the process of forming the contact bonding layer on the opposite side to the side in which the said primer layer was formed of the said film layer bonded together.

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