JP2013202821A - Metallic tone molding film, method of manufacturing the same, and metallic tone transfer film used for the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To solve such a problem that a manufacturing cost of a metallic tone molding film using a flexible plastic film is very high, and to provide an efficient method of manufacturing a metallic tone molding film at low manufacturing cost while maintaining a function of metallic gloss or the like without using the flexible plastic film.SOLUTION: In a method of manufacturing a metallic tone transfer film, a metallic tone transfer film, which is formed by sequentially laminating at least a function layer, a metal thin film layer, an adhesive layer on a peelable plastic film excellent in heat resistance, solvent resistance, and handleability, and a base material are adhered tightly so as to be in contact with each other. Then, the peelable plastic film is peeled, and the function layer and the metal thin film layer or the like of the metallic tone transfer film are transferred on the base material.

Description

The present invention relates to a metal-forming film, a method for producing the film, and a metal-tone transfer film used therefor.

Conventionally, many parts (molded products) used for automobiles and electrical products are generally metallic luster parts (metal molded products) for the purpose of improving the design of automobiles and electrical products. Widely used.
A method for imparting metallic luster to a molded product is generally a method in which metal surface is directly plated on the surface of the molded product. However, in the method of directly metal-plating the surface of the molded product, there is a risk that environmental problems may occur due to the treatment of the waste solution used in the metal-plating process.

For this reason, the metal tone forming film (general structure: base sheet (plastic film, etc.) / Metal thin film layer / adhesive layer / base material) is used to place the metal tone forming film in the mold. Then, after being sandwiched in the mold, a molten resin is injected into the mold, and at the same time as molding of the molded product, the metal tone molding film and the molded product are in close contact, so-called insert molding A metal-like molded product in which a metal-like film is laminated on the molded product using a method (general structure: molded product / base material / adhesive layer / metal thin film layer / substrate sheet (plastic film, etc.)) ) And a metallic luster is imparted to the molded product.

Using the insert molding method, if the shape of the molded product has a three-dimensional and complicated shape, or a deep-drawn shape, the metal tone molding film to be used does not follow the shape of the molded product, It has been difficult to make a close contact between the surface of the molded product and the film for metal-like molding without a gap.
Furthermore, the base sheet is stretched in places where the metallic tone forming film itself such as corners and deep drawn parts of the molded product is stretched, which causes the metal thin film layer laminated on the base sheet to be stretched. Cracks and the like are generated in the metal thin film layer, and the appearance of the metal-like molded product is whitened. As a result, a beautiful metallic luster could not be imparted to the molded product.

And as a film for metal-tone molding used for obtaining a metal-molded product using the insert molding method, Patent Document 1 discloses at least a flexible transparent resin on a flexible plastic film (base sheet). A sheet with a simultaneous molding picture (a film for metal tone molding) in which an anchor coat layer, a metal thin film layer, an adhesive layer, and a base material are laminated is described.
The manufacturing method is such that the above-mentioned sheet with simultaneous painting (metal-forming film) is prepared in advance by laminating a flexible transparent resin anchor coat layer and a metal thin film layer on a base sheet in advance. And a base material are laminated by using a dry laminating method.

Patent Document 2 discloses a first anchor coat layer formed of at least an acrylic resin on a plastic film (base sheet) having flexibility in the film itself, and a second formed of an aqueous polyurethane resin. A sheet for molding (laminated film) having a metallic luster in which an anchor coat layer and a vapor deposition layer (metal thin film layer) are laminated is described.
In order to make the molding sheet (laminated film) into a metal-like molding film, the molding sheet (laminate) is manufactured in advance, and the molding sheet (laminate) and the base material are dry-laminated. It is described to laminate using.

JP 2000-43082 A Japanese Patent No. 3704141

However, the metal-forming film described in Patent Document 1 and Patent Document 2 has a three-dimensional, complicated shape or a deep-drawn shape. Stretch degree of 130% for non-stretched polyethylene terephthalate film, acrylic film, vinyl chloride film (PVC film), nylon film, urethane film, polycarbonate film, etc. as base sheet to follow the shape of metal tone forming film The above-described plastic film having relatively excellent flexibility (hereinafter, these are collectively referred to as a flexible plastic film) is used.
In addition, the said base sheet may correspond to the functional layer of this application mentioned later.

Further, in this specification, the degree of stretching is any processing temperature within the processing temperature range under the processing temperature (100 to 180 ° C.) when laminating an anchor coat layer or the like on a plastic film. It is an index showing how much the area after heating is stretched with respect to the area before heating, the length in the vertical direction and the horizontal direction after heating, the length in the vertical direction and the horizontal direction before heating, respectively In comparison, the elongation in the vertical direction and the horizontal direction (length after heating / length before heating × 100) are integrated and calculated.
For example, when the elongation in the longitudinal direction and the transverse direction after heating is 110% and 140%, respectively, as compared with the longitudinal and transverse lengths before heating, respectively, the degree of stretching is the respective elongation. The rate is 154% (110% × 140%).
The flexible plastic film generally has a storage elastic modulus at 150 ° C. (150 ° C. storage elastic modulus) measured by a dynamic viscoelasticity measuring apparatus of 150 MPa or less.

The flexible plastic film, the metal-forming film described in Patent Document 1 and Patent Document 2 using the flexible plastic film, and the production method thereof include the following (1) to (3): There was a problem.

(1) A flexible plastic film has poor heat resistance. When a flexible plastic film is used to produce a metal-forming film, its production process (a process of laminating an anchor coat layer or a metal thin film layer) Etc.), it was easy for a flexible plastic film to stretch or break.
Therefore, it is necessary to process at a temperature lower than the general processing temperature in the manufacturing process so that the flexible plastic film does not stretch or break due to excessive heat, and an anchor coat layer is laminated. In order to completely dry the solvent, etc. contained in the anchor coating agent used, it is necessary to process at a lower temperature and at a lower speed than general processing conditions. .

(2) A flexible plastic film has poor solvent resistance, and a base material used for the purpose of bringing a laminated film in which a metal thin film layer or the like is laminated on the flexible plastic film and a molded product ( The surface on the side where the flexible plastic film adhesive is applied is whitened by the solvent contained in the adhesive for laminating, etc. Therefore, the film for metal-like molding using a flexible plastic film cannot maintain a desired appearance (such as metallic luster).
Therefore, when producing a film for forming metal like the film for forming metal like described in Patent Document 2, an aqueous polyurethane resin is used for the purpose of imparting a solvent barrier property to a flexible plastic film. It was necessary to take measures such as separately laminating the formed anchor coat layer.

(3) A flexible plastic film has the property of being easily broken, cut or torn, has poor handleability, and is used to produce a metal-like film using a flexible plastic film. In each process, it was necessary to handle the flexible plastic film carefully so as not to be broken, cut or torn.
Therefore, one side of the flexible plastic film (anchor coat layer) so that the flexible plastic film is easy to handle without cracking, breaking, or tearing in each process of producing metal-like film In addition, it is necessary to add measures to the manufacturing process, such as attaching a flexible plastic film to the other surface on which no metal thin film layer or the like is laminated.

As described above, when a metal-forming film is manufactured using the flexible plastic film, the flexible plastic film is “poor in heat resistance,” as described in (1) to (3) above. ”,“ Poor solvent resistance ”, and“ Poor handling ”, respectively,“ Processing at low temperature and low speed ”,“ Anchor coat layer that imparts solvent barrier properties is separately laminated ” It was necessary to take measures such as “adhering a flexible plastic film in advance to one side of a flexible plastic film”.

For this reason, when manufacturing the film for metal tone molding described in Patent Document 1 and Patent Document 2 using a flexible plastic film, the productivity and yield are very poor, and the resulting metal tone film is poor. There is a problem that the manufacturing cost of the film for molding becomes very expensive.

In addition, a metal thin film layer, a functional layer, etc. (colored layer, printed layer, hard coat layer, antifouling layer, reflective layer) are used on the base material used for the purpose of adhering to the molded product without using a flexible plastic film. The following problems also occur when a metal-forming film having a metal thin film layer or a functional layer laminated on a base material is produced by directly laminating a prevention layer, a weather resistant resin layer, an antifogging layer, etc.) There was a point.

When the base material used for the metal-like film is a three-dimensional, complex shape or deep-drawn shape of the metal-like product obtained using the metal-like film In addition, it is preferable to use a film that is relatively excellent in flexibility so that the film for molding follows the shape of the molded product and the surface of the molded product and the film for metal-like molding are in close contact with each other without a gap.
In that case, the substrate has problems such as “poor heat resistance”, “poor solvent resistance”, and “poor handleability”, as in the case of the flexible plastic film.
As a result, the production method of directly laminating a metal thin film layer, a functional layer, etc. on a substrate is similar to the case of producing a metal-forming film using the flexible plastic film. However, there was a problem that the manufacturing cost of the resulting film for forming a metal tone was very expensive.

From the above, the conventional metal-forming film using a flexible plastic film, and the metal-forming film that directly laminates a metal thin film layer or a functional layer on the substrate are very productive. There is a problem in that the yield is poor and the manufacturing cost is high, and it has been a problem to efficiently manufacture a metal-forming film at a low manufacturing cost.

[1] The present invention is a method for producing a metal-like film, comprising a metal-like transfer film in which at least a functional layer and a metal thin film layer are sequentially laminated on a peelable plastic film, and a substrate. After the metal thin film layer side of the metallic tone transfer film was brought into close contact with the substrate surface via an adhesive layer, the peelable plastic film of the metallic tone transfer film was peeled off and laminated on the metallic tone transfer film. By transferring at least the functional layer and the metal thin film layer to the surface of the base material, it is possible to manufacture a film for forming a metal layer in which at least the adhesive layer, the metal thin film layer, and the functional layer are sequentially laminated on the base material. It is the manufacturing method of the film for metal tone forming characterized.

[2] The present invention is a method for producing a metal-like film, which is a metal-like transfer film in which at least a functional layer, a metal thin film layer, and an adhesive layer are sequentially laminated on a peelable plastic film and a substrate Are adhered so that the adhesive layer side of the metal-tone transfer film is in contact with the substrate surface, and then the peelable plastic film of the metal-tone transfer film is peeled off and laminated on the metal-tone transfer film. By transferring at least the functional layer, the metal thin film layer, and the adhesive layer onto the surface of the base material, a metal-forming film in which at least the adhesive layer, the metal thin film layer, and the functional layer are sequentially laminated on the base material is obtained. It is the manufacturing method of the film for metal tone forming characterized by manufacturing.

[3] The present invention is a metal-forming film produced by the method for producing a metal-forming film according to [1] or [2].

[4] The present invention is a metallic tone transfer film used in the method for producing a metallic tone forming film according to [1], wherein at least a functional layer and a metal thin film layer are sequentially laminated on a peelable plastic film. This is a metallic tone transfer film.

[5] The present invention provides a metal-tone transfer film used in the method for producing a metal-forming film according to [2], wherein at least a functional layer, a metal thin film layer, and an adhesive layer are formed on the peelable plastic film. Is a metallic tone transfer film sequentially laminated.

The method for producing a metal tone forming film of the present invention comprises transferring a metal thin film layer or a functional layer laminated on the metal tone transfer film of the present invention onto the surface of a base material, While maintaining the same function and performance, the metal-forming film of the present invention can be efficiently manufactured at low cost and the conventional metal-forming film uses a flexible plastic film. This solves the problem that the productivity and the yield are very poor, and as a result, the manufacturing cost is high.

Specifically, as described in the following (1) to (3), the metal tone transfer film of the present invention used in the method for producing a metal tone molding film of the present invention is the above-mentioned flexible plastic film. The present invention uses a peelable plastic film which is not used and has a degree of stretching of less than 130%, “excellent heat resistance”, “excellent solvent resistance”, and “good handleability”. The metallic tone transfer film can be efficiently produced in large quantities.
Therefore, the productivity and yield can be greatly improved by producing the metal tone molding film of the present invention by the method of transferring the functional layer or metal thin film laminated on the metal tone transfer film of the present invention to the substrate. As a result, the metal-forming film of the present invention can be efficiently produced at a low production cost.

(1) The metal tone transfer film of the present invention used in the manufacturing method for metal tone molding of the present invention is not a flexible plastic film, but heat is applied to the plastic film in the manufacturing process of the metal tone transfer film of the present invention. Because it uses a plastic film with excellent heat resistance, as described above, it does not easily stretch or break even when applied, so the process of laminating functional layers and metal thin film layers has a lower temperature than general processing conditions. No need to process at low speed. Therefore, productivity and yield are greatly improved, and the metallic tone transfer film of the present invention can be efficiently produced in large quantities.

(2) The metal tone transfer film of the present invention used in the production method for producing the metal tone molding film of the present invention is not a flexible plastic film but a plastic film having excellent solvent resistance as described above. Therefore, it is not necessary to separately laminate an anchor coat layer that imparts solvent barrier properties. Therefore, productivity and yield are greatly improved, and the metallic tone transfer film of the present invention can be efficiently produced in large quantities.

(3) The plastic film used for the metal-tone transfer film of the present invention is not a flexible plastic film, but uses the above-mentioned plastic film which is easy to handle and is not easily broken, cut or torn. It is easy to handle in the manufacturing process of metallic tone transfer film.
Therefore, there is no need to perform an extra step such as pre-bonding a flexible plastic film to one side of the plastic film used in the metallic tone transfer film of the present invention, and the manufacturing process of the metallic tone transfer film of the present invention is eliminated. The number of processes can be reduced. Therefore, productivity and yield are greatly improved, and the metallic tone transfer film of the present invention can be efficiently produced in large quantities.

That is, if the metal tone forming film manufacturing method of the present invention using the metal tone transfer film of the present invention is used, the conventional metal tone forming film uses a flexible plastic film. “Processing at low temperature and low speed”, “Laminating an anchor coat layer that imparts a solvent barrier property”, “Prefixing a flexible plastic film on one side of a flexible plastic film in advance It is not necessary to take measures such as "."
For this reason, the method for producing a metal-forming film of the present invention is significantly improved in productivity and yield compared with the conventional method of producing a metal-forming film, and the metal-forming film of the present invention is efficiently produced. It can be manufactured.
As a result, while maintaining the functions such as weather resistance and beautiful metallic luster of the conventional metal-forming film, the metal-forming film of the present invention can be efficiently produced at a low production cost. Can do.

More specifically, the method for producing a metal tone forming film of the present invention uses the metal tone transfer film of the present invention in which at least a functional layer and a metal thin film layer are sequentially laminated on a peelable plastic film. After the metal tone transfer film of the present invention and the substrate are brought into close contact with the surface of the substrate through the adhesive layer, the metal tone transfer film of the present invention is peeled off. By peeling the possible plastic film, it is possible to obtain the metal-forming film of the present invention in which at least an adhesive layer, a metal thin film layer, and a functional layer are sequentially laminated on a substrate.

Alternatively, by using the metal tone transfer film of the present invention in which at least a functional layer, a metal thin film layer, and an adhesive layer are sequentially laminated on a peelable plastic film, the metal tone transfer film of the present invention and the substrate Are adhered so that the adhesive layer side of the metallic tone transfer film is in contact with the substrate surface, and then the peelable plastic film of the metallic tone transfer film is peeled off, so that at least the adhesive layer is formed on the substrate. In addition, the metal-forming film of the present invention in which the metal thin film layer and the functional layer are sequentially laminated can be obtained.

The method for producing a metal-tone forming film of the present invention does not increase the number of production steps as compared with the conventional method of producing a metal-forming film, and the metal-tone transfer film of the present invention is efficiently produced. It can be manufactured.

Since the flexible plastic film is “poor heat resistance”, “poor solvent resistance” and “poor handleability” as described above, a metal thin film layer or a functional layer is directly laminated on a substrate. It was difficult.
Therefore, if the metal thin film layer or functional layer laminated on the metal-tone transfer film of the present invention is transferred to a substrate and laminated, the method for producing a metal-tone molding film of the present invention is used. Even when a plastic film with a certain thickness is used as a base material, it becomes possible to easily laminate a functional layer, a metal thin film layer, etc. on the base material, and it can be used without limiting the type of the base material. It becomes possible, and the choice of the base material is expanded.

Furthermore, in the metal-forming film of the present invention, at least an adhesive layer, a metal thin film layer, and a functional layer are sequentially laminated on the base material. Using the metal-forming film of the present invention, the metal-forming film If the product is manufactured, even if the shape of the molded product is a three-dimensional and complicated shape or a deep-drawn shape, the metal tone molding film of the present invention follows the surface of the molded product, Compared with the conventional metal-molded film obtained by using the metal-molding film without causing any appearance defects such as whitening, because the surface of the molded product and the metal-molding film of the present invention can be closely adhered. Even so, it is possible to efficiently obtain a metal-molded product at a low production cost while maintaining functions such as weather resistance and performance such as beautiful metallic luster.

The manufacturing method of the film for metal tone molding of the present invention is the manufacturing method of [Manufacturing Method 1] or [Manufacturing Method 2] below.

[Production Method 1]
Using the metal tone transfer film of the present invention in which at least a functional layer and a metal thin film layer are sequentially laminated on a peelable plastic film, the metal tone transfer film and the substrate are transferred to a metal tone molding transfer film. After the metal thin film layer side of the substrate is adhered to the substrate surface via the adhesive layer, the peelable plastic film of the metallic tone transfer film is peeled off, so that at least the adhesive layer, the metal thin film layer, and It is a manufacturing method which manufactures the film for metal tone forming of this invention in which the functional layer was laminated | stacked sequentially.

[Production Method 2]
Using the metallic tone transfer film of the present invention in which at least a functional layer, a metal thin film layer, and an adhesive layer are sequentially laminated on a peelable plastic film, the metallic tone transfer film and the base material are transferred to the metallic tone transfer. After adhering the adhesive layer side of the film so as to be in contact with the substrate surface, the peelable plastic film of the metallic transfer film is peeled off, so that at least the adhesive layer, the metal thin film layer, and the functional layer are formed on the substrate. It is a manufacturing method which manufactures the film for metal tone forming of this invention laminated | stacked one by one.

In the case of the above [Production Method 1], the method of bringing the metal-like transfer film of the present invention in which at least a functional layer and a metal thin film layer are sequentially laminated onto a peelable plastic film and the substrate into close contact with each other is the present invention. The metallic tone transfer film of the present invention is not particularly limited as long as it can adhere the metallic tone transfer film to the substrate, but at least a functional layer and a metal thin film layer are sequentially laminated on a peelable plastic film. A film is manufactured in advance, and for example, each of the following (Step 1A) to (Step 3A) or (Step 1B) to (Step 3B) is sequentially performed as a series of operations using a single manufacturing apparatus. Use of a method in which the tone-transfer film and the substrate are brought into close contact with each other via an adhesive layer can be efficiently adhered. And
After the metal-tone transfer film of the present invention and the substrate are brought into close contact with each other, the metal-tone transfer film of the present invention can be efficiently produced at a low production cost by peeling off the peelable plastic film of the metal-tone transfer film. Since it can manufacture, it is preferable.
(Step 1A) An adhesive is applied on the substrate.
(Step 2A) The adhesive is dried, and an adhesive layer having a uniform thickness is laminated on the substrate.
(Step 3A) The adhesive layer laminated on the substrate and the metal thin film layer of the metal-tone transfer film of the present invention are brought into contact with each other and are brought into close contact with a roll or the like.
Or
(Step 1B) An adhesive is applied on the metal thin film layer of the metallic tone transfer film of the present invention.
(Step 2B) The adhesive is dried, and an adhesive layer having a uniform thickness is laminated on the metal thin film layer.
(Step 3B) The adhesive layer laminated on the metal thin film layer of the metallic tone transfer film of the present invention and the base material are pressed and adhered with a roll or the like so as to contact.

In the above (Step 1A) or (Step 1B), the adhesive applied on the substrate or the metal thin film layer is not particularly limited, and is an acrylic resin, polyethylene resin, polypropylene resin, polystyrene resin, vinyl chloride. Known resins such as polyester resins, polyester resins and urethane resins can be used. Adhesive type adhesives such as dry laminate adhesives and thermoplastic so-called hot melt type adhesives can be used. What is necessary is just to select suitably according to the base material to be performed and the method to crimp | bond. Also, the resin used for the adhesive may be either water-based or solvent-based.
In addition, when the said hot-melt-type adhesive agent is used for an adhesive agent, it is preferable to use a hot roll for the roll etc. which are used when crimping | bonding at the said (process 3A) or (process 3B).

The thickness of the adhesive layer is preferably in the range of 0.1 to 20 μm. If the thickness of the adhesive layer is less than 0.1 μm, the desired adhesion between the substrate and the metallic tone transfer film of the present invention may not be obtained. Is not preferable because it is difficult to laminate the film with a uniform thickness and the adhesive layer may cohesively break.

As a method for applying the adhesive, conventionally known coating methods such as a gravure coating method, a reverse coating method, and a die coating method can be used.

  In each step of bringing the metallic tone transfer film and the substrate of the present invention into close contact with each other, the processing conditions such as the processing speed and the processing temperature should be appropriately selected according to the type of resin used, the base material, etc. Good.

Further, in the case of [Production Method 2], the metallic transfer film of the present invention, in which at least a functional layer, a metal thin film layer, and an adhesive layer are sequentially laminated on a peelable plastic film, is adhered to the substrate. The method is not particularly limited as long as it can adhere the metallic tone transfer film of the present invention and the substrate, but at least a functional layer, a metal thin film layer, and an adhesive layer are sequentially formed on the peelable plastic film. The laminated metallic tone transfer film of the present invention is manufactured in advance, and for example, the following steps (Step 1C) and (Step 2C) are performed in order to adhere the metallic tone transfer film and the substrate. Then, it can be made to adhere efficiently. Then, after the metal-tone transfer film of the present invention and the base material are brought into close contact with each other, if the peelable plastic film of the metal-tone transfer film is peeled off, the metal-tone molding of the present invention can be efficiently performed at a low manufacturing cost. It is preferable because a film can be produced.
(Step 1C) The adhesive layer of the metallic tone transfer film of the present invention and the surface of the substrate are overlapped so as to contact each other.
(Step 2C) The metal-tone transfer film of the present invention and the base material are laminated by thermocompression bonding with a hot roll or the like.
The adhesive layer laminated on the metallic tone transfer film of the present invention used in the above [Production Method 2] is a hot melt type and will be described in detail later.

  In each step of bringing the metallic tone transfer film and the substrate of the present invention into close contact with each other, the processing conditions such as the processing speed and the processing temperature may be appropriately selected according to the type of the substrate to be used.

Next, the metal tone transfer film of the present invention used in the method for producing a metal tone molding film of the present invention will be described.

The metal-tone transfer film of the present invention used in the method for producing a metal-forming film of the present invention is one in which at least a functional layer and a metal thin film layer are sequentially laminated on a peelable plastic film, or is peelable. At least a functional layer, a metal thin film layer, and an adhesive layer are sequentially laminated on such a plastic film.

The peelable plastic film used in the metallic tone transfer film of the present invention has a degree of stretch of less than 130%, “excellent heat resistance”, “excellent solvent resistance”, and “excellent handleability”. Plastic films such as biaxially stretched polyethylene terephthalate film, polybutylene terephthalate film, polyethylene naphthalate film, polyimide film, etc. that have properties such as `` good '' can be used, and mechanical strength, solvent resistance, etc. In order to improve the performance, a biaxially stretched plastic film is preferable, and a biaxially stretched polyethylene terephthalate film is more preferable.
Specifically, a plastic film having a degree of stretching of less than 130% can satisfy the above characteristics and can be used without any particular limitation. A plastic film having a stretch degree of 130% or more is not preferable because it is the same as the flexible plastic film and the manufacturing cost of the metal-forming film is expensive as described above.
And the said plastic film may contain various additives, such as an antistatic agent, a coloring agent, and a heat stabilizer.
The peelable plastic film of the present invention preferably satisfies the above characteristics as long as the 150 ° C. storage elastic modulus measured by a dynamic viscoelasticity measuring apparatus exceeds 150 MPa, and preferably has a 150 ° C. storage elastic modulus. More preferably, it is 300 MPa or more.

The peelable plastic film used in the metallic tone transfer film of the present invention refers to a functional layer described later when the metallic tone transfer film of the present invention is used to produce the metallic tone molding film of the present invention. It is sufficient if it can be peeled off at the interface, and only a plastic film or a release layer having a releasing property such as a silicon resin layer, a fluororesin layer, a wax layer, a melamine resin layer, etc. is laminated on the plastic film. It is.

Specifically, when only a plastic film is a peelable plastic film, it is made of a known thermoplastic resin such as an acrylic resin or a urethane resin, and has a releasability to peel off at the interface with the plastic film. If the release layer is laminated so as to be in contact with the plastic film, the plastic film is peeled off at the interface between the plastic film and the release layer, and only the plastic film can be peeled off, when the metal tone forming film is manufactured. It becomes.
Further, when the plastic film on which the release layer is laminated is a peelable plastic film, it is peeled off at the interface between the release layer and the functional layer, and the plastic film on which the release layer is laminated can be peeled off. It becomes.
In addition, the stretch degree of the peelable plastic film on which the release layer is laminated is less than 130%, and the 150 ° C. storage elastic modulus is preferably more than 150 MPa, more preferably 300 MPa or more.

Furthermore, the release layer may be laminated on the release layer for the purpose of stabilizing the release property of the metallic tone transfer film of the present invention on the plastic film on which the release layer is laminated. In this case, peeling occurs at the interface between the release layer and the release layer.

The type of resin used for the release layer and the release layer, the thickness of the release layer and the release layer, and the method of laminating the release layer and the release layer may be appropriately selected according to the desired purpose and application.
In addition, when the release layer is the metal tone transfer film of the present invention in which the release layer is laminated to obtain the metal tone forming film of the present invention, the release layer will be described later. As a part of the functional layer, it is laminated on the outermost surface of the metal-forming film of the present invention.

Although the thickness of the peelable plastic film used for the metallic tone transfer film of the present invention is not particularly limited, it is preferably 12 to 200 μm. If the thickness is less than 12 μm, not only is it easy to curl when laminating functional layers or the like, but also when handling the metallic tone transfer film of the present invention, there is a risk that folding and wrinkling will easily occur, making it difficult to handle. Because there is, it is not preferable. When the thickness is more than 200 μm, it is not preferable because when the metal tone transfer film of the present invention is manufactured, the stiffness is strong and it may be difficult to handle the substrate.

The functional layer laminated on the metal tone transfer film of the present invention is a layer made of a resin, and the metal tone molding is performed using the metal tone molding film of the present invention in which the functional layer is transferred onto a substrate. When the product is obtained, it may be appropriately selected according to the function required for the use of the metal-molded product, and the design property, hard coat property, antifouling property, antireflection property, weather resistance, antifogging property For the purpose of imparting functions such as
The functional layer is a layer composed of any one of a colored layer, a printed layer, a hard coat layer, an antifouling layer, an antireflection layer, a weather resistant resin layer, an antifogging layer, or a combination of these layers, and constitutes a functional layer. All layers may be laminated on a completely or partially peelable plastic film, and any layer constituting the functional layer is laminated on a completely or partially peelable plastic film. It may be.

The resin used for the functional layer is not particularly limited, and various known resins such as a polypropylene resin, a polyethylene resin, a polyamide resin, a polyurethane resin, a polyester resin, an acrylic resin, and the like can be used. Alternatively, two or more kinds of different or the same kind of resins may be mixed and used, and may be appropriately selected according to the desired purpose.
As the method for laminating the functional layers, conventionally known coating methods such as gravure coating, reverse coating, and die coating can be used.
Further, one or more kinds of various additives such as an antistatic agent, an ultraviolet absorber, a heat stabilizer, and a curing agent may be added to the resin used for the functional layer. It may be appropriately selected depending on the situation.

The thickness of the functional layer is not particularly limited as long as the desired effect of the functional layer can be obtained, but is preferably 1 to 50 μm, and is appropriately selected depending on the desired function. do it.

For example, when a metal-like molded product obtained using the film for metal-like molding of the present invention is one that requires weather resistance, a weather-resistant acrylic type using a weather-resistant acrylic resin for the functional layer If the resin layer is laminated with a thickness of 10 to 40 μm, the weather-resistant acrylic resin layer is laminated on the outermost surface of the metal-like film and the metal-like molded product, and the shape of the molded product is three-dimensional and complicated Even if it has a deep shape or a deep-drawn shape, the metal tone molding film of the present invention follows the shape of the molded product, and not only a beautiful metallic luster on the molded product, but also a desired A weather-resistant function can be imparted, and as a result, a metal-like molded product having a desired beautiful metallic luster and weather resistance can be obtained.

The metal thin film layer laminated on the metallic tone transfer film of the present invention is a metallic luster to the metallic tone transfer film of the present invention, and the metallic tone molding film of the present invention manufactured using the metallic tone transfer film of the present invention. Laminate for the purpose of imparting.
The metal thin film layer is laminated on a functional layer laminated on a peelable plastic film, and the metal used is aluminum, chromium, tin, gold, silver, copper, nickel, indium, zinc sulfide, silicon or the like. Various metals or their compounds can be used, and may be appropriately selected depending on the desired purpose. Moreover, the metal thin film layer may be a single layer or a plurality of layers of two or more layers, and in the case of two or more layers, the metal used in each layer may be different between the layers or the same type. .

Moreover, the metal thin film layer may be laminated | stacked on the whole or a part on the said functional layer. The method for partially laminating the metal thin film layer is not particularly limited and may be appropriately selected depending on the desired purpose.

The thickness of the metal thin film layer is preferably in the range of 10 to 200 nm. If it is thinner than 10 nm, it may not be possible to give a desired metallic luster to the metallic tone transfer film of the present invention or the metallic tone molding film of the present invention. When the metal thin film layer is laminated on the layer, the peelable plastic film may be deformed and deteriorated, and the metal thin film layer is easily cracked. Since there is a possibility that a desired metallic luster cannot be imparted to the metal tone forming film of the present invention, it is not preferable.

As a method of laminating the metal thin film layer, a conventionally known method of laminating a metal thin film layer such as a vacuum deposition method, a sputtering method, a CVD method, or the like can be used, and may be appropriately selected according to a desired purpose.

The adhesive layer laminated on the metallic tone transfer film of the present invention is laminated for the purpose of bringing the metallic tone transfer film and a substrate described later into close contact.
The resin used for the adhesive layer is not particularly limited as long as it is a thermoplastic so-called hot-melt type resin, and is an acrylic resin, polyethylene resin, polypropylene resin, polystyrene resin, vinyl chloride resin, polyester resin. Well-known resins such as urethane-based resins can be used, and may be appropriately selected according to the substrate to be used. The resin used for the adhesive layer may be either water-based or solvent-based.
In addition, as will be described later, if the plastic film used for the base material of the metal-forming film of the present invention and a resin having good compatibility are used as the resin used for the adhesive layer, the compatibility with the base material is good and strong. It is preferable because adhesion can be obtained.

The thickness of the adhesive layer is preferably in the range of 0.1 to 20 μm. If the thickness of the adhesive layer is less than 0.1 μm, the desired adhesion between the substrate and the metallic tone transfer film may not be obtained. It is difficult to laminate with a thickness, and the adhesive layer is liable to cohesive failure.
As a method for laminating the adhesive layer, a conventionally known coating method such as a gravure coating method, a reverse coating method, a die coating method, or the like can be used.

Next, the metal tone forming film of the present invention will be described.

The film for metal tone molding of the present invention is obtained by the method for producing a metal tone transfer film of the present invention, and is obtained by sequentially laminating at least an adhesive layer, a metal thin film layer, and a functional layer on a substrate. is there.
Specifically, after the metal-tone transfer film of the present invention and the substrate are adhered, the peelable plastic film is peeled off, so that the functional layer and the metal thin film layer laminated on the metal-tone transfer film are removed. It can be obtained by transferring to the substrate surface.

The base material used for the metal-forming film of the present invention is obtained by using the metal-forming film of the present invention to obtain a metal-molded product. In order to make it easy to work in the process of bringing the metal-forming film of the present invention into close contact with the substrate, the above object is satisfied. A plastic film is preferred.
The plastic film used for the base material can be used without particular limitation as long as it satisfies the above-mentioned purpose, such as polyethylene terephthalate film (non-stretched), acrylic film, vinyl chloride film (PVC film), nylon film, urethane film, In addition to flexible plastic films such as polycarbonate film, biaxially oriented polyethylene terephthalate film, polybutylene terephthalate film, polyethylene naphthalate film, polyimide film polyethylene film, polypropylene film, polyamide film, acrylonitrile / butadiene / styrene copolymer synthetic resin Various conventionally known plastic films such as a film (ABS film) can be used.
What is necessary is just to select suitably the plastic film used for a base material according to purposes, such as a kind and shape of a molded article.

The thickness of the substrate is preferably in the range of 25 to 500 μm, more preferably 50 to 250 μm. If the thickness of the base material is less than 25 μm, the metal tone forming film of the present invention may not be firm and may be difficult to handle. Therefore, if it is thicker than 500 μm, it is not preferable. Since the moldability of the film is deteriorated and a metal-like molded product is obtained, a desired shape may not be obtained.
In addition, when a molded product used for a metal-finished molded product described later is a molded product made of resin (resin molded product), the resin used for the resin molded product and a plastic film having good compatibility with the resin of the present invention are used. If it is used as a base material for a film for metal-like molding, it is preferable because it has good compatibility with a resin molded product and a strong adhesion can be obtained.

For the purpose of improving adhesion, corrosion resistance, etc. between the functional layer and the metal thin film layer of the metal-like molding film of the present invention, and between the metal thin film layer and the adhesive layer, urethane resin, acrylic resin A conventionally known resin such as a polyester resin, a melamine resin, or an epoxy resin may be laminated by a conventionally known coating method, and an anchor coat layer, a protective coat layer, or the like may be laminated.
In addition, the kind of resin used for the anchor coat layer and the protective coat layer, the thickness of the anchor coat layer and the protective coat layer, and the method of laminating the anchor coat layer and the protective coat layer can be used without any particular limitation. What is necessary is just to select suitably according to a desired objective and a use.
Further, for the purpose of improving the adhesion between the functional layer and the metal thin film layer, the functional layer may be subjected to surface treatment such as corona treatment or plasma treatment, and the processing conditions at that time may be appropriately selected.

Next, a metal-molded product obtained using the metal-molding film of the present invention will be described.

The metal-like molded product obtained using the film for metal-like molding of the present invention is either the following [Metal-like molded product 1] or [Metal-like molded product 2].

[Metal-like molded product 1]
A film obtained by molding only the film for metal-like molding of the present invention in which at least an adhesive layer, a metal thin film layer, and a functional layer are sequentially laminated on a substrate.
[Metal-like molded product 2]
A product in which at least a substrate, an adhesive layer, a metal thin film layer, and a functional layer are sequentially laminated without any gaps on a molded product molded into a desired shape. (The metal-like film for molding of the present invention is laminated on the molded product without any gaps)

When the metal-shaped molded product is the above-mentioned [Metal-shaped molded product 1], the metal-shaped molded film of the present invention is desired by using a conventionally known molding method such as a press molding method, a vacuum molding method, a pressure molding method, or the like. What is necessary is just to shape | mold.

Further, when the metal-molded product is the above-mentioned [Metal-molded product 2], the metal-molded film of the present invention uses a conventionally known molding method such as an insert molding method or a vacuum thermocompression molding method (TOM molding method). Then, it may be laminated on the molded product.

The insert molding method refers to the metal-forming film of the present invention in a mold cavity for molding a resin-molded product, and the base material of the metal-forming film faces the molten resin injection hole. In such a state, the resin is sandwiched in the mold, the molten resin is injected into the mold, and simultaneously with the molding of the resin molded product, the resin molded product and the metal-like molding film are in close contact with each other. This is a processing method for laminating the metal-like film on a molded product.

In addition, the vacuum thermocompression molding method (TOM molding method) is a method in which a pre-molded product is placed in the chamber so that the base material side of the metal tone molding film of the present invention is opposed. After heating and softening the metal-forming film in a vacuum state in the chamber, the molded product and the metal-forming film are brought into close contact with each other by crimping the molded product and the metal-forming film. The processing method of laminating the film for metal-like molding on a molded product.

When the molded product is a resin molded product, the resin used for the resin molded product can be used without any particular limitation, and acrylic resin, polyethylene resin, polyamide resin, polypropylene resin, polystyrene resin, vinyl chloride (PVC) Conventional resins such as resin, polyester resin, urethane resin, acrylonitrile / butadiene / styrene copolymer synthetic resin (ABS resin), mixed resin of polycarbonate resin and ABS resin (PC / ABS resin) can be used, metal What is necessary is just to select suitably according to the objective of a preparation.

If a metal-like molded product is produced using the metal-like molding film of the present invention, even if the shape of the molded product has a complicated shape or a deep-drawn shape, the metal-like molded product is used. The film follows without forming a gap with the surface of the molded product, and can produce a metal-like molded product that maintains a beautiful metallic luster without causing appearance defects such as whitening.

From the above, if the metal tone transfer film of the present invention is used to produce the metal tone forming film of the present invention, the conventional metal tone forming film uses a flexible plastic film. Therefore, the productivity and yield of the conventional metal-forming film is very poor, and as a result, the manufacturing cost is high, and the same problem as the conventional metal-forming film is solved. While maintaining functionality and performance of metal light, etc., the productivity and yield of the metal-forming film of the present invention is greatly improved, and the metal-forming film of the present invention is efficiently manufactured at a low production cost. It becomes possible to do.
In addition, the metal-like transfer film of the present invention used in the method for producing a metal-forming film of the present invention was formed by sequentially laminating at least a functional layer, a metal thin film layer, and, if necessary, an adhesive layer on a peelable plastic film. It's best if you do things.
Furthermore, if a metal-like molded product is manufactured using the metal-tone transfer film of the present invention, the metal-shaped molded product can be efficiently manufactured at a low manufacturing cost.

[Manufacture of metallic tone transfer film]
[Example 1]
The following steps (Step 1) to (Step 3) are sequentially performed, and a weatherable acrylic resin layer as a functional layer for imparting a weather resistance function and a metal for imparting a metallic luster on a peelable plastic film. The metallic tone transfer film of the present invention in which indium thin film layers were sequentially laminated as a thin film layer was obtained.

(Step 1) A melamine resin layer having a thickness of 1 μm is coated on one surface of a biaxially stretched polyethylene terephthalate film having a thickness of 50 μm by a gravure coating method (processing temperature 150 ° C.) as a release layer having a releasability. Were laminated to obtain a peelable plastic film.
(Step 2) On the melamine resin layer (peel layer) of the peelable plastic film, a functional layer is coated with a weather-resistant acrylic resin added with a curing agent by a reverse coating method (processing temperature 150 ° C.). Then, a weather-resistant acrylic resin layer having a thickness of 20 μm was laminated.
(Step 3) After corona treatment is applied to the weather-resistant cryl-based resin layer for the purpose of strengthening the adhesion with the metal thin film layer, the metal thin film layer is formed by using indium as a metal and using a vacuum deposition method. A 25 nm indium thin film layer was laminated.
At any processing temperature, the stretch degree of the biaxially stretched polyethylene terephthalate film was less than 130%, and the 150 ° C. storage elastic modulus measured by a dynamic viscoelasticity measuring apparatus was 900 MPa.

[Example 2]
After performing each of the steps (step 1) to (step 3) in Example 1 in order, an acrylic system as a thermal transfer thermoplastic adhesive (hot melt type) as an adhesive layer on the laminated indium thin film layer. The resin was coated by a reverse coating method, and an adhesive layer for thermal transfer having a thickness of 2 μm was laminated to obtain a metallic tone transfer film of the present invention.

[Manufacture of film for metal-like molding]
[Example 3]
The following steps (Step 1) to (Step 3) are sequentially performed as a series of operations using one manufacturing apparatus, and an adhesive layer (dry laminate) is formed on an acrylonitrile / butadiene / styrene copolymer synthetic resin film (ABS film). The film for metal-forming molding of this invention in which the indium thin film layer and the weather-resistant acrylic resin layer were laminated | stacked one by one was obtained.

(Step 1) On the indium thin film layer of the metallic tone transfer film of the present invention obtained in Example 1, as a dry laminate adhesive, a urethane resin is coated by a reverse coat method, dried in a drying furnace, and thickened. A 5 μm thick adhesive layer (for dry lamination) was laminated.
(Step 2) The adhesive layer (for dry laminating) and the base material ABS film surface having a thickness of 250 μm are stacked so as to be in contact with each other. The ABS film was brought into close contact.
(Step 3) The peelable plastic film of the metallic tone transfer film of the present invention was peeled off.

[Example 4]
The following steps (Step 1) and (Step 2) are performed in order, and an adhesive layer (for thermal transfer), an indium thin film layer, and a weather-resistant acrylic resin layer are sequentially laminated on the ABS film. A film for molding was obtained.

(Step 1) The adhesive layer (for thermal transfer) of the metal-tone molding film of the present invention obtained in Example 2 and the surface of a 250 μm thick ABS film (same as the base material used in Example 3) The metal-tone transfer film of the present invention and the ABS film were brought into close contact with each other by heat and pressure bonding so as to be sandwiched between hot rolls heated to 200 ° C.
(Step 2) The peelable plastic film of the metallic tone transfer film of the present invention was peeled off.

[Manufacture of metal-like molded products]
[Reference Example 1]
By using the metal-forming film of the present invention obtained in Example 3 by an insert molding method, an ABS film, an adhesive layer, an indium thin film layer, and an acrylonitrile / butadiene / styrene copolymer synthetic resin (ABS resin) A metal-like molded product was obtained in which weather-resistant acrylic resin layers were sequentially laminated.
In addition, the process of the insert molding method performed each process of the following (process 1)-(process 3) in order.

(Step 1) The metal-forming film of the present invention obtained in Example 3 is placed in the mold cavity so that the ABS film side of the metal-forming film of the present invention faces the injection hole.
(Step 2) The metal mold forming film of the present invention is sandwiched in the mold by fastening the mold, and the molten ABS resin is injected into the mold.
(Process 3) A metal-molded product is taken out from the mold.

[Reference Example 2]
Similar to Reference Example 1 except that the metal-forming film of the present invention obtained in Example 4 was used instead of the metal-forming film of the present invention obtained in Example 3 used in Reference Example 1. A metal-like molded product was obtained.

[Reference Example 3]
The ABS film, adhesive layer, and indium thin film layer are formed on an ABS resin (ABS resin molded product) by vacuum thermocompression molding (TOM molding method) using the metal-like molding film of the present invention obtained in Example 3. And the metal-like molded product in which the weather-resistant acrylic resin layer was laminated | stacked one by one was obtained.
In addition, the process of the vacuum thermocompression molding method (TOM molding method) performed each process of the following (process 1)-(process 4) in order.

(Step 1) An ABS resin molded product obtained by molding an ABS resin in advance with a mold is placed on a table in a chamber box, and the ABS film of the metal-forming film of the present invention obtained in Example 3 and the ABS resin molded product are obtained. Are placed in the chamber so as to face each other.
(Step 2) After the chamber box is closed and the inside of the chamber is evacuated, the metal tone forming film of the present invention is heated with a heater and softened.
(Step 3) The table on which the ABS resin molded product in the chamber box is installed is raised, and the metal tone molding film of the present invention and the ABS resin molded product are brought into close contact with each other.
(Step 4) After the inside of the chamber box is brought to atmospheric pressure, the metal-molded product is taken out from the chamber box.

[Reference Example 4]
Similar to Reference Example 3 except that the metal-forming film of the present invention obtained in Example 4 was used instead of the metal-forming film of the present invention obtained in Example 3 used in Reference Example 3. A metal-like molded product was obtained.

The metal-forming film of the present invention obtained in Example 3 and Example 4 had a beautiful metallic luster, and also had very good productivity and yield and could be produced at a low production cost. .
In addition, the metal-molded articles of Reference Examples 1 to 4 obtained by using the metal-molding films of the present invention obtained in Example 3 and Example 4 have no gap between the ABS resin and the metal-molding film. The films were in close contact with each other, and the metallic gloss of the metal-forming film of Examples 3 and 4 of the present invention was maintained without deteriorating the metallic luster.
Moreover, the metal-tone molded products of Reference Examples 1 to 4 had not only a beautiful metallic luster but also excellent weather resistance.

[Comparative Example 1]
In the same manner as in Example 3 except that the following laminated film 1 was used in place of the metallic tone transfer film of the present invention obtained in Example 1 used in (Step 1) of Example 3, Comparative Example 1 was used. A metal-like film was obtained. However, (Step 3) of Example 3 was not performed because the acrylic film of the following laminated film 1 used could not be peeled off.
(Laminated film 1)
A patent in which a transparent anchor coat layer made of a mixed resin in which an isocyanate is added to an acrylic urethane resin and an indium thin film layer (metal thin film layer) are sequentially laminated on an acrylic film (substrate sheet), which is a flexible plastic film. Corresponds to the molded simultaneous picture sheet described in Document 1.
When manufacturing the said laminated | multilayer film 1, the process of laminating | stacking a transparent anchor coat layer on the said acrylic film processed at low temperature (processing temperature 60 degreeC) and low speed rather than general processing conditions.
Further, when the transparent anchor coat layer was coated at 150 ° C. as in Example 1, the acrylic film was cut and could not be processed.
The degree of stretching of the acrylic film was 130% or more, and the 150 ° C. storage elastic modulus measured by a dynamic viscoelasticity measuring apparatus was 5 MPa. Therefore, when laminating the transparent anchor coat layer, it was necessary to process at a low temperature so that the acrylic film was not cut.

[Comparative Example 2]
Comparative Example 2 was the same as Example 3 except that the following laminated film 2 was used instead of the metallic tone transfer film of the present invention obtained in Example 1 used in (Step 1) of Example 3. A metal-like film was obtained. However, (Step 3) of Example 3 was not performed because the acrylic film of the following laminated film 2 used could not be peeled off.
(Laminated film 2)
A first anchor coat layer made of acrylic resin, a second anchor coat layer made of water-based polyurethane resin, and an indium thin film layer (metal thin film layer) are sequentially laminated on an acrylic film (base sheet) which is a flexible plastic film. This corresponds to a molding sheet having a metallic luster described in Patent Document 2.
When the laminated film 2 is manufactured, the process of laminating the first anchor coat layer and the second anchor coat layer on the acrylic film is processed at a lower temperature (processing temperature 60 ° C.) and at a lower speed than general processing conditions. Went.
Further, when coating was performed at 150 ° C. in the same manner as in Example 1 in the step of laminating the first anchor coat layer or the second anchor coat layer, the acrylic film was cut and could not be processed.
The degree of stretching of the acrylic film was 130%, and the 150 ° C. storage elastic modulus measured by a dynamic viscoelasticity measuring apparatus was 5 MPa. Therefore, when laminating the first anchor coat layer and the second anchor coat layer, it is necessary to process at a low temperature so that the acrylic film is not cut.

The metal-forming film obtained in Comparative Example 1 not only has a white appearance and does not have a beautiful metallic luster, but also uses an acrylic film that is a flexible plastic film for the base sheet. Since the processing was performed at a lower temperature and lower speed than typical processing conditions, the productivity and yield were very poor and the manufacturing cost was very expensive.
Further, the metal-forming film obtained in Comparative Example 2 was a metal-forming film having a beautiful metallic luster, but an acrylic film, which is a flexible plastic film, was used for the base sheet. Since the processing was performed at a lower temperature and a lower speed than typical processing conditions, the productivity and the yield were still very bad, and the manufacturing cost was very expensive.

Claims (5)

A method for producing a film for forming a metal tone, comprising: a metal tone transfer film in which at least a functional layer and a metal thin film layer are sequentially laminated on a peelable plastic film; At least a functional layer laminated on the metal-tone transfer film, and a metal thin film after the thin-film layer side is brought into close contact with the substrate surface via an adhesive layer, and then the peelable plastic film of the metal-tone transfer film is peeled off By transferring the layer to the surface of the base material, a metal-forming film having at least an adhesive layer, a metal thin film layer, and a functional layer sequentially laminated on the base material is manufactured. Film production method. A method for producing a metal-like film, comprising a metal-like transfer film in which at least a functional layer, a metal thin film layer, and an adhesive layer are sequentially laminated on a peelable plastic film, and a base material. After the adhesive layer side of the film is brought into close contact with the substrate surface, the peelable plastic film of the metallic tone transfer film is peeled off, and at least a functional layer laminated on the metallic tone transfer film, a metallic thin film By transferring the layer and the adhesive layer to the surface of the base material, a metal-forming film in which at least the adhesive layer, the metal thin film layer, and the functional layer are sequentially laminated on the base material is manufactured. A method for producing a metal-like film.   The film for metal-like shaping | molding manufactured by the manufacturing method of the film for metal-like shaping | molding of Claim 1 or Claim 2. A metal tone transfer film used in the method for producing a metal tone molding film according to claim 1, wherein at least a functional layer and a metal thin film layer are sequentially laminated on a peelable plastic film. A metal tone transfer film used in the method for producing a metal tone forming film according to claim 2, wherein at least a functional layer, a metal thin film layer, and an adhesive layer are sequentially laminated on a peelable plastic film. Transcription film.