JP2013230575A - Transfer foil, method of manufacturing decorative molded article and decorative molded article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a transfer foil capable of imparting subtle uneven shapes while suppressing variation in a design and surface properties.SOLUTION: At least one layer out of layers comprising a transfer layer includes a foaming agent that foams by heating so that foaming of the foaming agent in the transfer layer and transfer of the transfer layer to a molded article can be simultaneously performed by heating when transferring. At this time, the foaming agent in the transfer layer is foamed so that subtle uneven shapes can be imparted to surfaces of a decorative molded article. Accordingly, (1) a surface decorative processing is not required after molding the molded article, and (2) when manufacturing a transfer foil, the transfer layer can be formed on a flat surface, and each layer can be formed with the even film thickness, suppressing variation in the design and surface properties.

Description

  The present invention relates to a transfer foil used for surface decoration of an article, a method for producing a decorative molded product using the transfer foil, and a decorative molded product using the transfer foil.

  Conventionally, articles are surface-decorated using a transfer foil in which a transfer layer is formed on a releasable film substrate. Surface decoration using a transfer foil is used in various applications that require a highly attractive design. For example, (1) equipment main bodies such as daily necessities and daily necessities, (2) containers for foods and various articles, (3) housings such as electronic equipment and office supplies, and the like.

  For example, a transfer foil is placed in an injection mold and the mold is closed, and a molten resin is injected into the mold to perform injection molding, thereby producing a decorative molded product to which the transfer layer of the transfer foil is transferred. A molding simultaneous decorating method (in-mold molding) has been proposed (see Patent Document 1).

  In addition, as a surface decoration of an article, fine irregularities are formed in a layer near the outer surface or on the outer surface. By forming fine irregularities, the surface of the article can be given a matte tone (matte tone, suede tone). Also, by forming fine irregularities, the surface of the article should have a good tactile sensation expressed by words such as moist feeling, smooth feeling, elasticity, etc. (hereinafter referred to as soft feeling). I can do it.

  For example, it has been proposed that a leather-like surface layer forming agent is spray-coated on the surface of a molded product to give the surface a leather-like tactile feel to the molded product (patent) Reference 2).

  For example, because the surface shape of the release layer of the transfer foil is matte, the surface shape of the release layer is transferred to the surface of the molded product when the transfer foil is peeled off after forming by the simultaneous molding method. It has been proposed to provide an uneven shape on the surface of a molded product (see Patent Document 3).

JP-A-1-120398 JP-A-6-330472 Japanese Unexamined Patent Publication No. 4-125198

  However, when performing surface decoration using coating, (1) it is necessary to perform a coating process as surface decoration after molding the molded product, (2) a surface protective layer with a uniform film thickness on the outer surface due to coating unevenness There is a problem that it is difficult to form the pattern and the design varies.

  In addition, when performing a simultaneous molding decoration method using a transfer foil provided with a release layer in which a concavo-convex shape is formed in advance, in the transfer foil, a surface protective layer is formed on the layer provided with the concavo-convex shape, There is a problem that it is difficult to form the surface protective layer with a uniform film thickness, and variations in surface properties occur.

  Therefore, the present invention has been made to solve the above-described problems, and an object of the present invention is to provide a transfer foil that can give a fine uneven shape while suppressing variations in design and surface properties.

  One embodiment of the present invention is a transfer foil in which a transfer layer is formed on a releasable film substrate, wherein the releasable film substrate is at least a base film and an upper layer than the base film. The transfer layer includes at least a surface protective layer laminated above the mold release layer, and an adhesive layer laminated above the surface protective layer. The transfer foil is characterized in that at least one of the layers constituting the transfer layer contains a foaming agent that foams by heating.

  The surface protective layer is a layer containing one or more resin mixtures selected from the group consisting of a resin mixture containing a polyester-based resin, a resin mixture containing a vinyl chloride / vinyl acetate copolymer and an acrylic resin. There may be.

  Further, the surface protective layer may be a layer containing elastic fine particles containing methacrylic acid ester.

  The transfer layer may be a transfer layer having a pattern layer between the surface protective layer and the adhesive layer.

  The transfer layer may be a transfer layer having a concealing layer between the surface protective layer and the adhesive layer.

  The transfer layer may be a transfer layer having a heat storage layer between the surface protective layer and the adhesive layer.

  One embodiment of the present invention includes an arrangement step of arranging the transfer foil described above in a mold, and an injection molding step of injection molding by injecting a molding resin into the mold, and the injection molding In the process, the decorative molded product manufacturing method is characterized in that the transfer layer of the transfer foil is transferred onto the surface of the molded product simultaneously with foaming of the surface protective layer by heat during injection molding.

  One embodiment of the present invention is a decorative molded product whose surface is decorated with the transfer foil described above, and is a decorative molded product having a foamed surface protective layer on the outer surface.

  Since the transfer foil of the present invention is a layer containing a foaming agent in which at least one of the layers constituting the transfer layer is foamed by heating, the foaming agent in the transfer layer is foamed and molded by heating during transfer. The transfer layer can be transferred to the product at the same time. At this time, when the foaming agent in the transfer layer is foamed, a fine uneven shape can be imparted to the surface of the decorative molded product. For this reason, (1) it is not necessary to perform surface decoration processing after molding a molded product. (2) Since the transfer layer can be formed on a flat surface during the production of the transfer foil, each layer is made uniform. The film can be formed with a film thickness, and there is an effect that variations in design and surface properties can be suppressed.

It is the schematic which shows an example of the transfer foil of this invention. It is the schematic which shows an example of the transfer foil of this invention. It is the schematic which shows an example of the transfer foil of this invention. It is the schematic which shows an example of the transfer foil of this invention.

Hereinafter, the transfer foil of the present invention will be described.
The transfer foil of the present invention is a transfer foil in which a transfer layer is formed on a releasable film substrate. The releasable film base material is constituted by laminating at least a base material film and a release layer. A transfer layer is a part laminated | stacked on the mold release layer side of a mold release film base material, and is transcribe | transferred to the surface of the decorative molded product using transfer foil. The transfer layer is configured by laminating at least a surface protective layer and an adhesive layer. Since the transfer foil of the present invention is a layer containing a foaming agent in which at least one of the layers constituting the transfer layer is foamed by heating, the foaming agent in the transfer layer is foamed and molded by heating during transfer. The transfer layer can be transferred to the product at the same time.

<Base film>
A base film is a site | part used as the base | substrate of a releasable film base material.

  The base film may be used by appropriately selecting a material from flexible materials. For example, (1) Polyester resin such as polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, (2) Polyolefin resin such as polyethylene, polypropylene, polybutene, polymethylpentene, ethylene-propylene-butene copolymer, (3) Nylon 6, polyamide resin such as nylon 66, (4) polyvinyl chloride, and the like may be used. In particular, a uniaxial or biaxially stretched polyester film is excellent in heat resistance and can prevent the transfer foil from being damaged at the temperature of the resin injected during in-mold molding. Therefore, the base material used in the transfer foil of the present invention Preferred as a film. The base film may be a multilayer composite film in which two or more kinds of films are bonded together.

  Further, the thickness of the base film is preferably in the range of about 5 μm to 200 μm, and more preferably in the range of about 25 μm to 100 μm. The base film having a thickness within the above range is a thickness that can be suitably handled in various printing methods (for example, gravure printing, offset printing, screen printing, flexographic printing, etc.), and can efficiently produce a transfer foil. I can do it. However, the thickness of the base film in the transfer foil of the present invention is not limited to the above range.

<Release layer>
The release layer is formed on the base film. After the transfer foil is integrated with the target article, the base film and the release layer are peeled off at the part of the release layer, so that the outermost surface of the obtained decorative molded product can be a surface protective layer described later. I can do it.

  As a material for the release layer, a release resin or a resin containing a release agent may be appropriately selected and used. For example, a melamine resin, acrylic resin, polyester resin, urethane resin, fluorine resin, silicone resin, epoxy resin, or the like may be used as the release resin. Further, for example, an acrylic resin, a vinyl resin, a polyester resin, a fiber resin, or the like to which a release agent is added or copolymerized may be used as the resin containing the release agent. At this time, for example, a fluorine-based resin, a silicone resin, or various waxes may be used as the release agent. Moreover, the material of the release layer may be a resin mixture obtained by mixing a plurality of resins. In particular, an acrylic resin made by melamine or isocyanate curing is excellent in heat resistance and can prevent the transfer foil from being damaged at the temperature of the resin injected during in-mold molding. Therefore, it is used for the transfer foil of the present invention. Preferred as a material for the release layer.

  In addition, the release layer is formed by adjusting a release layer coating liquid obtained by dispersing and dissolving the release layer material in a solvent, and applying the release layer coating liquid appropriately using a known coating formation method. It may be done by drying. At this time, as a coating formation method, for example, roll coating, reverse roll coating, gravure coating, reverse gravure coating, bar coating, rod coating, kiss coating, knife coating, die coating, comma coating, flow coating, spray coating, etc. A coating method may be used.

  The thickness of the release layer is preferably in the range of about 0.1 μm to 5.0 μm, and more preferably in the range of about 0.3 μm to 2.0 μm. A release layer having a thickness within the above range can form a uniform film by various general coating forming methods. However, the thickness of the release layer in the transfer foil of the present invention is not limited to the above range.

<Surface protective layer>
The surface protective layer is formed in an upper layer than the release layer. The surface protective layer becomes the outermost surface of the decorative molded product obtained after integrating the transfer foil with the target article.

  The material for the surface protective layer may be appropriately selected from known materials in consideration of various physical properties such as weather resistance, abrasion resistance, scratch resistance, and chemical resistance. For example, urethane resin, acrylic resin, polyester resin, or the like may be used.

  In particular, as the material for the surface protective layer, one or more resin mixtures selected from the group consisting of a resin mixture containing a polyester resin and a resin mixture containing a vinyl chloride / vinyl acetate copolymer and an acrylic resin should be used. Is preferred. When the above resin mixture is used, a soft feeling can be imparted excellently. In addition, foaming of the foaming agent is not hindered during foaming during transfer.

  Further, elastic fine particles containing a methacrylic acid ester may be added to the material of the surface protective layer. By adding elastic fine particles, the decorative molded product can have a soft feel. Further, since the elastic fine particles are diffused in the surface protective layer due to foaming during transfer, the elastic fine particles can be uniformly arranged in the surface protective layer.

  Moreover, you may add an additive to the material of a surface protective layer. Examples of the additive include an ultraviolet absorber, a light stabilizer, a heat stabilizer, a lubricant, a flame retardant, and an antiblocking agent.

Moreover, you may use resin containing active energy ray hardening-type resin as a material of a surface protective layer. The active energy ray-curable resin is a resin that is cured by irradiating an active energy ray to crosslink functional groups in the resin. For example, examples of the active energy ray-curable resin include a resin containing at least an acryloyl group or a methacryloyl group.
When an active energy ray-curable resin is used as the material for the surface protective layer, (1) while maintaining the thermoplasticity in the surface protective layer by irradiating the active foil after integrating the transfer foil with the target article Transfer can be performed while following the surface shape of the target article, and (2) the surface strength of the outermost surface portion of the decorative molded product can be improved by crosslinking and curing after the transfer foil is formed. For this reason, by using an active energy ray-curable resin as the material for the surface protective layer, both moldability and sufficient scratch resistance can be achieved. In particular, in the transfer of the transfer foil of the present invention, when the surface protective layer maintains thermoplasticity at the time of transfer, it easily follows the shape change due to the foaming effect of the foaming agent, so that a soft feel as a tactile sensation is provided. Improved and preferred.

  Further, when an active energy ray-curable resin is used as the material for the surface protective layer, after the surface protective layer is applied and formed, (1) irradiation with active energy rays not to be completely crosslinked, (2) heating, etc. The surface protective layer may be incompletely (partially) crosslinked. By making the surface protective layer incompletely (partially) crosslinked, (1) it can be dried more completely than in the uncrosslinked state, and handling of the transfer foil is improved. (2) There are effects that the surface protective layer can be prevented from flowing due to heat and stress during transfer.

  In addition, the surface protective layer is formed by adjusting a surface protective layer coating solution in which the material of the surface protective layer and the foaming agent are dispersed and dissolved in a solvent, and the surface protective layer coating solution is appropriately formed using a known coating formation method. It may be done by applying and drying. At this time, as a coating formation method, for example, roll coating, reverse roll coating, gravure coating, reverse gravure coating, bar coating, rod coating, kiss coating, knife coating, die coating, comma coating, flow coating, spray coating, etc. A printing method such as a coating method, gravure printing, or screen printing may be used. Moreover, you may perform the hardening method of a surface protective layer according to the composition of the material of the selected surface protective layer. For example, curing such as a one-component curing type, a two-component curing type using a curing agent, and a curing type by active energy ray irradiation may be performed.

  The thickness of the surface protective layer is preferably in the range of about 5 μm to 50 μm. However, the thickness of the surface protective layer in the transfer foil of the present invention is not limited to the above range.

<Adhesive layer>
The adhesive layer is formed in an upper layer than the surface protective layer. When the transfer foil is integrated with the target article, the adhesive layer is a portion that contacts the target article and adheres the transfer foil to the target article.

  The material used for the adhesive layer may be appropriately selected from materials having adhesiveness and tackiness with the surface material of the target article at normal temperature and heating. Specifically, it may be appropriately selected from materials known as adhesives, pressure-sensitive adhesives, hot melts, and the like. For example, acrylic, epoxy, vinyl acetate, vinyl chloride, isocyanate, silicone, styrene-butadiene, vinyl chloride-vinyl acetate, ethylene-vinyl acetate, polyester, rubber chloride, chlorinated polypropylene Or polyurethane resins may be used alone, or emulsion resins, organic solvent-type resins, water-soluble resins, and the like mainly composed of a mixture thereof may be used.

  Moreover, as a formation method of an adhesive layer, you may carry out by apply | coating suitably using a well-known application | coating formation method according to the material used for an adhesive layer, and making it dry. For example, as a coating forming method, (1) printing method such as gravure printing, offset printing, screen printing, etc. (2) roll coating, reverse roll coating, gravure coating, reverse gravure coating, bar coating, rod coat, kiss coating, knife Coating methods such as coating, die coating, comma coating, flow coating, spray coating, and extrusion coating may be used.

  The thickness of the adhesive layer is preferably in the range of about 1 μm to 10 μm. However, the thickness of the adhesive layer in the transfer foil of the present invention is not limited to the above range.

<Foaming agent>
The foaming agent is a material that foams when heated, and is contained in at least one of the layers constituting the transfer layer. Since at least one of the layers constituting the transfer layer is a layer containing a foaming agent that foams by heating, foaming of the foaming agent in the transfer layer and transfer of the transfer layer to a molded product by heating during transfer Can be performed simultaneously. At this time, when the foaming agent in the transfer layer is foamed, a fine uneven shape can be imparted to the surface of the decorative molded product. For this reason, (1) it is not necessary to perform surface decoration processing after molding a molded product. (2) Since the transfer layer can be formed on a flat surface during the production of the transfer foil, each layer is made uniform. The film can be formed with a film thickness, and there is an effect that variations in design and surface properties can be suppressed.

  For example, when the surface protective layer contains a foaming agent, foaming of the surface protective layer and transfer of the transfer layer to the molded product can be performed simultaneously by heating during transfer. At this time, when the surface protective layer is foamed, a fine uneven shape can be imparted to the surface protective layer. For example, when a foaming agent is included in the adhesive layer, foaming and transfer of the transfer layer to the target article can be performed simultaneously by heating during transfer. At this time, the gas foamed in the adhesive layer reaches the transfer surface side, and a fine uneven shape can be imparted to the surface protective layer.

  The foaming agent may be any foaming agent that foams by heating, and may be appropriately selected and used. For example, (1) a foaming agent that generates gas by a chemical reaction such as sodium hydrogen carbonate or azodicarbonamide and (2) has an outer shell formed from polyacrylonitrile, polyvinylidene chloride, etc. In addition, thermal expansion microcapsules generated by filling liquid hydrocarbons (for example, normal pentane, isopentane, etc.) may be used. In particular, the thermally expanded microcapsule has a stable physical property because the outer shell component and the like do not change chemically even after foaming, and is preferable as a foaming agent used in the transfer foil of the present invention. Further, the amount of foaming agent added may be appropriately adjusted and determined according to the desired specifications such as tactile sensation.

  Note that the transfer foil of the present invention has the desired effect as long as at least one of the layers constituting the transfer layer is a layer containing a foaming agent that is foamed by heating. Therefore, one of the layers constituting the transfer layer may be a layer containing a foaming agent, or a plurality of layers among the layers constituting the transfer layer may be a layer containing a foaming agent.

  Further, the transfer foil of the present invention may have a configuration in which a functional layer is additionally added at the layer interface of each layer. At this time, the functional layer added to the transfer layer may be a layer containing a foaming agent that foams by heating.

<Pattern layer>
For example, as a functional layer, a pattern layer may be provided between the surface protective layer and the adhesive layer. By providing the pattern layer, a variety of designs can be imparted, and the design can be improved.

  The pattern layer may be formed by selecting a material according to a desired pattern and using a forming method according to the selected material. For example, the picture layer may be a printed picture layer, a metallic luster layer, a metallic print layer, and the like.

  When the pattern layer is a printed pattern layer, the material used for the pattern layer may be appropriately selected from known inks. For example, coloring agents such as dyes or pigments and extenders are added to the vehicle, and plasticizers, stabilizers, waxes, greases, desiccants, curing agents, thickeners, dispersants, fillers, etc. are optionally added. Further, the ink may be prepared by sufficiently diluting and stirring with a solvent, a diluent or the like. When the picture layer is a printed picture layer, the pattern layer forming method may be appropriately selected from known printing methods according to the physical properties of the ink selected with the material used for the picture layer. For example, as a printing method, gravure printing, offset printing, intaglio printing, screen printing, flexographic printing, electrostatic printing, inkjet printing, or the like may be used.

  When the pattern layer is a metallic gloss layer or a metallic print layer, the material used for the pattern layer may be appropriately selected from glossy materials. In addition, when the pattern layer is a metallic luster layer or a metallic print layer, the pattern layer forming method is appropriately selected from known thin film forming methods according to the physical properties of the material having the metallic luster selected from the material used for the pattern layer. May be used. For example, (1) a metal thin film layer such as a metal such as aluminum, tin, chromium, nickel, gold, platinum, silver, copper, indium, titanium, zinc, or an oxide thereof, or an alloy or compound thereof, (2 ) A printed pattern layer formed using an ink containing a metallic pigment such as aluminum flakes may be used as a metallic glossy layer or a metallic tone printed layer. At this time, as a method for forming the metal thin film layer, for example, a vacuum deposition method, a sputtering method, an ion plating method, a plating method, or the like may be used. Moreover, as a formation method of a printing pattern layer, you may use printing methods, such as gravure printing, offset printing, intaglio printing, screen printing, flexographic printing, electrostatic printing, inkjet printing, for example.

<Concealment layer>
For example, a concealing layer may be provided as a functional layer between the surface protective layer and the adhesive layer. By providing the hiding layer, in the decorative molded product using the transfer foil of the present invention, the influence of the color on the inner side from the hiding layer can be suppressed when observed from the outermost surface. For this reason, especially the influence of the color of the base material of the target article which transfers a transfer foil can be suppressed.

  A material for the masking layer may be selected according to the color to be masked, and may be appropriately selected from known inks. The method for forming the masking layer may be appropriately selected from known printing methods according to the physical properties of the ink selected with the material used for the masking layer. For example, as a printing method, gravure printing, offset printing, intaglio printing, screen printing, flexographic printing, electrostatic printing, inkjet printing, or the like may be used.

<Heat storage layer>
For example, a heat storage layer may be provided as a functional layer between the surface protective layer and the adhesive layer. By providing the heat storage layer, the heat applied to the transfer foil during transfer can be stored. When there is a time from when the heat is applied until the transfer is completed, the foaming effect of the foam can be sufficiently expressed based on the heat source stored in the heat storage layer. For this reason, the deformation | transformation which arises at the time of foaming can be more effectively transmitted to the surface protective layer side, and the improvement of a tactile feeling can be anticipated.

  The heat storage layer may be any material that can temporarily store the amount of heat applied when the transfer foil is transferred, and may be appropriately selected from known materials such as a material having low thermal conductivity. For example, a resin layer in which hollow beads or hollow nanosilica is dispersed can be used. In this case, the material of the resin layer is desirably a material in which the hollow material can be uniformly dispersed. For example, the same material as that used for the surface protective layer can be used.

  The method for forming the heat storage layer may be appropriately selected from known thin film formation methods according to the material selected for the heat storage layer. For example, you may form using gravure printing, offset printing, screen printing, flexographic printing, etc.

FIG. 1 shows an example of the transfer foil of the present invention.
The transfer foil 1 of the present invention shown in FIG. 1 has a configuration in which a release film substrate 2 is laminated on a transfer layer 3. The release film 2 is formed by laminating a release layer 22 on a base film 21. In the transfer layer, the surface protective layer 4 is laminated on the adhesive layer 5. The surface protective layer 4 contains a foaming agent 6 that foams by heat.
After transferring the transfer foil 1, the releasable film substrate 2 is peeled off, and the outermost surface of the obtained decorative molded product becomes the surface protective layer 4 of the transfer layer 3. At this time, the foaming agent 6 inside the surface protective layer 4 is foamed by heat at the time of transfer, and the surface protective layer 4 which is the outermost surface of the obtained decorative molded product has a fine uneven shape. Thereby, the obtained decorative molded product has an excellent tactile sensation.

FIG. 2 shows an example of the transfer foil of the present invention in which a picture layer and a concealing layer are formed.
The transfer foil 1 of the present invention shown in FIG. 2 has a configuration in which a release film substrate 2 is laminated on a transfer layer 3. The release film 2 is formed by laminating a release layer 22 on a base film 21. Further, the transfer layer is formed by laminating the masking layer 8 on the upper layer of the adhesive layer 5, the pattern layer 7 on the masking layer 8, and the surface protective layer 4 on the pattern layer 7. The surface protective layer 4 contains a foaming agent 6 that foams by heat.

FIG. 3 shows an example of the transfer foil of the present invention in which a concealing layer and a heat storage layer are formed.
The transfer foil 1 of the present invention shown in FIG. 3 has a configuration in which a release film substrate 2 is laminated on a transfer layer 3. The release film 2 is formed by laminating a release layer 22 on a base film 21. In addition, the transfer layer is formed by laminating the heat storage layer 9 on the adhesive layer 5, the masking layer 8 on the heat storage layer 9, and the surface protection layer 4 on the masking layer 8. The surface protective layer 4 contains a foaming agent 6 that foams by heat.

FIG. 4 shows an example of the transfer foil of the present invention in which a picture layer, a concealing layer, and a heat storage layer are formed.
The transfer foil 1 of the present invention shown in FIG. 4 has a configuration in which a release film substrate 2 is laminated on a transfer layer 3. The release film 2 is formed by laminating a release layer 22 on a base film 21. Further, the transfer layer is formed by laminating the heat storage layer 9 on the adhesive layer 5, the masking layer 8 on the heat storage layer 9, the pattern layer 7 on the masking layer 8, and the surface protection layer 4 on the pattern layer 7. Yes. The surface protective layer 4 contains a foaming agent 6 that foams by heat.

Hereinafter, the decorative molded product of the present invention will be described.
The decorative molded product of the present invention is a decorative molded product using the transfer foil described above. By transferring the transfer foil of the present invention to the target article and peeling the release film substrate, a decorative molded product having the surface protective layer as the outermost surface can be obtained.

  The material of the target article to which the transfer foil is transferred is not particularly limited as long as it can adhere to the material selected for the adhesive layer of the transfer foil. For example, the material of the target article is (1) polyolefin resin such as polyethylene and polypropylene, acrylic resin, vinyl chloride resin, acrylonitrile-butadiene-styrene copolymer (ABS resin), polycarbonate resin, phenol resin, etc. (2) Metals or metal compounds such as aluminum, iron, stainless steel, brass, etc. (3) Wood such as wood plywood, wood veneer, medium density fiberboard (MDF), ceramics such as glass and ceramics ALC, lightweight aerated concrete (ALC), GRC (glass fiber reinforced concrete), cement such as slag cement, calcium silicate, paper, fabric, nonwoven fabric, and the like.

  Moreover, the shape of the target article to which the transfer foil is transferred is not particularly limited. For example, the shape of the target article may be a sheet (film), a flat plate, a curved plate, a rod-shaped body, a three-dimensional object, or the like.

  The transfer method for transferring the transfer foil may be any transfer method that generates heat suitable for the material selected as the foaming agent at the time of transfer, and may be appropriately selected from known transfer methods. For example, a transfer method such as in-mold molding or a roll thermal transfer method may be used. In-mold molding, in particular, is a molding simultaneous decoration method in which a transfer foil and a molded product are integrated to produce a decorative molded product, and has a three-dimensional shape (curved shape, uneven shape, perforated shape, etc.). Since a design can be suitably imparted to an article, it is preferable as a transfer method employed in the decorative molded product manufacturing method of the present invention.

<Expression of foaming effect>
Below, the foaming effect expression mechanism of the foaming agent in this invention is demonstrated.
According to the present invention, the foaming agent introduced into the transfer layer is foamed by heat applied during transfer, thereby causing a change in the shape of the surface. For example, when processing by the roll heat transfer method, the foaming agent is foamed by the heat applied from the releasable film substrate side, and the foaming effect appears in the surface protective layer by peeling the film substrate together with the transfer. In addition, when performing transfer processing by in-mold molding, the foaming effect of the foaming agent is suppressed in the mold immediately after molding, but when the mold is opened, the pressure of the injection resin is released along with peeling of the releasable film substrate. Is released, the original foaming effect is developed and the shape of the surface protective layer is changed. At this time, it is preferable to provide a heat storage layer capable of storing a heat source in the transfer layer because heat applied to the transfer foil during transfer can be efficiently transmitted to the foaming agent. In either case, when the release film substrate of the transfer foil is peeled off and the transfer layer is transferred, the foaming effect of the foaming agent foamed by heat appears as a change in the surface shape.

<Example 1>
Hereinafter, the transfer foil and the decorative molded product of the present invention will be described with specific examples.

(Production method of transfer foil)
First, a release layer was formed on the base film.
At this time, a biaxially stretched polyethylene terephthalate film (thickness: 50 μm) was used as the base film. The release layer material was melamine resin. A gravure coating method was used for forming the release layer. The dry thickness of the release layer was 2.0 μm.

Next, a surface protective layer was formed on the release layer.
At this time, as a material for the surface protective layer, a two-component curing type urethane resin to which a foaming agent was added was used. Further, screen printing was used for forming the surface protective layer. The dry thickness of the surface protective layer was 30.0 μm. The added foaming agent was a thermal expansion microcapsule (EXPANEL "EXPANEL 920-40", UK).

Next, a pattern layer was formed on the surface protective layer.
At this time, ultraviolet curing type silver ink (including aluminum paste) was used as a material for the pattern layer. Thereby, the pattern layer became a metallic print layer as a printed pattern layer. The pattern layer was formed by applying a material for the pattern layer by screen printing and then irradiating with ultraviolet rays to crosslink and cure the material of the pattern layer. At this time, the ultraviolet irradiation condition was such that the integrated light quantity was 500 mJ / cm ² using a high-pressure mercury lamp 120 W / cm.

Next, an adhesive layer was formed on the pattern layer.
At this time, a one-component curing type acrylic resin adhesive was used as a material for the adhesive layer. In addition, gravure printing was used for forming the adhesive layer. The dry thickness of the adhesive layer was 5.0 μm.

  From the above, it was possible to produce the transfer foil of the present invention in which the base film / release layer / surface protective layer / picture layer / adhesive layer were laminated in this order.

(Method for producing decorative molded products)
The transfer foil of the present invention produced as described above is placed in a mold, a resin is injected to the adhesive layer side of the transfer foil, a resin molded product is taken out from the mold, and a substrate is formed at the part of the release layer of the transfer foil. The film and the release layer were peeled from the resin molded product to obtain a decorative molded product of the present invention (in-mold molding).

  The outermost surface of the obtained decorative molded product was a surface protective layer, and the surface protective layer on the outermost surface was provided with an uneven shape on the surface due to the foaming effect during molding. Therefore, it was possible to obtain a decorative molded product having a soft feel.

  The transfer foil of the present invention is expected to be used in a wide range of fields for articles that require surface decoration. For example, portable information terminal casing, personal computer casing, air conditioner casing, TV casing, camera casing, home appliance operation panel, audio product panel, various equipment touch panel, automobile interior material, automobile exterior material, bicycle member, cosmetic container It can be used in fields such as food exterior materials, tableware, toiletries and toys.

DESCRIPTION OF SYMBOLS 1 ... Transfer foil 2 ... Releaseable film base material 3 ... Transfer layer 4 ... Surface protective layer 5 ... Adhesive layer 6 ... Foaming agent 7 ... Picture layer 8 ... Concealing layer 9 ... Thermal storage layer 21 …… Base film 22 …… Release layer

Claims (8)

A transfer foil having a transfer layer formed on a releasable film substrate,
The releasable film substrate comprises at least a substrate film, and a release layer laminated in an upper layer than the substrate film,
The transfer layer comprises at least a surface protective layer laminated above the release layer, and an adhesive layer laminated above the surface protective layer,
At least one of the layers constituting the transfer layer includes a foaming agent that foams by heating. The surface protective layer is a layer containing one or more resin mixtures selected from the group consisting of a resin mixture containing a polyester resin, a resin mixture containing a vinyl chloride / vinyl acetate copolymer and an acrylic resin. The transfer foil according to claim 1. The transfer foil according to claim 1, wherein the surface protective layer is a layer containing elastic fine particles containing a methacrylic acid ester. 4. The transfer foil according to claim 1, wherein the transfer layer is a transfer layer having a pattern layer between the surface protective layer and the adhesive layer. 5. The transfer foil according to claim 1, wherein the transfer layer is a transfer layer having a concealing layer between the surface protective layer and the adhesive layer. The transfer foil according to any one of claims 1 to 3, wherein the transfer layer is a transfer layer having a heat storage layer between the surface protective layer and the adhesive layer. An arrangement step of arranging the transfer foil according to claim 1 in a mold;
An injection molding step of injection molding by injecting a molding resin into the mold,
A method for producing a decorative molded product, wherein the transfer layer is transferred onto the surface of the molded product simultaneously with foaming of the surface protective layer by heat during injection molding in the injection molding process.   A decorative molded product, the surface of which is decorated with the transfer foil according to claim 1 and having a foamed surface protective layer on the outer surface.