JP2017056646A - Manufacturing method of designable film - Google Patents
Manufacturing method of designable film Download PDFInfo
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- JP2017056646A JP2017056646A JP2015183572A JP2015183572A JP2017056646A JP 2017056646 A JP2017056646 A JP 2017056646A JP 2015183572 A JP2015183572 A JP 2015183572A JP 2015183572 A JP2015183572 A JP 2015183572A JP 2017056646 A JP2017056646 A JP 2017056646A
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- thermoplastic resin
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- embossing roll
- designable film
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 25
- 229920005989 resin Polymers 0.000 claims abstract description 40
- 239000011347 resin Substances 0.000 claims abstract description 40
- 229920005992 thermoplastic resin Polymers 0.000 claims abstract description 36
- 239000011342 resin composition Substances 0.000 claims abstract description 29
- 238000000034 method Methods 0.000 claims abstract description 11
- 238000004049 embossing Methods 0.000 claims description 47
- -1 polybutylene terephthalate Polymers 0.000 claims description 16
- 229920001707 polybutylene terephthalate Polymers 0.000 claims description 12
- 238000002425 crystallisation Methods 0.000 claims description 8
- 230000008025 crystallization Effects 0.000 claims description 8
- 238000000113 differential scanning calorimetry Methods 0.000 claims description 7
- 238000002844 melting Methods 0.000 claims description 7
- 230000008018 melting Effects 0.000 claims description 7
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 7
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 7
- 238000002156 mixing Methods 0.000 claims description 6
- 229920001577 copolymer Polymers 0.000 claims description 3
- 238000007493 shaping process Methods 0.000 abstract description 2
- 238000001816 cooling Methods 0.000 abstract 1
- 238000013461 design Methods 0.000 description 19
- 239000010410 layer Substances 0.000 description 10
- 230000000052 comparative effect Effects 0.000 description 6
- 238000011156 evaluation Methods 0.000 description 6
- 229910000831 Steel Inorganic materials 0.000 description 4
- 239000010959 steel Substances 0.000 description 4
- 239000000654 additive Substances 0.000 description 3
- QQVIHTHCMHWDBS-UHFFFAOYSA-L isophthalate(2-) Chemical compound [O-]C(=O)C1=CC=CC(C([O-])=O)=C1 QQVIHTHCMHWDBS-UHFFFAOYSA-L 0.000 description 3
- 238000005259 measurement Methods 0.000 description 3
- 238000012546 transfer Methods 0.000 description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- WNLRTRBMVRJNCN-UHFFFAOYSA-N adipic acid Chemical compound OC(=O)CCCCC(O)=O WNLRTRBMVRJNCN-UHFFFAOYSA-N 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 239000010724 circulating oil Substances 0.000 description 2
- 238000005034 decoration Methods 0.000 description 2
- QQVIHTHCMHWDBS-UHFFFAOYSA-N isophthalic acid Chemical compound OC(=O)C1=CC=CC(C(O)=O)=C1 QQVIHTHCMHWDBS-UHFFFAOYSA-N 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 230000000737 periodic effect Effects 0.000 description 2
- 229920002120 photoresistant polymer Polymers 0.000 description 2
- 238000007711 solidification Methods 0.000 description 2
- 230000008023 solidification Effects 0.000 description 2
- 239000002344 surface layer Substances 0.000 description 2
- 229920003067 (meth)acrylic acid ester copolymer Polymers 0.000 description 1
- 229920002126 Acrylic acid copolymer Polymers 0.000 description 1
- 239000004831 Hot glue Substances 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000006096 absorbing agent Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 235000011037 adipic acid Nutrition 0.000 description 1
- 239000001361 adipic acid Substances 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 239000002216 antistatic agent Substances 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000003484 crystal nucleating agent Substances 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000004512 die casting Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005530 etching Methods 0.000 description 1
- 239000012760 heat stabilizer Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229920001519 homopolymer Polymers 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 239000011229 interlayer Substances 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 238000000691 measurement method Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 229920003207 poly(ethylene-2,6-naphthalate) Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920001225 polyester resin Polymers 0.000 description 1
- 239000004645 polyester resin Substances 0.000 description 1
- 239000011112 polyethylene naphthalate Substances 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000000630 rising effect Effects 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 230000001629 suppression Effects 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 239000000057 synthetic resin Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Landscapes
- Laminated Bodies (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
- Shaping Of Tube Ends By Bending Or Straightening (AREA)
Abstract
Description
本発明は、表面に意匠感のある凹凸を有する意匠性フィルムの製造方法に関する。詳しくは、フィルムの片面に万線状あるいは網点状の凹部または凸部を有し、独特の美的意匠感を表現する意匠性フィルムの製造方法に関する。尚、当該意匠性フィルムは、鋼板や木質板などの表面に貼合することにより、被貼合体に意匠性を付与するものである。 The present invention relates to a method for producing a designable film having irregularities with a design feeling on the surface. More specifically, the present invention relates to a method for producing a designable film having a line-like or halftone dot-like depression or projection on one surface of the film and expressing a unique aesthetic design feeling. In addition, the said designable film provides designability to a to-be-bonded body by bonding on the surfaces, such as a steel plate and a wooden board.
従来、建物の壁、天井等の内装、ユニットバスやシステムキッチン、家具、キャビネット等の表面装飾材として、表面に凹凸を有する意匠性フィルムが採用されている。該凹凸の柄の１つに「万線柄」とよばれる、複数の線状凹部または凸部（以下、必要に応じ「凹凸部」と略称する）が平行に並んだ柄がある。
万線柄は、しばしば「モアレ模様」といわれる意図しない柄を、意匠性フィルムを見た者に認識させる。意図しないモアレ模様は、意匠性フィルムの美的意匠感を損なうものである。
モアレ模様が発生する原因は定かではないが、一定幅、一定間隔でデザインされた線状凹凸部の幅や間隔が、エンボスロールを製造する過程で部分的に数百ｎｍ〜数μｍ程度ずれるためと思われる。エンボスロールの線状凹部（意匠性フィルムの線状凸部を成形する部分）の幅や間隔が部分的に数百ｎｍずれると、意匠性フィルムに周期的なずれが発生する。この周期的なずれがモアレ模様として視認されるのである。
2. Description of the Related Art Conventionally, a design film having irregularities on its surface has been adopted as an interior decoration such as a building wall and ceiling, a surface decoration material such as a unit bath, a system kitchen, furniture, and a cabinet. One of the concavo-convex patterns is a pattern in which a plurality of linear concave portions or convex portions (hereinafter, abbreviated as “concave portions” as necessary), called a “line pattern”, are arranged in parallel.
The line pattern allows a person who has seen a designable film to recognize an unintended pattern often referred to as a “moire pattern”. The unintended moire pattern impairs the aesthetic design feeling of the design film.
The cause of the occurrence of moire patterns is not clear, but the width and spacing of the linear irregularities designed with a constant width and a constant spacing are partially offset by several hundred nm to several μm during the embossing roll manufacturing process. I think that the. When the width and interval of the linear recesses of the embossing roll (the portion where the linear projections of the designable film are molded) are partially shifted by several hundreds of nanometers, periodic shifts occur in the designable film. This periodic shift is visually recognized as a moire pattern.
特許文献１は、木目柄を有する建材化粧シートに対し、複数種類の波線曲線で構成される細線パターンの凹凸模様を形成するための賦型版や、細線パターンからなる凹凸模様が賦型された化粧シート等に関する発明である。
特許文献１には、曲線間のスペースが変化している場合には、波状曲線の粗密に基づいてモアレ模様が発生すること（特許文献１［００１２］）や、細線パターンの段差或いは不連続性に基づいてモアレ模様あるいは意図しない不所望のパターンが現れ、それによって化粧シートには意図しない照り、及びその移動が発現してしまうこと（特許文献１［００１７］）が記載されている。
特許文献１では、このような問題を解決するために、化粧シートに凹凸を形成する賦型版の凸部の幅と凹部の幅の比率を一定にすることが提案されている（特許文献１［請求項１］［００２４］）。
In Patent Document 1, a building plate for forming a concavo-convex pattern of a thin line pattern composed of a plurality of types of wavy curves and a concavo-convex pattern composed of a fine line pattern are formed on a building material decorative sheet having a wood grain pattern The invention relates to a decorative sheet and the like.
In Patent Document 1, when the space between the curves changes, a moire pattern is generated based on the density of the wavy curve (Patent Document 1 [0012]), and the step or discontinuity of the fine line pattern. It is described that a moire pattern or an unintended undesired pattern appears on the basis of this, thereby causing unintended shine and movement of the decorative sheet (Patent Document 1 [0017]).
In Patent Document 1, in order to solve such a problem, it is proposed that the ratio between the width of the convex portion and the width of the concave portion of the shaping plate that forms the unevenness on the decorative sheet is made constant (Patent Document 1). [Claim 1] [0024]).
しかしながら、近年、意匠性フィルムにおいて採用されている万線柄は、線状凹凸部の幅や間隔が非常に小さくなっており（具体的には数μｍ〜数ｍｍ程度）、エンボスロールや賦型版の凸部の幅と凹部の幅の比率を、モアレ模様が発生しない程完璧に一致させることは、画像処理装置の解像度やエッチング精度の問題等で困難である。 However, in recent years, the line pattern employed in the designable film has a very small width and interval between the linear uneven portions (specifically, about several μm to several mm), and the embossing roll or molding It is difficult to make the ratio between the width of the convex portion of the plate and the width of the concave portion perfectly so that a moire pattern does not occur due to problems of resolution and etching accuracy of the image processing apparatus.
本発明は、万線柄や網点柄の意匠性フィルムにモアレ模様を発生させないことを目的とする。詳しくは、万線状または網点状の凹凸部を備えるエンボスロールを用いながら、モアレ模様が認識されない意匠性フィルムの製造方法を確立することを課題とする。 An object of the present invention is to prevent a moire pattern from being generated in a design film having a line pattern or a dot pattern. Specifically, it is an object to establish a method for producing a designable film in which a moire pattern is not recognized while using an embossing roll having a line-like or halftone dot-like uneven part.
図３は、モアレ模様が発生した意匠性フィルムの万線柄の細部を拡大したものである。線状凸部（黒色部分）の側縁１には、部分的に微細な段差Ｘがある。本発明者らは、該段差Ｘをなくすことがモアレ模様発生の抑制に繋がると考え、エンボスロールから線状凹凸部を鮮鋭に転写するのではなく、敢えて若干鈍らせて転写する方法を検討し、本発明に至った。 FIG. 3 is an enlarged view of the details of the line pattern of the designable film in which the moire pattern is generated. On the side edge 1 of the linear convex portion (black portion), there is a partially fine step X. The present inventors consider that eliminating the step X will lead to the suppression of the occurrence of moire patterns, and instead of sharply transferring the linear uneven portions from the embossing roll, a method of transferring with a slight dullness is studied. The present invention has been reached.
即ち本発明によると上記課題を解決するための手段として、ダイスから押出された熱可塑性樹脂組成物を、万線状または網点状の凹部または凸部を備えるエンボスロールに導き、前記熱可塑性樹脂組成物を冷却するとともに賦型する意匠性フィルムの製造方法において、前記熱可塑性樹脂組成物における熱可塑性樹脂成分の５０重量％以上が、ビカット軟化温度（ＪＩＳ Ｋ７２０６に準拠しＡ１２０法にて測定）が１６０℃以上の樹脂（α）からなり、該樹脂（α）のビカット軟化温度をＴｖ（℃）、エンボスロール温度をＴｒ（℃）とするとき、Ｔｖ−１８０≦Ｔｒ≦Ｔｖ−１６０であることを特徴とする意匠性フィルムの製造方法が提供される。
また前記ビカット軟化温度が１６０℃以上の樹脂（α）が、ポリブチレンテレフタレートであることを特徴とする前記意匠性フィルムの製造方法が提供される。
更に前記熱可塑性樹脂組成物が、ＪＩＳ Ｋ７１２１に準拠した示差走査熱量測定の昇温における融解ピーク温度Ｔｍ（℃）と降温における結晶化ピーク温度Ｔｃ（℃）の温度差△Ｔｍｃが１２０以上である樹脂（β）を、該熱可塑性樹脂組成物における熱可塑性樹脂成分の５０重量％以下含むことを特徴とする前記意匠性フィルムの製造方法が提供される。
さらにまた前記△Ｔｍｃが１２０以上である樹脂（β）が、ポリエチレンテレフタレート／イソフタレート共重合体であることを特徴とする前記意匠性フィルムの製造方法が提供される。
That is, according to the present invention, as a means for solving the above problems, a thermoplastic resin composition extruded from a die is led to an embossing roll having a line-like or halftone-like concave or convex portion, and the thermoplastic resin In the method for producing a designable film that cools and molds the composition, 50% by weight or more of the thermoplastic resin component in the thermoplastic resin composition is Vicat softening temperature (measured according to A120 method according to JIS K7206). Is made of a resin (α) having a temperature of 160 ° C. or higher, and when the Vicat softening temperature of the resin (α) is Tv (° C.) and the embossing roll temperature is Tr (° C.), Tv−180 ≦ Tr ≦ Tv−160. The manufacturing method of the designable film characterized by this is provided.
Also provided is a method for producing the design film, wherein the resin (α) having a Vicat softening temperature of 160 ° C. or higher is polybutylene terephthalate.
Further, in the thermoplastic resin composition, the temperature difference ΔTmc between the melting peak temperature Tm (° C.) at the temperature rise in differential scanning calorimetry according to JIS K7121 and the crystallization peak temperature Tc (° C.) at the temperature fall is 120 or more. Provided is a method for producing the designable film, wherein the resin (β) is contained in an amount of 50% by weight or less of the thermoplastic resin component in the thermoplastic resin composition.
Furthermore, the method for producing a designable film is provided, wherein the resin (β) having ΔTmc of 120 or more is a polyethylene terephthalate / isophthalate copolymer.
また前記熱可塑性樹脂組成物における、前記ビカット軟化温度が１６０℃以上の樹脂（α）と、前記△Ｔｍｃが１２０以上である樹脂（β）との配合割合が、α：β＝５０〜８０重量％：５０〜２０重量％であることを特徴とする前記意匠性フィルムの製造方法が提供される。
更にまた多層の意匠性フィルムの製造方法であって、少なくともエンボスロールと接する層が上記熱可塑性樹脂組成物から成ることを特徴とする前記意匠性フィルムの製造方法が提供される。
The blending ratio of the resin (α) having a Vicat softening temperature of 160 ° C. or higher and the resin (β) having a ΔTmc of 120 or higher in the thermoplastic resin composition is α: β = 50 to 80 wt. %: 50 to 20% by weight The method for producing the designable film is provided.
Furthermore, there is provided a method for producing a multi-layered designable film, wherein at least the layer in contact with the embossing roll is made of the thermoplastic resin composition.
本発明の製造方法は、従来の製造方法よりエンボスロール温度が高く設定されており、エンボスロールの凹凸が若干鈍って転写される。その結果、意匠性フィルムの凸部側縁に発生していた微細な段差はなくなり、意匠性フィルムを見た者にモアレ模様が認識されにくくなる。
また意匠性フィルムを形成する樹脂組成物に、副成分としてＤＳＣ測定の昇温時における融解ピーク温度と降温時における結晶化ピーク温度の温度差が大きい樹脂を添加すると、意匠性を損なわない程度にエンボス転写精度が低下し、モアレ模様が特に認識され難くなる。
In the manufacturing method of the present invention, the embossing roll temperature is set higher than in the conventional manufacturing method, and the embossing rolls are transferred with slightly unevenness. As a result, the fine level difference which has occurred on the convex side edge of the designable film disappears, and it becomes difficult for a person who has seen the designable film to recognize the moire pattern.
In addition, if a resin having a large temperature difference between the melting peak temperature at the time of DSC measurement temperature rise and the crystallization peak temperature at the time of temperature fall is added as a subcomponent to the resin composition forming the designable film, the designability is not impaired. The emboss transfer accuracy is lowered, and the moire pattern is particularly difficult to recognize.
［意匠性フィルム］
本発明の意匠性フィルムは熱可塑性樹脂に添加剤等が配合された熱可塑性樹脂組成物から成る。
＜ビカット軟化温度が１６０℃以上の樹脂（α）＞
本発明に用いられる熱可塑性樹脂組成物における熱可塑性樹脂成分の５０重量％以上は、ビカット軟化温度（ＪＩＳ Ｋ７２０６に準拠しＡ１２０法にて測定）が１６０℃以上の樹脂（α）（以下、必要に応じ樹脂（α）と略称する）からなる。樹脂（α）としてビカット軟化温度が１６０℃未満の樹脂を用いるためには、エンボスロール温度を０℃以下にする必要が生じ、既存の設備で本発明を実施することが困難となる。該樹脂（α）は、ビカット軟化温度が１６０℃以上であれば特に限定なく用いることができる。このような樹脂として、ポリエチレンテレフタレート、ポリブチレンテレフタレート、ポリエチレンナフタレート等のポリエステル系樹脂、エチレン−（メタ）アクリル酸共重合体、エチレン−（メタ）アクリル酸エステル共重合体、ポリアミド等を例示する。
[Designable film]
The designable film of the present invention comprises a thermoplastic resin composition in which an additive or the like is blended with a thermoplastic resin.
<Resin (α) with Vicat softening temperature of 160 ° C. or higher>
50% by weight or more of the thermoplastic resin component in the thermoplastic resin composition used in the present invention is a resin (α) having a Vicat softening temperature (measured by the A120 method in accordance with JIS K7206) of 160 ° C. or higher (hereinafter required) (Hereinafter abbreviated as resin (α)). In order to use a resin having a Vicat softening temperature of less than 160 ° C. as the resin (α), it is necessary to set the embossing roll temperature to 0 ° C. or less, making it difficult to implement the present invention with existing equipment. The resin (α) can be used without particular limitation as long as the Vicat softening temperature is 160 ° C. or higher. Examples of such resins include polyester resins such as polyethylene terephthalate, polybutylene terephthalate, and polyethylene naphthalate, ethylene- (meth) acrylic acid copolymers, ethylene- (meth) acrylic acid ester copolymers, and polyamides. .
本発明の特徴はエンボスロールから線状凸部を若干鈍らせて転写することであるが、鈍りすぎると、意匠性フィルムに求められる美的意匠感を発現できなくなる。よって意匠性フィルムの主成分となる樹脂（α）は、エンボス転写性に優れた樹脂を採用することが好ましい。ポリブチレンテレフタレートやポリブチレンテレフタレート／イソフタレート共重合体等のポリブチレンテレフタレート系樹脂（以下、必要に応じ「ＰＢＴ」と略称する）は、樹脂の結晶化が速やかに進行する為、意匠性フィルムの主成分として特に適している。 The feature of the present invention is that the linear convex portion is slightly dulled and transferred from the emboss roll, but if it is too dull, the aesthetic design feeling required for the design film cannot be expressed. Therefore, it is preferable to employ a resin excellent in emboss transferability as the resin (α) as the main component of the designable film. Polybutylene terephthalate resins such as polybutylene terephthalate and polybutylene terephthalate / isophthalate copolymers (hereinafter abbreviated as “PBT” if necessary) are used for the design film because the crystallization of the resin proceeds rapidly. Particularly suitable as a main component.
＜温度差△Ｔｍｃが１２０以上である樹脂（β）＞
本発明に採用される熱可塑性樹脂組成物には、ＤＳＣ測定の昇温時における融解ピーク温度Ｔｍ（℃）とＤＳＣ測定時の降温における結晶化ピーク温度Ｔｃ（℃）の温度差△Ｔｍｃが１２０以上である樹脂（β）（以下、必要に応じ樹脂（β）と略称する）が、副成分として配合されていることが望ましい。△Ｔｍｃが大きい樹脂は、溶融状態から冷却していくと広い温度範囲にわたって固化が進行する。その為、エンボスロールにより凹凸を転写すると、転写後にも凹凸部分の固化が徐々に進行し、最終的な凹凸形状がエンボス直後よりも若干鈍ったものとなる。
△Ｔｍｃが１２０以上の樹脂（β）としては、ポリエチレンテレフタレートにイソフタル酸を共重合したポリエチレンテレフタレート／イソフタレート、ポリブチレンテレフタレートにアジピン酸を共重合したＰＢＴ等があるが、特にポリエチレンテレフタレート／イソフタレートが、△Ｔｍｃが大きい為、本発明の副成分として適している。
<Resin (β) with a temperature difference ΔTmc of 120 or more>
In the thermoplastic resin composition employed in the present invention, the temperature difference ΔTmc between the melting peak temperature Tm (° C.) at the time of temperature rise in DSC measurement and the crystallization peak temperature Tc (° C.) at the time of temperature drop in DSC measurement is 120. The resin (β) as described above (hereinafter abbreviated as resin (β) if necessary) is desirably blended as a subcomponent. When the resin having a large ΔTmc is cooled from the molten state, solidification proceeds over a wide temperature range. For this reason, when the unevenness is transferred by the embossing roll, solidification of the unevenness portion gradually proceeds after the transfer, and the final unevenness shape becomes slightly duller than immediately after the embossing.
Examples of the resin (β) having a ΔTmc of 120 or more include polyethylene terephthalate / isophthalate copolymerized with polyethylene terephthalate and isophthalic acid, and PBT copolymerized with polybutylene terephthalate and adipic acid, and particularly polyethylene terephthalate / isophthalate. However, since ΔTmc is large, it is suitable as a subcomponent of the present invention.
＜配合割合＞
樹脂（α）と樹脂（β）の配合割合は、α：β＝５０〜８０重量％：５０〜２０重量％であることが望ましい。樹脂（α）の配合割合が５０重量％を下回ると、エンボスの転写精度が低くなり過ぎ、所望の美的意匠感を表現できない恐れがある。逆に樹脂（α）の配合割合が８０重量％を超えると、モアレ模様を視認させる恐れがある。
<Combination ratio>
The blending ratio of the resin (α) and the resin (β) is desirably α: β = 50 to 80% by weight: 50 to 20% by weight. When the blending ratio of the resin (α) is less than 50% by weight, the transfer accuracy of the emboss becomes too low, and there is a possibility that a desired aesthetic design feeling cannot be expressed. On the contrary, if the blending ratio of the resin (α) exceeds 80% by weight, the moire pattern may be visually recognized.
＜添加剤等＞
上述した熱可塑性樹脂組成物には、滑剤、ブロッキング防止剤、酸化防止剤、熱安定剤、耐候剤、紫外線吸収剤、着色剤、顔料、結晶核剤等、帯電防止剤等、添加剤を加えることができる。
<Additives>
Additives such as lubricants, antiblocking agents, antioxidants, heat stabilizers, weathering agents, UV absorbers, colorants, pigments, crystal nucleating agents, antistatic agents, etc. are added to the thermoplastic resin composition described above. be able to.
＜多層フィルム＞
以上、意匠性フィルムが単層のフィルムである場合について説明したが、本発明の意匠性フィルムは多層フィルムであっても良い。本発明の意匠性フィルムが多層フィルムである場合、少なくともエンボスロールと接する層が、上述した熱可塑性樹脂組成物から成る。
エンボスロールに接触しない層を形成する熱可塑性樹脂組成物について、本発明では特に限定しないが、製膜性、層間接着性等を考慮すると、その主成分はエンボスロールと接する層と同じであることが望ましい。
<Multilayer film>
The case where the designable film is a single-layer film has been described above, but the designable film of the present invention may be a multilayer film. When the designable film of the present invention is a multilayer film, at least the layer in contact with the embossing roll is composed of the above-described thermoplastic resin composition.
The thermoplastic resin composition that forms a layer that does not contact the embossing roll is not particularly limited in the present invention, but considering the film forming property, interlayer adhesion, etc., the main component is the same as the layer in contact with the embossing roll. Is desirable.
＜万線柄、網点柄＞
本発明の意匠性フィルムは、その表面に万線柄或いは網点柄の凹凸を備える。万線柄とは、線状凹凸部が平行に並んだ柄で、該線状凹凸部は直線状であっても、曲線状であってもよい。また各線状凹凸部は、完全な平行でなくてもよく、例えば上述した特許文献１の細線パターンのように略平行であっても良い。網点柄とは、小さな点状の凹凸部から成る柄である。
万線柄における線状凹凸部の幅や間隔、網点柄における点状凹凸部の大きさは特に限定されないが、本発明は線状凹凸部の幅や間隔、網点柄における点状凹凸部の直径が、０．１μｍ〜１ｍｍ、特に１μｍ〜５００μｍ程度であるとき、その効果が際立つ。本発明の製造方法を採用しない場合、幅や間隔、直径等が０．１μｍ〜１ｍｍのときに、特に当該モアレ模様が認識されやすいのである。
<Man line pattern, dot pattern>
The designable film of the present invention is provided with unevenness of a line pattern or a dot pattern on the surface thereof. The line pattern is a pattern in which linear uneven portions are arranged in parallel, and the linear uneven portions may be linear or curved. Moreover, each linear uneven | corrugated | grooved part does not need to be completely parallel, for example, may be substantially parallel like the thin line pattern of the patent document 1 mentioned above. A halftone dot pattern is a pattern composed of small dot-shaped irregularities.
The width and interval of the linear irregularities in the line pattern and the size of the dotted irregularities in the dot pattern are not particularly limited, but the present invention is not limited to the width and interval of the linear irregularities, the dot irregularity in the dot pattern. When the diameter is 0.1 μm to 1 mm, particularly about 1 μm to 500 μm, the effect stands out. When the manufacturing method of the present invention is not employed, the moire pattern is particularly easily recognized when the width, interval, diameter, etc. are 0.1 μm to 1 mm.
［製造方法］
次に本発明の意匠性フィルムの製造方法について説明する。本発明の意匠性フィルムは、加熱溶融した熱可塑性樹脂組成物をＴダイと呼ばれるダイスから、キャスティングロールを兼ねるエンボスロールに導き製膜する、いわゆるＴダイ−キャスト法にて製造される。
[Production method]
Next, the manufacturing method of the designable film of this invention is demonstrated. The designable film of the present invention is produced by a so-called T-die casting method in which a heat-melted thermoplastic resin composition is led from a die called a T-die to an embossing roll that also serves as a casting roll to form a film.
＜エンボスロール温度＞
本発明の特徴は、エンボスロールの温度が通常の設定よりも高いことである。具体的には、エンボスロールと接する層を形成する熱可塑性樹脂組成物における熱可塑性樹脂成分の５０重量％以上を占める樹脂（α）のビカット軟化温度をＴｖ（℃）、エンボスロールの温度をＴｒ（℃）とするとき、Ｔｖ−１８０≦Ｔｒ≦Ｔｖ−１６０であることを特徴とし、特にＴｖ−１７５≦Ｔｒ≦Ｔｖ−１６５であることが好ましい。エンボスロールと接する層の主成分がポリブチレンテレフタレートホモポリマーの場合は、Ｔｖ（℃）≒１７０あるので、Ｔｒ（℃）は４０~６０程度が望ましい。
Ｔｒ＜Ｔｖ−１８０の場合、エンボスロールに刻まれた凹凸が意匠性フィルムに精度よく転写され、モアレ模様が目立ってしまう。逆にＴｒ＞Ｔｖ−１６０の場合、熱可塑性樹脂組成物がエンボスロールにて十分に冷却されない為、エンボスロールからの剥がれが悪くなる。
<Embossing roll temperature>
A feature of the present invention is that the temperature of the embossing roll is higher than the normal setting. Specifically, the Vicat softening temperature of the resin (α) occupying 50% by weight or more of the thermoplastic resin component in the thermoplastic resin composition forming the layer in contact with the embossing roll is Tv (° C.), and the embossing roll temperature is Tr (° C.), Tv−180 ≦ Tr ≦ Tv−160, and Tv−175 ≦ Tr ≦ Tv−165 is particularly preferable. In the case where the main component of the layer in contact with the embossing roll is a polybutylene terephthalate homopolymer, Tv (° C.) ≈170, so Tr (° C.) is preferably about 40 to 60.
In the case of Tr <Tv-180, the unevenness carved in the embossing roll is accurately transferred to the design film, and the moire pattern becomes conspicuous. On the other hand, in the case of Tr> Tv-160, the thermoplastic resin composition is not sufficiently cooled by the embossing roll, so that peeling from the embossing roll becomes worse.
尚、本発明において用いられる「エンボスロールの温度」とは、エンボスロールの設定温度を意味する。具体的には、エンボスロールが循環油によってコントロールされている場合は、該循環油の温度を意味する。
エンボスロールの表面温度はダイスから押出された熱可塑性樹脂組成物と接触する部分において最高となり、その後、熱可塑性樹脂組成物の熱を奪いながら、速やかに設定温度付近まで低下する。よって、本発明のエンボスロールの温度Ｔｒ（℃）は、エンボスロール表面の最低温度に近似する。
The “temperature of the embossing roll” used in the present invention means a set temperature of the embossing roll. Specifically, when the embossing roll is controlled by circulating oil, it means the temperature of the circulating oil.
The surface temperature of the embossing roll becomes the highest in the portion that comes into contact with the thermoplastic resin composition extruded from the die, and then quickly decreases to around the set temperature while taking the heat of the thermoplastic resin composition. Therefore, the temperature Tr (° C.) of the embossing roll of the present invention approximates the minimum temperature of the embossing roll surface.
＜エンボスロール＞
本発明に用いられるエンボスロールは、その表面に万線状または網点状の凹凸部を備えるものであれば、特に限定なく用いることができる。
このようなエンボスロールは、例えば以下のような方法で製造することができる。
１）万線状または網目状のデザインを、エンボスロール用のシリンダーロールのサイズに合わせてエンドレス画像になるよう調整する。
２）銅メッキを施したシリンダーロール上に、フォトレジストをコーティングする。
３）２）のフォトレジスト上に１）のデザインをレーザーにて焼き付ける。
４）その後、現像され、露出した銅部分をエッチングする。
５）レジスト膜をすべて除去し、シリンダーロール表面をクロムメッキする。
<Embossing roll>
The embossing roll used in the present invention can be used without particular limitation as long as it has a line-like or halftone dot-like uneven part on its surface.
Such an embossing roll can be manufactured by the following methods, for example.
1) Adjust the line-like or mesh-like design to an endless image according to the size of the cylinder roll for the embossing roll.
2) A photoresist is coated on the cylinder roll plated with copper.
3) The design of 1) is baked on the photoresist of 2) with a laser.
4) After that, the developed and exposed copper part is etched.
5) Remove all resist film and chrome-plat the cylinder roll surface.
［使用方法］
本発明の意匠性フィルムは、鋼板や木質板、合成樹脂板といった板状物に貼合され、使用される。これら板状物との貼合方法は、特に限定されるものではなく、例えば従来使用されている溶剤系接着剤、ホットメルト系接着剤を用いて貼合すると良い。また被貼合体が鋼板の場合は、あらかじめ鋼板を加熱しておくことにより、被貼合体との接着強度を高めることができる。
[how to use]
The designable film of the present invention is used by being bonded to a plate-like material such as a steel plate, a wooden board, or a synthetic resin board. The bonding method with these plate-shaped objects is not particularly limited, and it may be bonded using, for example, a conventionally used solvent-based adhesive or hot-melt adhesive. Moreover, when a to-be-bonded body is a steel plate, the adhesive strength with a to-be-bonded body can be raised by heating a steel plate beforehand.
次に、本発明を実施例により詳細に説明するが、本発明はこれらにより何ら限定されるものではない。また本発明における測定方法、評価方法は以下の通りである。
［ビカット軟化温度］
ＪＩＳ Ｋ７２０６に準拠し、Ａ１２０法（試験荷重１０Ｎ、昇温速度１２０℃／ｈ）で測定する。
［△Ｔｍｃ（融解ピーク温度Ｔｍと結晶化ピーク温度Ｔｃとの差）］
ＪＩＳ−Ｋ７１２１に準じた示差走査熱量測定（ＤＳＣ）により昇温時の融解ピーク温度Ｔｍ（℃）と降温時の結晶化ピーク温度Ｔｃ（℃）とを求め、△ＴｍｃをＴｍ−Ｔｃにより求める。
尚、示差走査熱量測定では、装置を３０℃で安定させた後、昇温速度１０℃／ｍｉｎで３２０℃まで昇温し、同速度で０℃まで降温させる際に観測される最大発熱ピークのピークトップ温度を結晶化ピーク温度Ｔｃ（℃）とする。０℃まで降温させた後に再び昇温速度１０℃／ｍｉｎで３２０℃まで昇温させる際（２ｎｄステージ）に観測される最大吸熱ピークのピークトップ温度を融解ピーク温度Ｔｍ（℃）とする。
［モアレ模様評価］
実施例１乃至７、比較例１乃至４の意匠性フィルム表面を目視により確認する。本来の万線柄はほとんど視認されず、モアレ模様の方が強く視認されてしまうものを×、本来の万線柄とモアレ模様が同等に視認されるものを△、本来の万線柄が視認されるが、若干のモアレ模様が感じられるものを○、モアレ模様が全く視認されないものを◎と評価する。
EXAMPLES Next, although an Example demonstrates this invention in detail, this invention is not limited at all by these. The measurement method and evaluation method in the present invention are as follows.
[Vicat softening temperature]
Based on JIS K7206, it is measured by A120 method (test load 10N, temperature rising rate 120 ° C./h).
[ΔTmc (difference between melting peak temperature Tm and crystallization peak temperature Tc)]
A differential scanning calorimetry (DSC) according to JIS-K7121 determines a melting peak temperature Tm (° C.) at the time of temperature rise and a crystallization peak temperature Tc (° C.) at the time of temperature fall, and ΔTmc is obtained by Tm-Tc.
In differential scanning calorimetry, after the apparatus was stabilized at 30 ° C., the maximum exothermic peak observed when the temperature was increased to 320 ° C. at a rate of temperature increase of 10 ° C./min and decreased to 0 ° C. at the same rate. The peak top temperature is defined as a crystallization peak temperature Tc (° C.). The peak top temperature of the maximum endothermic peak observed when the temperature is lowered to 0 ° C. and then raised again to 320 ° C. at a temperature raising rate of 10 ° C./min (2nd stage) is defined as a melting peak temperature Tm (° C.).
[Moire pattern evaluation]
The designable film surfaces of Examples 1 to 7 and Comparative Examples 1 to 4 are confirmed visually. X where the original line pattern is hardly visible, and the moire pattern is more visually recognized, x, where the original line pattern and the moire pattern are equally visible, Δ, where the original line pattern is visible However, a case where a slight moiré pattern is felt is evaluated as 、, and a case where no moiré pattern is visually recognized is evaluated as ◎.
［実施例１］
ビカット軟化温度２２０℃のＰＢＴ（樹脂（α）に相当）と、△Ｔｍｃが１５２．４（Ｔｍ＝２３４．５、Ｔｃ＝８２．１）のポリエチレンテレフタレート／イソフタレート（以下、ＰＥＴ−ｉと記す）（樹脂（β）に相当）からなる熱可塑性樹脂組成物を、Ｔダイから押出し、ニップロールと、万線状の凹部を有する４０℃に設定されたエンボスロールとで挟み、冷却するとともに賦型して、実施例１の意匠性フィルムを製造した。
尚、該意匠性フィルムは３層構造をしており、各層におけるＰＢＴとＰＥＴ−ｉの配合比率（重量％）、各層厚（μｍ）は表１に示すとおりである。
得られたフィルムのモアレ模様評価の結果を表１に併せて記す。
[Example 1]
PBT (corresponding to resin (α)) having a Vicat softening temperature of 220 ° C. and polyethylene terephthalate / isophthalate (hereinafter referred to as PET-i) having ΔTmc of 152.4 (Tm = 234.5, Tc = 82.1) ) (Equivalent to resin (β)), extruded from a T-die, sandwiched between a nip roll and an embossing roll set at 40 ° C. having a line-shaped recess, cooled and shaped And the designable film of Example 1 was manufactured.
The designable film has a three-layer structure, and the blending ratio (% by weight) of PBT and PET-i in each layer and the layer thickness (μm) are as shown in Table 1.
The results of the moiré pattern evaluation of the obtained film are also shown in Table 1.
［実施例２乃至５、比較例１乃至４］
エンボスロールの温度設定を表１に記すように変化させた以外は、実施例１と同様にして意匠性フィルムを製造した。
得られたフィルムのモアレ模様評価の結果を表１に併せて記す。
[Examples 2 to 5, Comparative Examples 1 to 4]
A designable film was produced in the same manner as in Example 1 except that the temperature setting of the embossing roll was changed as shown in Table 1.
The results of the moiré pattern evaluation of the obtained film are also shown in Table 1.
［実施例６乃至８］
意匠性フィルムを構成する３層のうち、表面層を形成する樹脂組成物を表１に記すように変えた以外は、実施例３と同様にして、意匠性フィルムを製造した。
得られたフィルムのモアレ模様評価の結果を表２に併せて記す。
[Examples 6 to 8]
A designable film was produced in the same manner as in Example 3 except that the resin composition forming the surface layer among the three layers constituting the designable film was changed as shown in Table 1.
The results of the moire pattern evaluation of the obtained film are also shown in Table 2.
実施例１乃至８の意匠性フィルムはモアレ模様がほとんど認識されなかった。特に、エンボスロールと接する表面層に△Ｔｍｃが１５２．４のＰＥＴ−ｉを３０~５０重量％含む実施例３、７、８は、エンボスロール温度が同じである実施例６の意匠性フィルムよりもモアレ模様評価が良好であった。これはＰＥＴ−ｉがモアレ模様抑制に効果があることを裏付ける。
一方、エンボスロール温度が従来と同程度の比較例１、２の意匠性フィルムは、モアレ模様が強く認識された。本発明のエンボスロールのデザインは、図１であるが、比較例１、２の意匠性フィルムは図２のように、右に凸状のモアレ模様が認識された。また、比較例４はエンボスロールの温度が高すぎた為、エンボスロールから意匠性フィルムがうまく剥離せず、フィルム表面には剥離痕が残り、本来の万線柄もモアレ模様も認識されなかった。
In the design films of Examples 1 to 8, almost no moire pattern was recognized. In particular, Examples 3, 7, and 8 in which 30 to 50% by weight of PET-i having a ΔTmc of 152.4 are included in the surface layer in contact with the embossing roll are from the design film of Example 6 having the same embossing roll temperature. Also, the moire pattern evaluation was good. This confirms that PET-i is effective in suppressing moire patterns.
On the other hand, the moiré pattern was strongly recognized in the design films of Comparative Examples 1 and 2 having the same embossing roll temperature as in the past. The design of the embossing roll of the present invention is shown in FIG. 1, but the design films of Comparative Examples 1 and 2 have a moire pattern that is convex to the right as shown in FIG. Moreover, since the temperature of the embossing roll was too high in the comparative example 4, the designable film did not peel off from the embossing roll well, and peeling marks remained on the film surface, and neither the original line pattern nor the moire pattern was recognized. .
１ 意匠性フィルムの線状凸部の側縁
Ｘ 側縁に形成された段差
1 Step edge formed on side edge X side edge of linear convex part of designable film
Claims (6)
前記熱可塑性樹脂組成物における熱可塑性樹脂成分の５０重量％以上が、ビカット軟化温度（ＪＩＳ Ｋ７２０６に準拠しＡ１２０法にて測定）が１６０℃以上の樹脂（α）からなり、
該樹脂（α）のビカット軟化温度をＴｖ（℃）、エンボスロール温度をＴｒ（℃）とするとき、Ｔｖ−１８０≦Ｔｒ≦Ｔｖ−１６０であることを特徴とする意匠性フィルムの製造方法。 A method for producing a designable film in which a thermoplastic resin composition extruded from a die is led to an embossing roll having a line-like or half-tone-like depression or projection, and the thermoplastic resin composition is cooled and shaped In
50% by weight or more of the thermoplastic resin component in the thermoplastic resin composition is composed of a resin (α) having a Vicat softening temperature (measured by the A120 method in accordance with JIS K7206) of 160 ° C. or higher,
A process for producing a designable film, characterized in that Tv−180 ≦ Tr ≦ Tv−160, where the Vicat softening temperature of the resin (α) is Tv (° C.) and the embossing roll temperature is Tr (° C.).
The method for producing a multi-layered designable film according to any one of claims 1 to 5, wherein at least a layer in contact with the embossing roll is made of the thermoplastic resin composition. Method.
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| JP2013202999A (en) * | 2012-03-29 | 2013-10-07 | Toray Ind Inc | Film for forming, and forming transfer foil using the same |
| JP2014044912A (en) * | 2012-08-28 | 2014-03-13 | Sumitomo Chemical Co Ltd | Method for manufacturing resin sheet |
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| JP2006130901A (en) * | 2004-10-07 | 2006-05-25 | Teijin Chem Ltd | Manufacturing method for polycarbonate resin sheet having fine protrusion on surface and sheet having fine protrusion on surface |
| JP2009056620A (en) * | 2007-08-30 | 2009-03-19 | Toray Ind Inc | Laminated polyester film |
| JP2013202999A (en) * | 2012-03-29 | 2013-10-07 | Toray Ind Inc | Film for forming, and forming transfer foil using the same |
| JP2014044912A (en) * | 2012-08-28 | 2014-03-13 | Sumitomo Chemical Co Ltd | Method for manufacturing resin sheet |
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