JP4022241B2 - LAMINATE MANUFACTURING METHOD, LAMINATE, AND LAMINATE MANUFACTURING DEVICE - Google Patents

Description

  The present invention relates to a laminate manufacturing method, a laminate obtained by the manufacturing method, and a manufacturing apparatus capable of executing the manufacturing method. Specifically, for example, the shape of a surface subjected to a hard coat treatment, for example Relates to a hard coat film having a fine uneven shape such as a hairline tone or a matte tone, and a method for producing the hard coat film.

  In recent years, as the market for home appliances and audio-related products has matured and saturated, there is a strong demand for clear differentiation for each product. This differentiation means, for example, a high-class feeling of a product, an excellent specific function or property, or an excellent product.

  From the perspective of product luxury, if it is a household electrical appliance (hereinafter simply referred to as “home appliance”) called a so-called white goods, the surroundings of the product are usually monotonous plastic plywood. Although it is used, it has been developed to give a high-class feeling to the product by providing an appearance with innumerable fine lines, so-called hairline shapes (hereinafter also simply referred to as “hairlines”). Moreover, this hairline is not only used for home appliances, but is also widely used in exteriors of audio devices such as home audio devices and portable music playback devices, so-called mobile devices such as mobile phones and laptop computers.

  Also, as a case that excels in specific functions and properties, for example, in order to improve the visibility of the liquid crystal display of a mobile phone or a notebook computer, the surface is subjected to a matte process called matte tone. . This is because a normal liquid crystal display has reduced visibility due to reflection of external light on its image display surface. In order to reduce this phenomenon, matte processing (“matte”) is used to roughen the surface of the liquid crystal display. It is also referred to as “processing”.

  In order to provide a hairline or a matte tone in this way, conventionally, it has been dealt with by directly processing the material itself. For example, when a hairline is provided on the surface of a home appliance, the hairline is provided by shaving the surface of the decorative board that forms the housing of the home appliance into a hairline shape. It was by the method of doing.

  However, if this is done, there may be cases where the product cannot be used as a product due to processing errors such as the surface being missed in the manufacturing process or being too rough. It has become desirable to have a hairline and matte tone.

  Therefore, prepare a film with a hairline in advance and a film with a matte finish on the surface, and stick it in advance on the surface of a decorative board used as a raw material for a housing of a household appliance, for example. A technique of making a household appliance having a hairline on the surface by using a casing has been proposed, and various film manufacturing methods have been proposed.

  For example, in the case of the production method described in Patent Document 1, an ionizing radiation curable resin is applied on a transparent substrate sheet, and a shaped sheet having a concavo-convex pattern is laminated on the coating film of the ionizing radiation curable resin. By irradiating with ionizing radiation, the ionizing radiation curable resin is cured, and the shaped sheet is removed to obtain a decorative sheet with an uneven pattern on the surface.

JP-A-4-314540

  In the method for manufacturing a decorative sheet described in Patent Document 1, it seems that a hairline sheet can be easily obtained if the concavo-convex pattern has a hairline shape.

  However, with the invention disclosed in Patent Document 1, the following problems occur and cannot be solved. That is, in this invention, since the base material sheet is transparent, if the ionizing radiation is irradiated after laminating the base material sheet, the ionizing radiation is blocked by this because the base material sheet is transparent in terms of expression. It seems as if it is possible to cure the ionizing radiation curable resin at the same time without reaching it. However, it has been found that even if the inventor according to the present invention actually attempts to manufacture in accordance with this description, the ionizing radiation curable resin is not necessarily cured to a necessary and sufficient extent.

  That is, in the invention disclosed in Patent Document 1, when the shaped sheet is a material such as paper or synthetic paper, the ionizing radiation curable resin must be irradiated with ionizing radiation from the base sheet side in order to cure the ionizing radiation curable resin. However, in such a case, the substrate sheet must necessarily be a sheet that transmits ionizing radiation, and the ionizing radiation curable resin may not be sufficiently cured unless a suitable sheet is selected. And in order to avoid that such a state generate | occur | produces, the combination of a shaping sheet and a base material sheet must be selected carefully, and it can be said that it is troublesome.

  In view of this point, in the invention disclosed in Patent Document 1, it is basically necessary that the base sheet is always transparent, and as a result, it is necessary to say that it lacks diversity from the viewpoint of design. I don't get it.

  Furthermore, in the invention disclosed in Patent Document 1, if it is intended to obtain a laminate having a precise uneven pattern, a sand mat shape, or a hairline shape on its surface, a transparent base sheet and ionization are simply and darkly clouded. Even if the radiation curable resin and ionizing radiation are appropriately combined depending on the situation, there is a high possibility that the effect cannot be obtained.

  Therefore, the present invention has been made in view of such problems, and the object thereof is to make it possible to easily and reliably manufacture a fine uneven pattern so as to be surely called a hairline or a sand mat on the surface. The surface with irregular shapes in a rough cross-sectional view such as a matte tone can be made into a product while maintaining the irregular shape in a beautiful state without being damaged by external factors during its production, etc. It is providing the manufacturing method of a laminated body provided with the uneven | corrugated shape, a laminated body, and its manufacturing apparatus.

In order to solve the above-mentioned problems, the invention relating to the method for producing a laminate according to claim 1 of the present invention is characterized in that a coating mainly composed of a photocurable resin is applied to at least one surface of a plastic film as a base material. Lamination process of laminating a photocurable layer, a drying process of drying the photocurable layer after the laminating process, and an unevenness process of a stamper film in which a rough surface process is performed in advance on the surface after the drying process. A sticking step of sticking a surface side to the surface of the photocurable layer to obtain a laminate, and an irradiation step of irradiating light from the stamper film side to the whole laminate after the sticking step; In this order, wherein the photocurable resin is one or more of urethane acrylate, epoxy acrylate, or polyester acrylate, Wavelength of the light irradiated on the entire laminate is not less 200nm or 500nm or less, and is the peak wavelength 360nm or more, yet peak irradiance of the irradiated light is 200 mW / cm ² or more, yet integrated light quantity 200 mJ / cm ² The stamper film is a plastic that can transmit the wavelength of the light, using a polycarbonate film, a polyethylene terephthalate film, a polymethyl methacrylate film, a pyrivinyl carbonate film, or a PS film as a raw material. It is a film and the thickness is 25 micrometers or more and 100 micrometers or less, It is characterized by the above-mentioned.

  The method for manufacturing a laminate according to claim 2 of the present invention is the method for manufacturing the laminate according to claim 1, wherein the substantially uneven processing is hairline processing, mat processing, embossing, or regular or It is characterized by any one of irregular irregular shape processing or a combination thereof.

  The manufacturing method of the laminated body of Claim 3 of this invention is a manufacturing method of the laminated body of Claim 1 or Claim 2, Comprising: The said stamper film is peeled from the said laminated body after the said irradiation process. And a stamper film collecting step for collecting the peeled stamper film in the peeling step.

  The manufacturing method of the laminated body of Claim 4 of this invention is a manufacturing method of the laminated body of Claim 1 or Claim 2, Comprising: The said photocurable layer is hard-coat property, antifouling property, It is characterized by having one or a plurality of functions of anti-fingerprint property, anti-glare property, and antistatic property.

  The manufacturing method of the laminated body of Claim 5 of this invention is a manufacturing method of the laminated body of any one of Claim 1 thru | or 3, Comprising: On the surface of the one side or both sides of the said plastic film Any one or a plurality of layers of an adhesive layer having adhesiveness, a metal layer exhibiting a metallic luster, or a printed layer on which printing has been performed is laminated.

  The laminate according to claim 6 of the present invention is obtained by the method for manufacturing a laminate according to any one of claims 1 to 5.

  The manufacturing apparatus for a laminate according to claim 7 of the present invention is a manufacturing apparatus for manufacturing the laminate according to claim 6, and is a base film unwinding section for carrying out a plastic film as a base. And a coating laminate portion formed by laminating a photocurable resin layer on the surface of the plastic film unloaded from the base film unwinding portion and laminating a photocurable resin layer, and the coating lamination A drying section for drying a photocurable resin layer laminated on the surface of the plastic film that has passed through the section, a stamper film unwinding section for unloading a stamper film whose surface has been roughened in advance, and the stamper film A sticking part for sticking the uneven surface side of the stamper film unloaded from the unwinding part to the surface of the plastic film on which the photocurable resin layer is laminated to obtain a laminate; Be provided with an irradiation unit formed by irradiating light from the stamper film side with respect to the entire laminate through said adhesive portion, wherein.

  An apparatus for manufacturing a laminate according to claim 8 of the present invention is the apparatus for manufacturing a laminate according to claim 7, wherein a peeling portion is formed by peeling the stamper film from the laminate through the irradiation portion. A stamper film winding unit that winds up the stamper film peeled off at the peeling unit, and a film winding unit that winds up the film in a state where the stamper film is peeled off through the peeling unit. It is characterized by.

  The laminate manufacturing apparatus according to claim 9 of the present invention is the laminate manufacturing apparatus according to claim 7 or claim 8, wherein the substantially uneven processing includes hairline processing, mat processing, embossing, Or, regular or irregular concavo-convex shape processing, or a combination thereof.

  As described above, the method for manufacturing a laminate according to the present invention has a configuration of base plastic film / photocurable resin layer / stamper film, and the surface of the stamper film has an uneven shape in a substantially sectional view. It consists of the procedure of manufacturing a laminate that has been processed with irregularities, and then curing the photocurable resin layer by irradiating the entire laminate with ultraviolet rays or the like. Since the stamper film remains adhered when the curable resin layer is cured, it is possible to eliminate the oxygen inhibition that has frequently occurred in the past during the curing operation, and the unevenness of the photocurable resin layer. Can be sufficiently cured to the bottom of the recess in the part, so it is very excellent in terms of hardness compared to the simple processing method of irradiating ultraviolet rays etc. after the conventional photocurable resin layer coating It can be as.

  In addition, since the irradiation is always performed from the stamper film side, the substrate film does not need to be transparent, that is, a film on which a metal vapor deposition has been applied in advance or a film on which an arbitrary design is printed. Therefore, it is possible to easily obtain a very wide laminate in terms of design. Furthermore, by adding the procedure of peeling the stamper film from the entire laminate, the work process is greatly simplified as compared with the conventional processing method, so that the production efficiency is improved.

  Furthermore, by irradiating light to the entire laminate formed by laminating the photocurable resin layer, the photocurable resin layer is solidified as if it were solidified as a result, and as a result, the stamper film side Or, after the photocurable resin layer is cured, it is easy to provide a separate release layer such as laminating a special release layer on the side of the photocurable resin layer or applying a release coating liquid. The stamper film can be peeled, and even after the stamper film is peeled off, the stamper film's surface processed shape does not suffer from damage such as adhesion of the resin that formed the photocurable resin layer. The film can be reused any number of times. If the shape of the substantially uneven processing provided on the stamper film is adjusted, for example, the obtained film can be very easily made into a hairline processed film, and in addition, mat processing and embossing can be done very easily. . Furthermore, it can be easily processed into a regular uneven shape or an irregular uneven shape. And by selecting or adjusting the photo-curable resin, it is possible to make a laminate having properties such as hard coat properties, antifouling properties, fingerprint resistance properties, antiglare properties, and antistatic properties. As a result, it becomes possible to manufacture a laminate such as a hairline film having hard coat properties and an embossed film having antifouling properties very easily.

  Embodiments of the present invention will be described below. The embodiment shown here is merely an example, and is not necessarily limited to this embodiment.

(Embodiment 1)
A laminate manufacturing method and an apparatus for manufacturing the laminate according to the present invention will be described as a first embodiment.

The method for producing a laminate according to the present embodiment includes a laminating step of laminating a photocurable layer by applying a paint having a photocurable resin as a main component on at least one surface of a plastic film as a base material, After the laminating step, the drying step of drying the photocurable layer, and after the drying step, the uneven surface side of the stamper film, which has been roughly roughened on the surface in advance, is attached to the surface of the photocurable layer. Thus, the sticking step of obtaining a laminate and the irradiation step of irradiating light from the stamper film side to the whole laminate after the sticking step are performed in this order.
Hereinafter, although it demonstrates sequentially, it will refuse beforehand that it describes as what a photocurable layer is provided with hard-coat property in it.

  First, a plastic film as a base material will be described. The plastic film is not particularly limited, but specifically, a polycarbonate (PC) film, a polyethylene terephthalate (PET) film, a polymethyl methacrylate (PMMA) film, a polyvinyl chloride (PVC) film, or polystyrene A plastic film such as a (PS) film is preferable, and in the present embodiment, it is a PC film. In addition, the thickness is preferably 25 μm or more and 500 μm or less. However, if the thickness is 25 μm or less, the plastic film is damaged during various processes such as lamination on the surface. This is because the possibility that the finally obtained laminate is easily damaged during transportation or use is very high, and if it is 500 μm or more, the manufacturing according to the present embodiment This is because even if an attempt is made to reduce the thickness of the entire laminate obtained by the method to a desired thickness, there is a limit to reducing the thickness, and the desired thickness cannot be finally obtained.

  In addition, the laminate obtained by the method for producing a laminate according to the present embodiment is used to further produce a high-class feeling while maintaining the original color sense of a decorative board that forms a housing of a household appliance such as a refrigerator. If it is, it is preferable that the plastic film used as this base material is transparent. For example, if the surface of the transparent plastic film is applied to the surface of the decorative board, for example, by applying a hairline or matte surface to the decorative board, this embodiment is used. This is because the laminate itself according to the form is preferably transparent. For that purpose, it is desirable that the plastic film as the base material of the laminate is also transparent.

  However, even if a non-transparent material is selected as the base plastic film, the utility value is never reduced.For example, if a metallic high-class feeling is given, the base plastic film has some metallic luster from the beginning. It should also be mentioned that a thin film to be presented can be laminated on the surface, and that it is possible to improve the design by applying some printing in advance.

  And in the manufacturing apparatus which concerns on this Embodiment, the unwinding part which carries out and sends out this plastic film to a manufacturing apparatus sequentially is provided.

Next, the hard coat layer provided on the surface of the plastic film will be described.
This hard coat layer is provided by applying a photocurable resin. The photocurable resin is a so-called ultraviolet curable resin that is cured by, for example, irradiating ultraviolet rays, such as urethane acrylate and epoxy acrylate. Or polyester acrylate. In the present embodiment, urethane acrylate is used, but the present invention is not necessarily limited thereto, and may be a photocurable resin other than an ultraviolet curable resin.

  As a method for applying the hard coat layer, a conventionally known method may be used, for example, a die coating method, a comma coating method, a gravure coating method, a kiss reverse coating method, or the like. In this embodiment, the kiss reverse coating method is used, but the method is not necessarily limited to this method. The thickness of the hard coat layer laminated on the surface of the plastic film is preferably 1 μm or more and 15 μm or less. If it is 1 μm or less, the function as a hard coat layer cannot be exhibited in the first place, and, as will be described later, a sufficient thickness when performing hairline processing, mat processing, etc. on the surface of the hard coat layer, That is, if the thickness is less than the thickness necessary for the treatment such as hairline processing, the hard coat layer itself is not present by applying the surface treatment such as hairline processing, and more than 15 μm. If this is the case, as described above, there is a limit to reducing the thickness of the entire laminated body to be obtained, that is, the whole laminated body cannot be made thin. In the manufacturing method according to the present embodiment, the stacking process is performed in this way.

  And in the manufacturing apparatus which concerns on this Embodiment, the application | coating lamination | stacking part which apply | coats the photocurable resin mentioned above is provided on the surface of the plastic film carried out from the above-mentioned unwinding part. In this coating and laminating portion, a member may be configured so that a known coating method, for example, a die coating method, a comma coating method, a gravure coating method, or a kiss reverse coating method, can be performed. Although the structure is such that coating by a coating method can be performed, the structure of the coating layered portion may be a known one, and further description thereof is omitted here.

  And the solvent containing resin which forms a hard-coat layer is evaporated by drying the hard-coat layer laminated | stacked on the surface of the plastic film. To further explain this point, the photocurable resin that forms the hard coat layer exists in a solvent such as methyl ethyl ketone or methyl isobutyl ketone, and the photocurable resin is applied to the surface of the plastic film. Thus, when the hard coat layer is formed, the surface of the plastic film is in a state in which the photocurable resin and the solvent containing it exist. However, the solvent here is necessary to apply the photocurable resin to the surface of the plastic film, but once it is laminated, it becomes unnecessary. Therefore, by drying the entire hard coat layer, the solvent containing the resin evaporates when it reaches a certain temperature, and disappears as a result. In this embodiment, urethane acrylate, which is an ultraviolet curable resin, is used as a photocurable resin as described above, and methyl ethyl ketone is used as a solvent containing the same, but it is not necessarily limited to this. I will refuse that.

  However, although the hard coat layer is dried as described above, it is important to take care not to completely cure the hard coat layer at this point.

  This is because drying at this point is only to eliminate the presence of the solvent (that is, only to “fly off” the solvent), and not to harden the hard coat layer.

  In other words, as will be described later, after the drying step, the stamper film may be attached and the unevenness processing is executed, but if the hard coat layer has been cured at this time, This is because it is very difficult to form a desired surface shape even if a stamper film is stuck to the hard coat layer in this state.

  After the stamper film is applied, not only the hard coat layer is cured with the stamper film attached, but also the drying as described above is performed to eliminate the presence of the solvent. It is very difficult to eliminate the solvent from the hard coat layer by drying while it is stuck, and it is not preferable because it wastes time until it is unnecessary. Therefore, in the present embodiment, the procedure of first laminating a hard coat layer, then eliminating the solvent from the laminated hard coat layer, and then irradiating the hard coat layer with light to cure it. I am stepping on.

  As for the drying conditions, it is sufficient that the above conditions can be realized, that is, the conditions that can realize that the solvent is only evaporated and the hard coat layer is not dried. It should be noted that no particular restrictions are imposed here.

  In the manufacturing method according to the present embodiment, the drying process is performed in this way, and the manufacturing apparatus according to the present embodiment includes a drying unit for executing the drying process. It may be a conventionally known one, and if necessary, it is only necessary to dry the hard coat layer laminated on the surface of the plastic film through the process in the coating and laminating section, and therefore the detailed structure is omitted here.

  When a hard coat layer is laminated on the surface of the plastic film and dried, a sticker film is then attached to the further surface of the hard coat layer, whereby the attaching step in the present embodiment is performed.

  This stamper film is transparent in the present embodiment, and has some sort of surface on a plastic film made of any one or more of PC film, PET film, PMMA film, PVC film, or PS film, Cross-sectional view rough unevenness processing is performed, for example, hairline processing, mat processing, embossing, other regular uneven shape processing, irregular uneven shape processing, or a combination of a plurality of them However, in the following description, it is assumed that hairline processing is performed on one side of the PC film. The width of the stamper film is substantially the same as that of the plastic film serving as the base material, and the length will be described later. The thickness of the stamper film is not particularly specified, but may be a thickness suitable for the usage described later. For example, if the thickness is about 25 μm or more and 100 μm or less, the stamper film itself is not bent or broken. It can be said that it is preferable because it can maintain properties, flexibility, and moderate hardness.

  Also, in order to make it suitable for the usage described later, this stamper film is formed of a material that can transmit light that cures the photocurable resin that forms the hard coat layer described above. Important and necessary.

  And in the manufacturing apparatus which concerns on this Embodiment, the stamper film unwinding part for carrying out this stamper film, and the hairline processing surface of the stamper film unloaded from the stamper film unwinding part serve as the above-mentioned base material And a sticking part formed by sticking the hard coat layer so as to be in contact with the surface of the hard coat layer laminated on the surface. These devices are not specifically described here, but the structure related to the stamper film unloading at the stamper film unwinding section is not special and may have a known structure. In this case, the hairline on the surface of the stamper film It is important to ensure that the processing is not damaged in any way. In addition, the stamper film is stuck at the sticking part so that the hairline processed surface of the stamper film is in contact with the surface of the hard coat layer laminated on the surface of the plastic film as the base material. In addition to the stamper film being placed on the surface of the coat layer, the sticking part must be equipped with a pressing means that can execute a pressing step that applies a pressure to the extent that they become laminated. It is necessary to be in a laminated state through processing at the landing part. In addition, in the manufacturing apparatus which concerns on this Embodiment, although a press means may exist independently, it shall be contained in the sticking part here.

  Then, the hard coat layer and the stamper film are stuck and laminated by this pressing means. At this time, it is important that foreign matters such as air do not exist on these sticking surfaces. Therefore, when pressing the stamper film with the pressing means, do not apply equal pressure to the pressing surface at once and uniformly, but gradually apply pressure from the end of the stamper film sequentially in a certain direction. For example, foreign matters such as air bubbles between the hard coat layer and the stamper film are also pushed out from the sticking surface, and as a result, these are stuck in a suitable state. For example, if pressure is applied to the pressing surface at once and uniformly, air bubbles may be trapped between the hard coat layer surface and the stamper film. Then, since there are bubbles, the situation will be such that the quality deterioration state such as oxygen inhibition occurs, the hairline shape will be damaged, but sequentially from the end toward the constant direction By applying pressure, even if bubbles are present at the initial application stage, the bubbles are pushed out by applying pressure sequentially, and as a result, the hard coat layer surface and the stamper film There is no foreign matter such as air bubbles between them.

  Here, the width of the stamper film described above will be described repeatedly. The width of the stamper film may be approximately the same size as the plastic film as the base material. As you can see from the process of laminating the layers and then sticking the stamper film to the surface, the width of the hard coat layer is inevitably the same as the width of the plastic film. Since the stamper film has to be adhered over the area, at least the width of the plastic film and the width of the stamper film need to be the same. In addition, the width of the stamper film may be slightly wider than the width of the plastic film, but the width of both is the same or the width of the stamper film is slightly wider, so that the entire hard coat layer surface is surely Since the stamper film can be in a state of being stuck, the width of the stamper film is preferably substantially the same as the width of the plastic film.

  Furthermore, since it is used by sticking in this way, it is necessary that the stamper film itself is not damaged or broken in the processing after sticking, and the stamper film-derived laminate must not be damaged. The stamper film itself needs to have flexibility, flexibility, and appropriate hardness, and the stamper film itself needs to have a thickness sufficient to ensure these properties. In this embodiment, the thickness that can secure these properties is 25 μm or more and 100 μm or less.

  In this way, the stamper film is unloaded from the stamper film unwinding part, passed through the sticking part, and laminated on the surface of the plastic film serving as the base material, and the hairline processed surface is applied to the hard coat layer subjected to the drying treatment. When it is in a stuck state, light is irradiated in that state. In the present embodiment, the process of irradiating light in this way becomes the irradiation process, and the manufacturing apparatus according to the present embodiment includes an irradiating unit that executes the process of irradiating light in this way.

The wavelength of the light irradiated here needs to correspond to the characteristics of the photocurable resin that forms the hard coat layer used in the present embodiment. That is, the hard coat layer is not completely cured unless the wavelength of light for curing the photocurable resin is irradiated. If an ultraviolet curable resin is used as the photocurable resin as in the present embodiment, The wavelength of the light applied to the entire laminate is 200 nm or more and 500 nm or less, the peak wavelength is 360 nm or more, the peak illuminance of the irradiated light is 200 mW / cm ² or more, and the integrated light quantity is 200 mJ / cm. ² is necessary. In order to stably supply such light, a high-pressure mercury lamp, an ultra-high pressure mercury lamp, a metal halide lamp, or the like is used for the irradiation unit, and the manufacturing apparatus according to the present embodiment uses a high-pressure mercury lamp. It shall be.

  In addition, simply adding the relationship between the peak illuminance and the integrated light quantity, if necessary, irradiate the light with the intensity (peak illuminance) more than the necessary minimum amount more than the minimum necessary quantity (integrated light quantity). Otherwise, the photo-curing resin will not cure, in other words, even if it is a strong light, if it is only irradiated instantaneously, or if the light is weak even after long-time irradiation, the photo-curing resin The phenomenon of not curing as much as necessary occurs, and the conditions under which such a phenomenon does not occur are the peak illuminance and the integrated light amount.

  And while satisfying this condition, as a combination thereof, if the material described above is used as a stamper film, the stamper film does not absorb the light even if the light beam satisfying the above condition is irradiated from the stamper film side of the laminate. This is not a cause for inhibiting the curing of the photocurable resin.

Further, in this embodiment, it is not good if the wavelength simply satisfies the above conditions, and in order to sufficiently cure the photocurable resin in the configuration according to this embodiment, a certain peak illuminance and It is necessary to satisfy the integrated light quantity. That is, if the wavelength merely satisfies the above conditions, the photocurable resin may not be sufficiently cured. Conversely, in order to sufficiently cure the photocurable resin, an appropriate amount of light is irradiated. Although it is necessary to continue, the light quantity for sufficiently curing this photo-curable resin is studied through sufficient consideration and consideration of the presence of the stamper film in the present embodiment, In this embodiment, the peak illuminance is 200 mW / cm ² or more, and the integrated light quantity is 200 mJ / cm ² . This is because these two conditions are satisfied, and the wavelength of illumination used satisfies the above conditions, and for the first time, it has been found that the photocurable resin is sufficiently cured in the present embodiment.

  Here, the direction in which light is irradiated must be from the stamper film side. This does not require the base film to be transparent in order to make the design of the laminate finally obtained in the present embodiment diverse, that is, a metal vapor-deposited film provided with a metallic luster. Or, when a film with a specific design or character printed in advance is used as the base film, even if light is irradiated from the base film side, the irradiated light cannot reach the photocurable resin layer sufficiently. As a result, the photocurable resin is not cured, and as a result, the laminate according to the present embodiment cannot be obtained.

  In short, in order to realize a variety of design properties, in this embodiment, the light irradiation direction must always be from the stamper film side. Therefore, as described above, the stamper film cures the photocurable resin. It must be able to transmit light of a certain wavelength.

  And finally, by irradiating light in an irradiation part, the photocurable resin which forms a hard-coat layer as mentioned above hardens | cures. Then, since the photocurable resin solidifies and solidifies itself by being cured by light, the sticking state between the hard coat layer and the stamper film that has been laminated in the sticking part is naturally loose. Become.

  Here, the reason why the stamper film needs to be formed of a material capable of transmitting the curing light of the photocurable resin forming the hard coat layer described above will be described. If the condition that the photocurable resin that forms the film can transmit the light to be cured is not satisfied, a laminate having the structure of a base plastic film / hard coat layer (by photocurable resin) / stamper film is formed. On the other hand, no matter how much light having a wavelength at which the photo-curing resin is cured, the stamper film cannot transmit the light, eventually the stamper film becomes a shield and the hard coat layer is cured forever. Because it does not. Therefore, it is most preferable that the stamper film is transparent. However, it is not always necessary that the stamper film is transparent. Rather, it is important whether or not the irradiated light is transmitted.

  In addition, as described above, when the entire body is exposed to light irradiation with foreign matters such as bubbles between the hard coat layer and the stamper film, the hard coat layer is cured while holding foreign matters such as bubbles. In other words, the hard coat layer in a state where such foreign matters exist cannot achieve the original purpose, and therefore it is important to stick the hard coat layer so that no foreign matters exist.

  As described above, a photocurable resin is applied to the surface of the plastic film as a base material in the laminating step, a hard coat layer is laminated, and then the hard coat layer laminated in the drying step is dried to be photocurable. Unnecessary substances are removed by evaporating the solvent used when applying the resin, and in the pasting process, the surface of the hard coat layer that has been dried is brought into contact with the surface of the hairline processed surface. By carrying out each step of the manufacturing method according to the present embodiment, which is made into a laminated state by sticking in this way, and irradiating light having a specific wavelength with respect to the whole by the irradiation step, a base plastic film / Hard coat layer / stamper film, hard coat layer and stamper fill Surface bets are stuck is to obtain a laminate peeling was kept easily state at this portion and at the same time a so-called hairline shape. And the effect as a protective film which protects the hard coat layer surface of the part which a stamper film has the structure of a base material plastic film / hard coat layer, if the state where the hard coat layer and the stamper film are stuck is maintained. Therefore, it can be said that it is preferable to keep the stamper film stuck until it is necessary, because there is no fear of inadvertently and unnecessarily damaging the surface of the hard coat layer.

  In order to embody such a manufacturing method, as in the manufacturing apparatus according to the present embodiment, a base film unwinding unit for unloading a plastic film as a base material, and an unloading from the base film unwinding unit. An application lamination part formed by applying a photocurable resin on the surface of the plastic film and laminating a hard coat layer, and a drying part for drying the hard coat layer laminated on the plastic film surface through the application lamination part A stamper film unwinding portion for unloading a stamper film whose surface has been previously subjected to hairline processing or matting, and the hairline or matting surface side of the stamper film unloaded from the stamper film unwinding portion, Adhering part that adheres to the surface of the plastic film on which the hard coat layer is laminated, and lamination through the adhering part If the configuration includes an irradiating unit that irradiates light to the whole, it is possible to manufacture them continuously by arranging them in the order of the processes, and more efficiently. It becomes.

  In the above description, it is assumed that the photocurable layer has a hard coat property, but other than this, for example, antifouling property, fingerprint resistance, antiglare property, or antistatic property, It is conceivable that one or a plurality of functions are provided and provided, but in any case, it can be dealt with in the same manner as described above, and therefore, detailed description thereof is omitted here. .

(Embodiment 2)
About the manufacturing method of the laminated body which concerns on this invention, and the apparatus for manufacturing this laminated body, the manufacturing method further provided with the manufacturing process and the apparatus member with respect to the manufacturing method and manufacturing apparatus which were demonstrated in 1st Embodiment The manufacturing apparatus will be described as a second embodiment. It should be noted that the photocurable resin layer is the same as that of the previous embodiment, and that the stamper film is also the same as that of the embodiment described on the left.

  The manufacturing method according to the present embodiment further includes a peeling step for peeling the stamper film and a stamper film collecting step for collecting the peeled stamper film in addition to the first embodiment described above. Is a feature.

  First, the peeling process will be described. By the manufacturing method according to the first embodiment described above, a laminate having the structure of plastic film / hard coat layer / stamper film as a base material can be obtained. In this peeling step, the stamper film is peeled off. It is supposed to be.

  As described above, the laminate obtained by the first embodiment has already hardened the hard coat layer by irradiation with light having a specific wavelength in the irradiation section. The layer itself is solidified and solidified. And if the state is maintained, the stamper film exhibits the effect of protecting the hard coat layer, but when this is peeled off, the unevenness corresponding to the unevenness of the hairline processing previously applied to the stamper film surface is hard coat layer It is in a state formed on the surface. That is, the hairline processed surface of the stamper film surface is attached to the hard coat layer surface at the attaching portion and laminated, so that the irregularities of the hairline applied to the stamper film surface press the hard coat layer surface. The surface of the hard coat layer is provided with unevenness similar to the unevenness of the hairline, that is, the unevenness becomes the hairline on the surface of the hard coat layer. Then, the entire surface is irradiated with light having a specific wavelength while maintaining this state, so that the hard coat layer is cured while maintaining the uneven shape of the hard coat layer surface, that is, the hairline shape. And since the whole hard coat layer is solidified and solidified only by itself by light irradiation, if the stamper film is peeled later, the hairline processing provided on the hard coat layer surface will be exposed, As a result, a film whose surface is hard-coated is obtained.

  Next, the stamper film recovery process will be explained. Since the hard coat layer is solidified and solidified, when it is peeled off, the photocurable resin that forms the hard coat layer adheres to the hairline processed surface of the stamper film surface. The situation where the hairline portion is filled does not occur. That is, the recovered stamper film is returned to the state before the first sticking to the hard coat layer, and as a result, the stamper film can be recovered and reused. The stamper film recovery step is a step of recovering the stamper film peeled in this way so that it can be reused. The stamper film recovered here is again the stamper film described in the first embodiment. It becomes possible to use for the sticking process of sticking.

  The manufacturing apparatus according to the present embodiment includes a peeling portion that can execute the above-described peeling means and a stamper film recovery portion that can recover the stamper film. Here, a more detailed description of the device is provided here. This is omitted.

  Further, as can be seen from the manufacturing process described above, the length of the stamper film may be as long as it can be used in this manufacturing process. But it can be reused automatically and repeatedly.

  And if it is the manufacturing method which concerns on 1st Embodiment and 2nd Embodiment, the method which carved the hairline-like line | wire directly on the hard-coat layer surface, and the hairline process with a sheet | seat etc. Compared to the method of directly processing the hard coat layer surface, it is a very simple process of applying to a film, further sticking, curing the whole, and peeling, especially Since the whole is configured in a state where a fine work such as processing the surface of the hard coat layer is omitted, the work itself can be speeded up and can be made very suitable.

  Furthermore, if the laminate obtained in the first embodiment is used, the hairline on the surface of the hard coat layer is not damaged until the actual use is started by using the stamper film itself as a protective film. If it is a laminate obtained in the second embodiment, cost reduction by manufacturing can be suppressed, mass production at high speed is not only possible, and there is no contamination of foreign substances such as bubbles. It can be made suitable from the viewpoint of improving quality.

  In addition, the hairline processing has been described above. However, if the surface processing shape of the stamper film is, for example, mat processing, the surface of the hard coat layer of the obtained laminate is mat processing, and other special designs are used for the stamper. If it is provided on the film surface, the shape can be provided on the surface of the hard coat layer by a simple method.

  Furthermore, in the case of a laminate obtained by performing hairline processing on the surface of the hard coat layer obtained as described above, the glossiness such as metallic luster can be obtained by performing printing or vapor deposition on the hairline surface. It is also possible to easily obtain the effect of improving the special designability.

  In addition, in any case of the first embodiment and the second embodiment, by providing an adhesive layer having adhesiveness on any surface of the plastic film as the base material, for example, It becomes easy to stick this to the outer panel of so-called white goods, that is, it becomes easy to use the laminate according to these embodiments, it becomes easy to give unique design, and the metal layer exhibiting metallic luster, printing In addition to the design effect obtained by hairline etc., the laminated body according to these embodiments is provided with a unique metallic luster, or some printing design, character design, etc. Although it is conceivable that a new effect that a new design effect due to is easily added can be obtained, further detailed description is omitted here.

Hereinafter, the laminated body according to the present invention will be further described with reference to examples.
The following samples were created according to the first embodiment described above.
As the base film, a PET film having a thickness of 50 μm (manufactured by Teijin Limited: trade name “Tetron HPE”) was used.
As a photocurable resin, urethane acrylate was laminated on the surface of the base film by a kiss reverse coating method so as to have a thickness of 10 μm.
For the light irradiation, a high pressure mercury lamp (USHIO INC .: high pressure UV lamp) was used.
After each sample was irradiated with light, the cured film properties were examined for pencil height and steel wool (SW) resistance.
The configuration of each sample and the results are shown below.

  As can be seen from the above results, regardless of the material of the stamper film, a cured film can be effectively obtained as long as it appropriately transmits a desired light beam, and the shape thereof is also desired. Yes (Sample 1 to Sample 12). Further, when attention is paid to the relationship between the peak illuminance and the integrated light amount, it is not simply that the integrated light amount is sufficient, but it is understood that effective curing cannot be performed unless the peak illuminance reaches a certain amount ( Samples 13-18). (These were considered based on the results shown in Samples 19-21.)

Claims (9)

On at least one side of the plastic film as the base material,
A laminating step of laminating a photocurable layer by applying a paint mainly composed of a photocurable resin;
After the lamination step, a drying step for drying the photocurable layer;
After the drying step, a sticking step for obtaining a laminate by sticking the uneven surface side of the stamper film, which is preliminarily roughened on its surface, to the surface of the photocurable layer;
After the sticking step, an irradiation step of irradiating light from the stamper film side to the entire laminate,
In this order, and a method for manufacturing a laminate,
The photo-curable resin is urethane acrylate, epoxy acrylate, or polyester acrylate, or a plurality thereof,
The wavelength of light applied to the entire laminate is 200 nm or more and 500 nm or less, the peak wavelength is 360 nm or more, the peak illuminance of the irradiated light is 200 mW / cm 2 or more, and the integrated light quantity is 200 mJ / cm 2. Yes,
The stamper film is a plastic film capable of transmitting the wavelength of the light, using a polycarbonate film, a polyethylene terephthalate film, a polymethyl methacrylate film , a pyrivinyl carbonate film, or a PS film as a raw material. And the thickness is 25 μm or more and 100 μm or less,
A method for producing a laminate, comprising: It is a manufacturing method of the layered product according to claim 1,
The substantially uneven processing is a hairline processing, mat processing, embossing, or regular or irregular uneven shape processing, or a combination thereof,
A method for producing a laminate, comprising: It is a manufacturing method of the layered product according to claim 1 or 2,
After the irradiation step, a peeling step formed by peeling the stamper film from the laminate,
In the peeling step, a stamper film collecting step for collecting the peeled stamper film,
Further comprising
A method for producing a laminate, comprising: It is a manufacturing method of the layered product according to claim 1 or 2,
The photocurable layer has one or a plurality of functions of hard coat property, antifouling property, anti-fingerprint property, anti-glare property, or antistatic property,
A method for producing a laminate, comprising: It is a manufacturing method of the layered product according to any one of claims 1 to 3,
On one or both surfaces of the plastic film,
An adhesive layer with adhesive properties, a metallic layer exhibiting a metallic luster, or a printed layer with printing,
Any one or a plurality of layers are laminated,
A method for producing a laminate, comprising: It is obtained by the manufacturing method of the layered product according to any one of claims 1 to 5.
A laminate characterized by the following. A manufacturing apparatus for manufacturing the laminate according to claim 6,
A base film unwinding section for unloading a plastic film as a base;
An application lamination part formed by applying a paint mainly composed of a photocurable resin on the surface of the plastic film unloaded from the base film unwinding part and laminating a photocurable resin layer;
A drying section for drying the photocurable resin layer laminated on the surface of the plastic film that has undergone the coating lamination section;
A stamper film unwinding section for unloading a stamper film whose surface has been roughened in advance on its surface;
A sticking part for sticking the concavo-convex surface side of the stamper film unloaded from the stamper film unwinding part to the plastic film surface on which the photocurable resin layer is laminated, to obtain a laminate;
An irradiation part formed by irradiating light from the stamper film side with respect to the entire laminate through the sticking part;
Comprising
A laminate manufacturing apparatus. It is a manufacturing apparatus of the layered product according to claim 7,
A peeling part formed by peeling the stamper film from the laminate through the irradiation part,
A stamper film winding unit for winding the stamper film peeled off at the peeling unit;
A film winding unit for winding the film in a state where the stamper film has been peeled through the peeling unit;
Further comprising
A laminate manufacturing apparatus. It is the manufacturing apparatus of the laminated body of Claim 7 or Claim 8, Comprising:
The substantially uneven processing is a hairline processing, mat processing, embossing, or regular or irregular uneven shape processing, or a combination thereof,
A laminate manufacturing apparatus.