JP6991605B1 - Manufacturing method of hard coat film for insert molding and insert molded products - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a hard coat film for insert molding, which has excellent scratch resistance, suppresses indentations during storage, and has excellent surface smoothness after preformation. SOLUTION: The base film 12 has a base film 12 and a hard coat layer 14 formed on the surface of the base film 12, and the hard coat layer 14 is composed of a composition which is cured by ionizing radiation. The hard coat film 10 for insert molding has an indentation hardness of the hard coat layer 14 measured by the nanoindentation method of 10 to 200 N / mm2 at 30 ° C. and 100 N / mm2 or less at 150 ° C. [Selection diagram] Fig. 1

Description

The present invention relates to a hard coat film for insert molding and a method for manufacturing an insert molded product.

Conventionally, for resin molded products used for interior parts of automobiles and panels and exterior parts of electric appliances such as mobile phones, inserts are used to integrate a film decorated on the surface or a film having functionality. The molding method is widely used.

For example, in Patent Document 1, an insert film provided with an uncured or semi-cured hard coat layer is molded into the shape of the surface of a molded product by a preform mold, and then the hard coat layer is irradiated with ionizing radiation. Disclosed is a method for manufacturing an insert-molded article, which is completely cured, and the cured insert film is integrated with a molding resin and injection-molded.

Japanese Unexamined Patent Publication No. 2009-20249

However, the insert film of Patent Document 1 is only described as having an uncured or semi-cured hardcourt layer, and is uncured or uncured or semi-cured before being molded into the shape of the molded product surface by the preform mold. No mention is made of maintaining the smoothness of the soft hardcourt layer in the semi-cured state, and there remains a problem in terms of smoothness that does not impair the surface quality of the insert molded product.

An object to be solved by the present invention is to provide a hard coat film for insert molding, which has excellent scratch resistance, suppresses indentations during storage, and has excellent surface smoothness after preformation. Another object of the present invention is to provide a method for manufacturing an insert-molded product that is not easily scratched, has less unevenness, and has an excellent appearance.

In order to solve the above problems, the hard coat film for insert molding according to the present invention has a base film and a hard coat layer formed on the surface of the base film, and the hard coat layer is ionized. It is composed of a composition that cures by radiation, and the indentation hardness of the hardcoat layer measured by the nanoindentation method is 10 to 200 N / mm ² at 30 ° C and 100 N / mm ² at 150 ° C. It is as follows.

The base film is composed of a multilayer structure having a layer containing polycarbonate and a layer containing poly (meth) acrylate, and the hard coat layer is in contact with the layer containing the poly (meth) acrylate layer of the base film. It should be formed.

When a protective film is arranged on the surface of the hard coat layer via the pressure-sensitive adhesive layer, the arithmetic average surface roughness (Ra) of the surface of the pressure-sensitive adhesive layer in contact with the hard coat layer is 200 nm or less. good.

Further, the method for manufacturing an insert molded product according to the present invention has the following steps (1) to (7).
(1) The indentation hardness, which is composed of a composition that is cured by ionizing radiation on the surface of the base film and is measured by the nanoindentation method, is 10 to 200 N / mm ² at 30 ° C. and at 150 ° C. A step of forming a hard coat layer of 100 N / mm ² or less to obtain a hard coat film.
(2) A step of laminating a protective film having an adhesive layer having an arithmetic average surface roughness (Ra) of 200 nm or less on the surface of the hard coat layer in contact with the hard coat layer.
(3) A step of peeling off the protective film and molding the hard coat film into the shape of the surface of the molded product by a preform mold.
(4) A step of irradiating the molded hard coat film with ionizing radiation to cure the hard coat layer.
(5) A step of arranging the cured hard coat film between a movable mold and a fixed mold, which are molding dies of an injection molding machine.
(6) A step of injecting and molding a resin into a cavity after molding the molding die, and at the same time, integrally adhering the cured hard coat film to the surface of the resin molded product.
(7) A step of opening the mold after cooling and solidifying the resin molded product, and taking out the insert molded product in which the cured hard coat film is integrally adhered to the surface of the resin molded product to the outside of the mold for molding. ..

The hard coat film for insert molding according to the present invention has a base film and a hard coat layer formed on the surface of the base film, and the hard coat layer is cured by ionizing radiation. It is composed of a composition, and the indentation hardness of the hard coat layer measured by the nanoindentation method is 10 to 200 N / mm ² at 30 ° C. and 100 N / mm ² or less at 150 ° C. Therefore, it has excellent scratch resistance, suppresses indentations during storage, and has excellent surface smoothness after preformation.

Further, according to the method for manufacturing an insert molded product according to the present invention, scratches are less likely to occur, unevenness is suppressed, and the appearance is excellent.

It is sectional drawing of the hard coat film for insert molding which concerns on one Embodiment of this invention. It is sectional drawing of the hard coat film for insert molding which concerns on other embodiment. It is sectional drawing of the hard coat film for insert molding after preform. It is sectional drawing of the insert molded product. It is a process drawing which shows the manufacturing process of an insert molded article.

Hereinafter, the present invention will be described in detail.

FIG. 1 is a cross-sectional view of a hard coat film for insert molding according to an embodiment of the present invention. As shown in FIG. 1, the insert molding hard coat film 10 according to the embodiment of the present invention has a base film 12 and a hard coat layer 14 formed on the surface of the base film 12.

(Base film)
The base film 12 is not particularly limited as long as it has transparency. Examples of the base film 12 include a transparent polymer film and a glass film. Transparency means that the total light transmittance in the visible light wavelength region is 50% or more, and the total light transmittance is more preferably 85% or more. The total light transmittance can be measured according to JIS K7361-1 (1997).

Examples of the polymer material of the base film 12 include polyesters such as polyethylene terephthalate and polyethylene naphthalate, polycarbonate, poly (meth) acrylate, polystyrene, polyamide, polyimide, polyacrylonitrile, polypropylene, polyethylene, polycycloolefin and cycloolefin copolymer. Polyolefin, polyphenylene sulfide, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol and the like can be mentioned. The polymer material of the base film 12 may be composed of only one of these, or may be composed of a combination of two or more. Of these, polyethylene terephthalate, polyimide, polycarbonate, poly (meth) acrylate, polycycloolefin, and cycloolefin copolymer are more preferable from the viewpoint of optical properties and durability.

The base film 12 may have a single-layer structure or a multi-layer structure having two or more layers. The base film 12 may have a multilayer structure of two or more layers from the viewpoint of easy formability and hardness adjustment. From the viewpoint of moldability and hardness, the base film 12 having a multilayer structure of two or more layers may have a layer containing polycarbonate on one surface and a layer containing poly (meth) acrylate on the other surface. That is, the base film 12 may be composed of a multilayer structure (PC / PMMA composite film) having a layer containing polycarbonate and a layer containing poly (meth) acrylate. The hard coat layer 14 may be formed in contact with the layer including the poly (meth) acrylate layer of the base film 12. The layer containing polycarbonate is a layer containing polycarbonate as the main component of the polymer. The layer containing poly (meth) acrylate is a layer containing poly (meth) acrylate as a polymer main component. The polymer main component is the polymer component having the highest content in the layer. That is, it is a polymer component contained in the layer in an amount of 50% by mass or more. The polymer main component may be more preferably contained in the layer in an amount of 60% by mass or more, more preferably 70% by mass or more.

The glass transition temperature (Tg) of the base film 12 is preferably in the range of 80 to 170 ° C., more preferably in the range of 90 to 160 ° C., and more preferably 120 to 160 ° C. from the viewpoint of durability and moldability in a high temperature and high humidity environment. The ° C range is even more preferred. In the base film 12 having a multilayer structure, it is preferable that each layer is in the range of the glass transition temperature (Tg).

The thickness of the base film 12 is not particularly limited, but is preferably in the range of 2 to 500 μm from the viewpoint of excellent handleability and the like. It is more preferably in the range of 30 to 450 μm, still more preferably in the range of 75 to 400 μm. The term "film" generally means a film having a thickness of less than 0.25 mm, but even if the film has a thickness of 0.25 mm or more, the thickness is 0 if it can be rolled into a roll. Even if it is .25 mm or more, it shall be included in the "film".

(Hard coat layer)
The hard coat layer 14 contributes to improving the scratch resistance of the hard coat film 10 for insert molding. The hard coat layer 14 preferably has a pencil hardness of H or higher, more preferably 3H or higher, and even more preferably 4H or higher. Pencil hardness can be measured according to JIS K5600-5-4.

The hard coat layer 14 is preferably composed of a composition that is cured by ionizing radiation from the viewpoint of scratch resistance, productivity and the like. Ionizing radiation means electromagnetic waves or charged particle beams that have energy quanta capable of polymerizing or cross-linking molecules. Examples of ionizing radiation include electromagnetic waves such as ultraviolet rays (UV), electron beams (EB), X-rays and γ-rays, and charged particle beams such as α-rays and ion rays. Of these, ultraviolet (UV) is particularly preferable from the viewpoint of productivity.

The composition cured by ionizing radiation contains at least a monomer, an oligomer, and a prepolymer having an ionizing radiation-reactive reactive group. Examples of the ionizing radiation-reactive reactive group include a radically polymerized reactive group having an ethylenically unsaturated bond such as an acryloyl group, a methacryloyl group, an allyl group and a vinyl group, and a cationically polymerizable reactive group such as an oxetanyl group. And so on. Of these, an acryloyl group, a methacryloyl group, and an oxetanyl group are more preferable, and an acryloyl group and a methacryloyl group are particularly preferable. That is, (meth) acrylate is particularly preferable. In addition, in this specification, "(meth) acrylate" means "at least one of acrylate and methacrylate". "(Meta) acryloyl" means "at least one of acryloyl and methacryloyl". "(Meta) acrylic" means "at least one of acrylic and methacrylic".

The (meth) acrylate may be composed of only a monofunctional (meth) acrylate, may be composed of only a polyfunctional (meth) acrylate, or may be composed of a monofunctional (meth) acrylate and a polyfunctional (meth) acrylate. It may be composed of a combination of acrylates. The composition cured by ionizing radiation preferably contains a polyfunctional (meth) acrylate.

Examples of the monofunctional (meth) acrylate include methyl (meth) acrylate, ethyl (meth) acrylate, propyl (meth) acrylate, isopropyl (meth) acrylate, butyl (meth) acrylate, amyl (meth) acrylate, and isobutyl (meth) acrylate. , T-butyl (meth) acrylate, pentyl (meth) acrylate, isoamyl (meth) acrylate, hexyl (meth) acrylate, heptyl (meth) acrylate, octyl (meth) acrylate, isooctyl (meth) acrylate, 2-ethylhexyl ( Meta) acrylate, nonyl (meth) acrylate, decyl (meth) acrylate, isodecyl (meth) acrylate, undecyl (meth) acrylate, dodecyl (meth) acrylate, lauryl (meth) acrylate, stearyl (meth) acrylate, isostearyl (meth) ) Acrylate, Isobornyl (meth) acrylate, 1-adamantyl (meth) acrylate, 2-methyl-2-adamantyl (meth) acrylate, 2-ethyl-2-adamantyl (meth) acrylate, Bornyl (meth) acrylate, tricyclodeca Nyl (meth) acrylate, dicyclopentanyl (meth) acrylate, dicyclopentenyl (meth) acrylate, cyclohexyl (meth) acrylate, benzyl (meth) acrylate, 1-naphthylmethyl (meth) acrylate, 2-naphthylmethyl (meth) ) Acrylate, Phenoxyethyl (meth) acrylate, Phenoxy-2-methylethyl (meth) acrylate, Phenoxyethoxyethyl (meth) acrylate, 3-Phenoxy-2-hydroxypropyl (meth) acrylate, 2-Phenylphenoxyethyl (meth) Acrylate, 4-phenylphenoxyethyl (meth) acrylate, 3- (2-phenylphenyl) -2-hydroxypropyl (meth) acrylate, 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, 2- Hydroxybutyl (meth) acrylate, tetrahydrofurfuryl (meth) acrylate, butoxyethyl (meth) acrylate, ethoxydiethylene glycol (meth) acrylate, polyethylene glycol mono (meth) acrylate, polypropylene glycol mono (meth) acrylate, methoxyethylene glycol (meth) ) Acrylate, ethoxye Examples thereof include chill (meth) acrylate, methoxypolyethylene glycol (meth) acrylate, and methoxypolypropylene glycol (meth) acrylate.

Examples of the polyfunctional (meth) acrylate include bifunctional (meth) acrylate, trifunctional (meth) acrylate, and tetrafunctional (meth) acrylate. More specifically, 1,4-butanediol di (meth) acrylate, 1,6-hexanediol di (meth) acrylate, 1,9-nonandiol di (meth) acrylate, ethylene glycol di (meth) acrylate, Diethylene glycol di (meth) acrylate, neopentyl glycol di (meth) acrylate, triethylene glycol di (meth) acrylate, tetraethylene glycol di (meth) acrylate, polyethylene glycol di (meth) acrylate, trimethyl propantri (meth) acrylate , Pentaerythritol tri (meth) acrylate, pentaerythritol tetra (meth) acrylate, dipentaerythritol penta (meth) acrylate, dipentaerythritol hexa (meth) acrylate, tripentaerythritol tetra (meth) acrylate, tripentaerythritol penta (meth) acrylate ) Acrylate, tripentaerythritol hexa (meth) acrylate, tripentaerythritol hepta (meth) acrylate, tripentaerythritol octa (meth) acrylate and the like can be mentioned.

Examples of the oligomer and prepolymer include urethane (meth) acrylate, silicone (meth) acrylate, alkyl (meth) acrylate, and aryl (meth) acrylate. In addition, a polymer having an ionizing radiation-reactive reactive group and the like can also be mentioned.

The (meth) acrylate of the composition cured by ionizing radiation may be composed of one kind of the above-mentioned (meth) acrylate alone, or may be composed of two or more kinds.

The composition that is cured by ionizing radiation may or may not contain a polymer that is not cured by ionizing radiation, in addition to the polymer that is cured by ionizing radiation. Further, the composition cured by ionizing radiation may contain a polymerization initiator. Further, if necessary, an additive or the like to be added to the curable composition may be contained. Examples of the additive include a dispersant, a leveling agent, a defoaming agent, a stiffening agent, an antifouling agent, an antifouling agent, an antibacterial agent, a flame retardant, a slip agent, an inorganic particle, and a resin particle. Further, if necessary, a solvent may be contained.

Examples of the polymer that is not cured by ionizing radiation include thermoplastic resins and thermosetting resins. Examples of the thermoplastic resin include polyester resin, polyether resin, polyolefin resin, polyamide resin, (meth) acrylic resin and the like. Examples of the thermosetting resin include unsaturated polyester resin, epoxy resin, alkyd resin, and phenol resin.

Examples of the polymerization initiator include a photopolymerization initiator. Examples of the photopolymerization initiator include alkylphenone-based, acylphosphine oxide-based, and oxime ester-based photopolymerization initiators. Examples of the alkylphenone-based photopolymerization initiator include 2,2'-dimethoxy-1,2-diphenylethane-1-one, 1-hydroxy-cyclohexyl-phenyl-ketone, and 2-hydroxy-2-methyl-1-phenyl-. Propane-1-one, 1- [4- (2-hydroxyethoxy) -phenyl] -2-hydroxy-2-methyl-1-propane-1-one, 2-hirodoxy-1- {4- [4- ( 2-Hydroxy-2-methyl-propionyl) -benzyl] phenyl} -2-methyl-propane-1-one, 2-methyl-1- [4- (methylthio) phenyl] -2-morpholinopropane-1-one, 2-benzylmethyl-2- (dimethylamino) -1- (4-morpholinophenyl) -1-butanone, 2- (dimethylamino) -2-[(4-methylphenyl) methyl] -1- (4-morpholino) Phenyl) -1-butanone, 2- (4-methylbenzyl) -2- (dimethylamino) -1- (4-morpholinophenyl) -1-butanone, N, N-dimethylaminoacetophenone and the like can be mentioned. Examples of the acylphosphine oxide-based photopolymerization initiator include 2,4,6-trimethylbenzoyldiphenylphosphine oxide, bis (2,4,6-trimethylbenzoyl) -phenylphosphine oxide, and bis (2,6-dimethoxybenzoyl) -2. , 4,4-trimethyl-pentylphosphine oxide and the like. Examples of the oxime ester-based photopolymerization initiator include 1,2-octanedione, 1- [4- (phenylthio) phenyl] -2- (O-benzoyloxime), and etanone-1- [9-ethyl-6- (2-). Methylbenzoyl) -9H-carbazole-3-yl] -1- (O-acetyloxime) and the like can be mentioned. The photopolymerization initiator may be used alone or in combination of two or more.

The content of the photopolymerization initiator is preferably in the range of 0.1 to 10% by mass based on the total amount of the composition cured by ionizing radiation. More preferably, it is in the range of 1 to 5% by mass.

Inorganic particles and resin particles are added to the hard coat layer 14 for the purpose of preventing blocking from the hard coat layer 14, suppressing wrinkles in insert molding, improving surface hardness, and the like. By forming fine surface irregularities on the hard coat layer 14 with the added inorganic particles and resin particles, blocking in which the front surface and the back surface adhere to each other when the hard coat film 10 for insert molding is wound or stacked in a roll shape. Is easy to suppress. Further, since it has an appropriate slipperiness with the insert molding die, it is possible to suppress the occurrence of wrinkles in the insert molding hard coat film 10.

The anti-fingerprint agent is added to the hard coat layer 14 for the purpose of making it difficult for fingerprints to adhere to the hard coat layer 14, making it easier to wipe off fingerprints, or making the wiped marks less noticeable. Examples of the anti-fingerprint agent include a fluorine-containing compound having an ultraviolet reactive group, and among them, a (meth) acrylate containing a perfluoroalkyl group is preferably used. Examples of such a compound include "KY-1203" manufactured by Shin-Etsu Chemical Co., Ltd., "Megafuck RS-75" manufactured by DIC, "Optur DAC-HP" manufactured by Daikin Industries, Ltd., and "Futergent 601AD" manufactured by Neos.

The content of the fluorine-containing compound having an ultraviolet reactive group is preferably in the range of 0.1 to 13% by mass with respect to 100% by mass of the solid content contained in the hard coat layer 14. It is more preferably in the range of 0.3 to 10% by mass, still more preferably in the range of 0.5 to 9% by mass. When the content of the fluorine-containing compound having an ultraviolet reactive group is 0.1% by mass or more, the slipperiness of the surface of the hard coat layer 14 is improved, so that excellent scratch resistance can be obtained and antifouling can be obtained. It is possible to improve the sex. On the other hand, if the content of the fluorine-containing compound having an ultraviolet reactive group exceeds 13% by mass, the scratch resistance of the hard coat layer 14 may decrease.

The composition cured by ionizing radiation may be diluted with a solvent. Examples of the solvent include ethanol, isopropyl alcohol (IPA), n-butyl alcohol (NBA), ethylene glycol monomethyl ether (EGM), ethylene glycol monoisopropyl ether (IPG), propylene glycol monomethyl ether (PGM), diethylene glycol monobutyl ether and the like. Alcohol solvents, ketone solvents such as methyl ethyl ketone (MEK), methyl isobutyl ketone (MIBK), cyclohexanone, acetone, aromatic solvents such as toluene and xylene, ethyl acetate (EtAc), propyl acetate, isopropyl acetate, butyl acetate. Examples thereof include an ester solvent such as (BuAc) and an amide solvent such as N-methylpyrrolidone, acetamide and dimethylformamide. These may be used alone as a solvent, or may be used in combination of two or more.

The solid content concentration (concentration of components other than the solvent) of the composition cured by ionizing radiation may be appropriately determined in consideration of coatability, film thickness and the like. For example, it may be 1 to 90% by mass, 1.5 to 80% by mass, 2 to 70% by mass, and the like.

The thickness of the hard coat layer 14 is not particularly limited, but is preferably 0.5 μm or more from the viewpoint of having sufficient hardness and the like. It is more preferably 2.0 μm or more, still more preferably 3.0 μm or more. Further, it is preferably 15 μm or less from the viewpoint that curl due to the difference in heat shrinkage with the base film 12 can be easily suppressed. It is more preferably 10 μm or less, still more preferably 5.0 μm or less. The thickness of the hard coat layer 14 is the thickness of a relatively smooth portion in a portion having no unevenness caused by inorganic particles or resin particles in the thickness direction.

The indentation hardness of the hard coat layer 14 measured by the nanoindentation method is 10 to 200 N / mm ² at 30 ° C., more preferably 12 to 160 N / mm ² , still more preferably 15 to 130 N / mm ² . Is. If the indentation hardness at 30 ° C. is less than 10 N / mm ² , there is a possibility that indentations may be generated on the hard coat layer 14 due to foreign matter contamination or external force during storage or in the decoration process. Further, when the protective film is peeled off before the preform step described later, the hard coat layer 14 may be transferred to the protective film or the peelability of the protective film may be deteriorated. On the other hand, if it is 200 N / mm ² or more, the crosslink density cannot be made sufficient, and the hardness of the hard coat layer 14 after curing may be insufficient.

The indentation hardness of the hard coat layer 14 measured by the nanoindentation method is 100 N / mm ² or less at 150 ° C. It is more preferably 98 N / mm ² or less, still more preferably 90 N / mm ² or less. If the indentation hardness at 150 ° C. exceeds 100 N / mm ² , smoothing due to the fluidity when the hard coat layer 14 is heated becomes difficult, unevenness cannot be suppressed, and the appearance is deteriorated. Further, the indentation hardness at 150 ° C. is preferably 0.1 N / mm ² or more. It is more preferably 0.5 N / mm ² or more, and further preferably 1.0 N / mm ² or more. If the indentation hardness at 150 ° C. is less than 0.1 N / mm ² , the fluidity of the hard coat layer 14 becomes excessively high, and the hard coat layer 14 may hang down and the uniformity of the thickness may be impaired.

The hard coat film 10 for insert molding can be manufactured by forming the hard coat layer 14 on one surface of the base film 12. The hard coat layer 14 can be formed by applying a composition for forming the hard coat layer 14 on one surface of the base film 12 and drying the hard coat layer 14 as necessary. At this time, in order to improve the adhesion between the base film 12 and the hard coat layer 14, the surface of the base film 12 may be surface-treated before coating. Examples of the surface treatment include corona treatment, plasma treatment, hot air treatment, ozone treatment, and ionizing radiation treatment.

Examples of the coating of the composition forming the hard coat layer 14 include a reverse gravure coat method, a direct gravure coat method, a die coat method, a bar coat method, a wire bar coat method, a roll coat method, a spin coat method, and a dip coat method. , Various coating methods such as spray coating method, knife coating method, and kiss coating method, and various printing methods such as inkjet method, offset printing, screen printing, and flexo printing can be used.

The drying step is not particularly limited as long as the solvent or the like used in the coating liquid can be removed, but it is preferably performed at a temperature of 50 to 150 ° C. for about 10 seconds to 180 seconds. In particular, the drying temperature is preferably 50 to 120 ° C.

It is preferable that the hard coat layer 14 remains uncured or semi-cured and is not completely cured. By setting the hard coat film for insert molding into a uncured or semi-cured state, it is possible to prevent cracks from occurring in the hard coat layer 14 even when the hard coat film for insert molding is preformed into a deep shape.

The hard coat film 10 for insert molding may be provided with a decorative layer, if necessary. The decorative layer is formed on the surface of the base film 12 opposite to the surface having the hard coat layer 14. The decorative layer is usually formed as a print layer.

As the material of the printing layer, a resin such as a polyvinyl resin, a polyamide resin, a polyacrylic resin, a polyurethane resin, a polyvinyl acetal resin, a polyester urethane resin, a cellulose ester resin, or an alkyd resin is used as a binder, which is appropriate. It is preferable to use a coloring ink containing a color pigment or dye as a coloring agent. Further, in the case of metal coloring, metal particles such as aluminum, titanium and bronze, and a pearl pigment obtained by coating mica with titanium oxide can also be used. As a method for forming the decorative layer, a normal printing method such as an offset printing method, a gravure printing method, or a screen printing method may be used. In particular, the offset printing method and the gravure printing method are suitable for performing multicolor printing and gradation expression.

The decorative layer may be made of a metal thin film layer or a combination of a printed layer and a metal thin film layer. The metal thin film layer is formed by a vacuum vapor deposition method, a sputtering method, an ion plating method, a plating method, or the like. Further, a metal foil may be used. Metals such as aluminum, nickel, gold, platinum, chromium, iron, copper, tin, indium, silver, titanium, lead and zinc, alloys or compounds thereof are used depending on the metallic luster color to be expressed.

When the metal thin film layer is provided, an anchor layer such as a front anchor layer or a rear anchor layer may be provided in order to improve the adhesion between the other transfer layer and the metal thin film layer. As the material of the anchor layer, it is preferable to use a two-component curable urethane resin, a thermosetting urethane resin, a thermosetting resin such as a melamine resin or an epoxy resin, or a thermoplastic resin such as a vinyl chloride copolymer resin. .. Examples of the method for forming the anchor layer include a coating method such as a gravure coating method, a roll coating method, and a comma coating method, and a printing method such as a gravure printing method and a screen printing method.

According to the hard coat film 10 for insert molding having the above configuration, the base film 12 and the hard coat layer 14 formed on the surface of the base film 12 are provided, and the hard coat layer 14 has ionizing radiation. The indentation hardness of the hardcourt layer 14, measured by the nanoindentation method, is 10 to 200 N / mm ² at 30 ° C and 100 N / mm ² or less at 150 ° C. Therefore, it has excellent scratch resistance, suppresses indentations during storage, and has excellent surface smoothness after preformation.

FIG. 2 is a cross-sectional view of a hard coat film for insert molding according to another embodiment. As shown in FIG. 2, the hard coat film 20 for insert molding according to another embodiment includes the base film 12, the hard coat layer 14 formed on the surface of the base film 12, and the hard coat layer 14. It has a pressure-sensitive adhesive layer 16 formed on the surface and a protective film 18 formed on the surface of the pressure-sensitive adhesive layer 16. A protective film 18 is arranged on the surface of the hard coat layer 14 via the adhesive layer 16. If the protective film 18 has self-adhesiveness, the pressure-sensitive adhesive layer 16 may be omitted.

The insert forming hard coat film 20 according to another embodiment is a protective film on the surface of the hard coat layer 14 via the adhesive layer 16 as compared with the insert forming hard coat film 10 according to one embodiment. The difference is that 18 is arranged, and other than that, it is the same as the hard coat film 10 for insert molding according to one embodiment, and the description thereof will be omitted for the same configuration.

(Adhesive layer)
The pressure-sensitive adhesive layer 16 is for attaching the protective film 18 on the surface of the hard coat layer 14. The pressure-sensitive adhesive layer 16 is composed of a pressure-sensitive adhesive composition containing a pressure-sensitive adhesive. Examples of the pressure-sensitive adhesive include an acrylic pressure-sensitive adhesive, a silicone-based pressure-sensitive adhesive, and a urethane-based pressure-sensitive adhesive. Further, the pressure-sensitive adhesive layer 16 may be composed of a resin composition containing a pressure-sensitive adhesive. Examples of the resin of the resin composition include polyethylene and an ethylene / vinyl acetate copolymer.

As the pressure-sensitive adhesive, an acrylic pressure-sensitive adhesive is particularly preferable from the viewpoint of excellent transparency and heat resistance. The acrylic pressure-sensitive adhesive is preferably formed from a pressure-sensitive adhesive composition containing a (meth) acrylic polymer and a cross-linking agent.

The (meth) acrylic polymer is a homopolymer or a copolymer of the (meth) acrylic monomer. Examples of the (meth) acrylic monomer include an alkyl group-containing (meth) acrylic monomer, a carboxyl group-containing (meth) acrylic monomer, and a hydroxyl group-containing (meth) acrylic monomer.

Examples of the alkyl group-containing (meth) acrylic monomer include (meth) acrylic monomers having an alkyl group having 2 to 30 carbon atoms. The alkyl group having 2 to 30 carbon atoms may be linear, branched chain, or cyclic. More specifically, examples of the alkyl group-containing (meth) acrylic monomer include, for example, isostearyl (meth) acrylate, stearyl (meth) acrylate, lauryl (meth) acrylate, dodecyl (meth) acrylate, and (meth). ) Decyl acrylate, (meth) isononyl acrylate, (meth) nonyl acrylate, (meth) isooctyl acrylate, (meth) octyl acrylate, (meth) isobutyl acrylate, (meth) n-butyl acrylate, ( Pentyl acrylate, (meth) hexyl acrylate, cyclohexyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, propyl (meth) acrylate, ethyl (meth) acrylate, methyl (meth) acrylate, etc. Can be mentioned.

Examples of the carboxyl group-containing (meth) acrylic monomer include (meth) acrylic acid, carboxyethyl (meth) acrylate, and carboxypentyl (meth) acrylate. The carboxyl group may be located at the end of the alkyl chain or may be located in the middle of the alkyl chain.

Examples of the hydroxyl group-containing (meth) acrylic monomer include (meth) hydroxylauryl acrylate, (meth) hydroxydecyl acrylate, (meth) hydroxyoctyl acrylate, (meth) hydroxyhexyl acrylate, and (meth) hydroxybutyl acrylate. Examples thereof include hydroxypropyl (meth) acrylate and hydroxyethyl (meth) acrylate. The hydroxyl group may be located at the end of the alkyl chain or may be located in the middle of the alkyl chain.

The (meth) acrylic monomer forming the (meth) acrylic polymer may be any one of the above, or may be a combination of two or more.

Examples of the cross-linking agent include isocyanate-based cross-linking agents, epoxy-based cross-linking agents, metal chelate-based cross-linking agents, metal alkoxide-based cross-linking agents, carbodiimide-based cross-linking agents, oxazoline-based cross-linking agents, aziridine-based cross-linking agents, and melamine-based cross-linking agents. .. As the cross-linking agent, one of these may be used alone, or two or more thereof may be used in combination.

The pressure-sensitive adhesive composition may contain other additives in addition to the (meth) acrylic polymer and the cross-linking agent. Other additives include cross-linking accelerators, cross-linking retarders, tackifiers, antistatic agents, silane coupling agents, plasticizers, release aids, pigments, dyes, wetting agents, thickeners, etc. Examples include ultraviolet absorbers, preservatives, antioxidants, metal deactivators, alkylating agents, flame retardants and the like. These are appropriately selected and used according to the use and purpose of use of the pressure-sensitive adhesive.

The thickness of the pressure-sensitive adhesive layer 16 is not particularly limited, but is preferably in the range of 1 to 10 μm. More preferably, it is in the range of 2 to 7 μm.

The arithmetic average surface roughness (Ra) of the surface of the pressure-sensitive adhesive layer 16 in contact with the hard coat layer 14 is preferably 200 nm or less. It is more preferably 150 nm or less, still more preferably 100 nm or less. If the arithmetic average surface roughness (Ra) is 200 nm or less, the hard coat layer 14 is uneven even after being bonded to the hard coat layer 14 for storage, transportation, and a decoration process performed as necessary. Can be made excellent in aesthetics with suppressed.

(Protective film)
The protective film 18 can prevent the surface of the hard coat layer 14 from being scratched during continuous processing, for example, in a roll process or the like, or during handling such as a decoration step following the formation of the hard coat layer 14. .. The protective film 18 is peeled off from the surface of the hard coat layer 14 together with the adhesive layer 16 after the printing process and before preform. Therefore, the adhesive layer 16 has a stronger adhesive force between the protective film 18 and the adhesive layer 16 than the adhesive force between the hard coat layer 14 and the adhesive layer 16, and the hard coat layer 14 and the adhesive layer 16 have a stronger adhesive force. The adhesive strength is adjusted so that the interface can be peeled off between 16.

The material constituting the protective film 18 is, for example, polyester such as polyethylene terephthalate or polyethylene naphthalate, polycarbonate, poly (meth) acrylate, polystyrene, polyamide, polyimide, polyacrylonitrile, polypropylene, polyethylene, polycycloolefin, cycloolefin copolymer and the like. Polyolefin, polyphenylene sulfide, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol and the like can be mentioned. The material constituting the protective film 18 may be composed of only one of these, or may be composed of a combination of two or more. Of these, polyethylene terephthalate, polypropylene, and polyethylene are more preferable from the viewpoint of mechanical properties and material cost.

The protective film 18 may be composed of a single layer composed of a layer containing one or more of the above-mentioned polymer materials, or a layer containing one or more of the above-mentioned polymer materials and this layer. It may be composed of two or more layers such as a layer containing one kind or two or more kinds of polymer materials different from the above.

The thickness of the protective film 18 is not particularly limited, but can be in the range of 2 to 500 μm and in the range of 2 to 200 μm.

The protective film 18 is attached to the surface of the hard coat layer 14 via the pressure-sensitive adhesive layer 18. For the bonding, for example, a laminator or the like can be used. In addition, after bonding, aging may be performed if necessary.

The hard coat film for insert molding according to the present invention is arranged on the surface of a resin molded product molded by injection molding or the like to improve the scratch resistance of the resin molded product. The hard coat film for insert molding according to the present invention is integrally adhered to the resin molded product by being insert-molded into the resin molded product. As a result, the insert molded product according to the present invention can be obtained. The insert molded product according to the present invention is suitable as a resin molded product used for interior parts of automobiles, panels and exterior parts of electric appliances such as mobile phones. In particular, it is suitable as a resin molded product that is deeply drawn.

The insert-molded product according to the present invention can be obtained by the method for producing an insert-molded product according to the present invention. The method for producing an insert molded product according to the present invention has the following steps (1) to (7). Depending on the case, the following step (2) may be omitted. FIG. 5 shows a manufacturing process of an insert molded product.

(1) A step of forming a hard coat layer on the surface of a base film to obtain a hard coat film.
(2) A step of adhering a protective film on the surface of the hard coat layer via an adhesive layer.
(3) A step of peeling off the protective film together with the adhesive layer and molding the hard coat film into the shape of the surface of the molded product by a preform mold.
(4) A step of irradiating a molded hardcoat film with ionizing radiation to cure the hardcoat layer.
(5) A step of arranging the cured hard coat film between a movable mold and a fixed mold, which are molding dies of an injection molding machine.
(6) A step of injecting and molding a resin into a cavity after molding a molding die, and at the same time, integrally adhering a cured hard coat film to the surface of the resin molded product.
(7) A step of taking out an insert molded product having a hard coat film cured on the surface of the resin molded product, which is integrally bonded to the surface of the resin molded product by opening the mold after cooling and solidifying the resin molded product, to the outside of the mold for molding.

The above (1) is a step of obtaining the above-mentioned hard coat film 10 for insert molding. As shown in FIG. 5A, a hard coat layer 14 is formed on the surface of the base film 12 to obtain a hard coat film 10 for insert molding. As described above, the hard coat layer 14 is composed of a composition that is cured by ionizing radiation, and the indentation hardness measured by the nanoindentation method is 10 to 200 N / mm ² at 30 ° C. and at 150 ° C. It is 100 N / mm ² or less.

The above (2) is a step of obtaining the above-mentioned hard coat film 20 for insert molding. As shown in FIG. 5B, the protective film 18 is attached onto the surface of the hardcoat layer 14 via the adhesive layer 16. As described above, the pressure-sensitive adhesive layer 16 has an arithmetic average surface roughness (Ra) of 200 nm or less on the surface in contact with the hard coat layer 14.

The above (3) is a preform step of the hard coat film 10 for insert molding. As shown in FIG. 5 (c), the protective film 18 is peeled off from the insert molding hard coat film 20 together with the adhesive layer 16, and the insert molding hard coat film 10 is formed into a molded product surface shape by the preform mold 24. Mold into. In this preform step, the hard coat film 10 for insert molding is molded using a preform mold 24 that matches the shape of the surface of the molded product. The hard coat film 10 for insert molding is subjected to the above-mentioned decoration as necessary before the preform step.

The preform step is a step of heating the insert molding film 10 and shaping it by using a preform mold corresponding to the shape of the injection molding die by a method such as vacuum molding, pressure molding, vacuum pressure molding, or press molding. be. In vacuum forming, for example, the insert molding film 10 is heated in advance to soften it, a vacuum is created between the preform mold 24 and the insert molding hard coat film 10, and the insert molding hard coat film 10 is placed along the preform mold. It is a vacuum forming. In the pressure-pneumatic molding, for example, the insert molding film 10 is heated in advance to be softened, and the insert molding film 10 is stretched by the force of compressed air to be molded along the preform mold 24. In the press molding, for example, the insert molding film 10 is heated in advance to be softened, the insert molding film 10 is sandwiched between the preform mold 24 and the concave mold, and the insert molding film 10 is formed along the preform mold 24.

The temperature at which the hard coat film 10 for insert molding is heated in advance is preferably close to the glass transition temperature of the base film 12. Specifically, when the base film 12 is a two-layer laminated film of polycarbonate and polymethyl methacrylate, it is in the range of 130 to 200 ° C, preferably in the range of 145 to 180 ° C, and more preferably in the range of 145 to 160 ° C. Is. The heating temperature can be measured by detecting the surface temperature of the hard coat film 10 for insert molding using, for example, an infrared radiation thermometer.

The above (4) is a step of irradiating the molded hard coat film 10 for insert molding with ionizing radiation to cure the hard coat layer 14. In the above (4), after the preform step is completed, the insert forming hard coat film 10 is kept along the preform mold 24 or removed from the preform mold 24, as shown in FIG. 5 (d). The hardcourt layer 14 is completely cured by irradiating the ionizing radiation from the device 26 that irradiates the ionizing radiation. Here, "completely curing" means that the degree of curing of the hardcoat layer 14 is 60% or more, preferably 70% or more, more preferably 80% or more, and the upper limit is 100%. The degree of curing is attributed to the ethylenically unsaturated bond of the hard coat layer 14 immediately after being applied to the base film 12 and dried using a Fourier converted infrared spectrophotometer (“IR-PRESTIGE 21” manufactured by Shimadzu Corporation). The absorbance is set to 0, and after irradiating with an ultraviolet ray having an integrated light amount of 1000 mJ / cm ² , another irradiation with an ultraviolet ray having an integrated light amount of 1000 mJ / cm ² is performed, and the value when the absorbance attributed to the ethylenically unsaturated bond does not change is set to 100. It can be obtained from the magnitude of the absorbance attributable to the ethylenically unsaturated bond of the hard coat layer 14 after curing.

As the ionizing radiation, ultraviolet rays and electron beams can be used. In the case of ultraviolet curing, a high-pressure mercury lamp, an electrodeless (microwave method) lamp, a xenon lamp, a metal halide lamp, or any other ultraviolet irradiation device can be used. Irradiation with ultraviolet rays may be carried out in an atmosphere of an inert gas such as nitrogen, if necessary. The amount of ultraviolet irradiation is not particularly limited, but is preferably 50 to 500 mJ / cm ² , and more preferably 100 to 400 mJ / cm ² .

In the case of electron beam curing, electron beams emitted from various electron beam accelerators such as Cockloftwald type, Van de Graaff type, resonance transformer type, insulated core transformer type, linear type, dynamitron type, and high frequency type can be used. .. The electron beam preferably has an energy of 50 to 1000 KeV. An electron beam having an energy of 100 to 300 KeV is more preferable.

The above (5) to (7) are insert molding steps. The insert molding method is a type of plastic injection molding technology, and among synthetic resins, it is mainly a thermoplastic resin that is melted (plasticized) by applying heat and pressure to achieve an appropriate flow state. In injection molding, which is poured into a closed mold at high speed under high pressure (injection pressure) to be sufficiently solidified and taken out, a preformed insert molding film is inserted into the mold in advance, and the film is formed. It is a method of obtaining a resin molded product integrated with.

For insert molding, first, the preformed hard coat film 10 for insert molding is placed inside a molding die (movable mold) of an injection molding machine. Next, the mold is closed, the thermoplastic resin, which is the molding resin supplied to the hopper of the injection molding machine, is weighed and kneaded by the rotation of the screw, and the molding resin melted at a high temperature is injected, and the pressure and heat at the time of molding are injected. At the same time as forming the resin molded product, the hard coat film 10 for insert molding is integrated and adhered to the surface thereof. Next, after cooling the mold, the mold is opened, and as shown in FIG. 5 (e), the insert molded product 30 in which the hard coat film 10 for insert molding is integrated with the resin molded product 22 is taken out.

The molding resin used for such injection molding is not particularly limited as long as it has transparency, but (meth) acrylic resin, polycarbonate resin, polystyrene resin, ABS resin, polyethylene resin, polypropylene resin, and the like. Thermoplastic resins such as fluororesins and polyamide resins and other thermocurable resins can be used.

Hereinafter, the present invention will be described in detail with reference to Examples and Comparative Examples.

(Composition for forming a hard coat layer <1>)
An ultraviolet curable composition containing an acrylic resin (“NXD-001A” manufactured by Nippon Kako Paint Co., Ltd. “was used.

(Composition for forming a hard coat layer <2>)
<Preparation of Resin Composition 2 for Forming Hard Court Layer>
An ultraviolet curable composition (“Z-624-12L” manufactured by Aica Kogyo Co., Ltd.) containing a modified acrylic resin and silica particles was used.

(Composition for forming a hard coat layer <3>)
A solvent is added to an ultraviolet curable composition (“Z-608-2AF (PGM)” manufactured by Aica Kogyo Co., Ltd.) containing a modified acrylic resin, diluted to a solid content concentration of 20% by mass, and used for forming a hard coat layer. The composition <3> was obtained.

(Composition for forming a hard coat layer <4>)
An ultraviolet curable composition containing a modified acrylic resin and silica particles (“Z-624-12L” manufactured by Aika Industries) and an ultraviolet curable composition containing dipentaerythritol penta / hexaacrylate (“M403” manufactured by Toa Synthetic). ) Is mixed so that the mass ratio of the solid content is 8: 1, a solvent is added, and the mixture is diluted so that the solid content concentration becomes 30% by mass to obtain a composition for forming a hard coat layer <4>. rice field.

(Formation of hard coat layer)
After applying the composition for forming a hard coat layer on the PMMA layer of the base film (“C003F” manufactured by Escarbo Sheet, PC / PMMA composite film (PC thickness 230 μm / PMMA thickness 70 μm)) using a wire bar. , 80 ° C. × 60 seconds to form a hard coat layer (thickness 3.5 μm) on the surface of the base film.

(Attachment of protective film)
A protective film with an adhesive layer was placed on the surface of the hard coat layer so that the adhesive layer was in contact with the hard coat layer, bonded using a hand roller, and then pressure-bonded using a laminator (nip pressure). 0.6MPa / 500mm). Then, the film was cut to 294 × 210 mm, loaded with 16.2 g / cm ² (10 kg for a 294 × 210 mm film), and allowed to stand for 48 hours. From the above, a hard coat film was produced.

-Protective film with adhesive layer <1>: "HPF13" manufactured by Higashiyama Film (polyester film 38 μm, acrylic adhesive layer 10 μm)
-Self-adhesive protective film <2>: "7A82" manufactured by Toray Film Processing (polypropylene film 30 μm having a polyethylene-based adhesive layer containing an adhesive-imparting agent)
-Self-adhesive protective film <3>: "FSA-150M" manufactured by Futamura Chemical Co., Ltd. (polypropylene film with a rubber-based adhesive layer 30 μm)

(Preform)
The prepared hard coat film was cut into a size of 210 × 148 mm, the protective film with an adhesive layer was peeled off, and then the hard coat film was heated by sandwiching it from above and below using two infrared heaters. The distance between the infrared heater and the hard coat film was 100 mm, the temperature of the infrared heater was 600 ° C., and the heating temperature was 7 seconds. The surface temperature of the hard coat film 1 after 7 seconds of heating was 150 ° C. Next, move the infrared heater on the opposite side of the hard coat layer away from the hard coat film, and immediately make a vacuum between the preform type (42 x 60 mm, box type with a drawing depth of 30 mm) and the hard coat film to make the hard. The surface of the coat film opposite to the hard coat layer was pressed against the film and molded along the preform mold. At this time, the infrared heater on the hard coat layer side continued to heat at 600 ° C., and the temperature of the preform type was set to 90 ° C. The hard-coated film was pressed against the preform mold and allowed to stand for 5 seconds, and then removed from the preform mold.

(Ultraviolet irradiation)
The hard coat layer side of the preformed hard coat film was irradiated with ultraviolet rays having a light intensity of 200 mJ / cm ² using an ultraviolet irradiation device (high pressure mercury lamp manufactured by Eye Graphics) to completely cure the hard coat layer. ..

<Evaluation method>
(Thickness of hard coat layer)
The thickness of the hard coat layer of the hard coat film was measured by a spectral interferometry using a thickness measuring system (“Filmtrics F20” manufactured by Filmometrics).

(Indentation hardness of hard coat layer)
The hard coat film from which the protective film with the adhesive layer was peeled off was cut into 15 mm × 15 mm, and using an ultra-fine indentation hardness tester (“ENT-NEXUS” manufactured by Elionix Inc.), based on ISO14577 Standard measurement, 30 A Berkovich indenter (triangular pyramid diamond indenter, interridge angle 115 °) was pushed into the measurement sample in an environment of ° C and 150 ° C, a load-unloading test was performed, and the indentation hardness of the hard coat layer was obtained by analyzing the test data. .. The maximum pushing load was 400 μN, the maximum load holding time was 5 seconds, and the unloading ratio used during the analysis was 200%.

(Arithmetic mean surface roughness)
The arithmetic mean roughness Ra of the surface was measured using a non-contact surface / layer cross-sectional shape measurement system (“Vertcan 2.0 (model: R5300GL-LA100-AC)” manufactured by Mitsubishi Chemical Systems).

(Roughness on the surface of the hard coat layer)
The hard-coated film for insert molding after preform was visually observed under a fluorescent lamp and evaluated according to the following criteria.
〇 ・ ・ ・ No unevenness is seen △ ・ ・ ・ The surface looks slightly wavy × ・ ・ ・ The unevenness is clearly visible

(Indentation)
The hardcourt film was placed on an iron plate (thickness 6 mm) with the protective film facing up, and a stainless steel indenter (1.5 kg, a cylinder with a tip shape diameter of 1 mm) was placed on it. After applying the load for 5 seconds, the load was removed, and after 5 minutes, the protective film with the adhesive layer was peeled off, and the surface of the hard coat layer was visually observed under a fluorescent lamp and evaluated according to the following criteria.
〇 ・ ・ ・ No trace of indenter can be seen × ・ ・ ・ Trace of indenter can be seen

(Pencil hardness of hard coat layer)
After pre-formation, the hard coat film for insert molding after being completely cured by irradiating with ultraviolet rays was cut into 50 mm × 100 mm, placed on a glass plate having a thickness of 2 mm, and the pencil hardness on the surface of the hard coat layer was measured. .. It was measured by the method specified in JIS K 5600-5-4 using a pencil hardness tester (manufactured by Tester Sangyo). The test load was 500 g, and repeated tests were performed while changing the hardness of the pencil, and the maximum hardness when the scratches and dents generated by the same pencil were within 1 out of 5 times was used as the evaluation value.

In Comparative Example 1, since the indentation hardness at 30 ° C. exceeds 200 N / mm ² , the pencil hardness of the hard coat layer after being completely cured is as low as HB. In Comparative Examples 2 to 4, since the indentation hardness at 30 ° C. is less than 10 N / mm ² , indentations are likely to occur during storage and in the decorating process. Further, since the indentation hardness at 150 ° C. exceeds 100 N / mm ² , the surface roughness after curing is large due to insufficient leveling property during heating in the preform step, and the appearance is inferior. Further, in Comparative Example 4, since the surface roughness Ra of the protective film is relatively high at 180 nm, the hard coat surface tends not to return to smooth even when heated in the preform step.

On the other hand, Examples 1 to 6 are composed of a composition in which the hard coat layer is cured by ionizing radiation, and the indentation hardness of the hard coat layer measured by the nanoindentation method is 10 at 30 ° C. Since it is ~ 200 N / mm ² and 100 N / mm ² or less at 150 ° C., the pencil hardness of the hard coat layer after complete curing is as hard as 3H or 4H, and it is excellent in scratch resistance. In addition, it can be seen that indentations during storage can be suppressed. Furthermore, it can be seen that the surface smoothness after preformation is excellent.

10, 20 Hard coat film for insert molding 12 Base film 14 Hard coat layer 16 Adhesive layer 18 Protective film 22 Resin molded product 24 Preform type 26 Device to irradiate ionizing radiation

Claims (3)

It has a base film and a hard coat layer formed on the surface of the base film.
The hardcourt layer is composed of an ultraviolet curable composition containing at least one of acrylate and methacrylate, or an ultraviolet curable composition containing at least one of acrylate and methacrylate and silica particles .
The indentation hardness of the hard coat layer measured by the nanoindentation method is 10 to 200 N / mm ² at 30 ° C. and 100 N / mm ² or less at 150 ° C.
Further, a protective film is arranged on the surface of the hard coat layer via the pressure-sensitive adhesive layer, and the arithmetic average surface roughness (Ra) of the surface of the pressure-sensitive adhesive layer in contact with the hard coat layer is 200 nm or less. There is a hard coat film for insert molding. The base film is composed of a multilayer structure having a layer containing polycarbonate and a layer containing poly (meth) acrylate, and the hard coat layer is in contact with the layer containing the poly (meth) acrylate layer of the base film. The hard coat film for insert molding according to claim 1, which is formed. A method for manufacturing an insert molded product, which comprises the following steps (1) to (7).
(1) A nanoindentation method comprising an ultraviolet curable composition containing at least one of acrylate and methacrylate or an ultraviolet curable composition containing at least one of acrylate and methacrylate and silica particles on the surface of the base film. A step of forming a hard coat layer having an indentation hardness of 10 to 200 N / mm ² at 30 ° C. and 100 N / mm ² or less at 150 ° C. to obtain a hard coat film.
(2) A step of laminating a protective film having an adhesive layer having an arithmetic average surface roughness (Ra) of 200 nm or less on the surface of the hard coat layer in contact with the hard coat layer.
(3) A step of peeling off the protective film and molding the hard coat film into the shape of the surface of the molded product by a preform mold.
(4) A step of irradiating the molded hard coat film with ionizing radiation to cure the hard coat layer.
(5) A step of arranging the cured hard coat film between a movable mold and a fixed mold, which are molding dies of an injection molding machine.
(6) A step of injecting and molding a resin into a cavity after molding the molding die, and at the same time, integrally adhering the cured hard coat film to the surface of the resin molded product.
(7) A step of opening the mold after cooling and solidifying the resin molded product, and taking out the insert molded product in which the cured hard coat film is integrally adhered to the surface of the resin molded product to the outside of the mold for molding. ..

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