JP7156785B2 - decorative film - Google Patents

Description

BACKGROUND OF THE DISCLOSURE The present disclosure relates to decorative films, and more particularly to textured decorative films.

Decorative films are used for the purpose of decorating the inner and outer walls of buildings. In recent years, in the construction and building industry, there is an increasing demand for interior materials that exhibit authentic textures. For example, one method of making a design such as wood grain or stone grain more realistic is to make the surface of the interior material as uneven as those materials have, that is, to create a large difference in height (asperity) in the plane of the surface of the interior material. It is desirable to have In addition, the designs required for decorative films are diversified, and decorative films having a three-dimensional concave-convex design on the surface to match the decorative design are also desired.

Patent Document 1 (Japanese Patent Application Laid-Open No. 2014-100811) describes "a base material, and a surface pattern layer formed by printing a pattern on the base material using a transparent ink. "Laminate to be used" is described.

Patent Document 2 (Japanese Unexamined Patent Application Publication No. 2008-080650) discloses that "on a base sheet, a bright colored layer, a picture pattern layer, a transparent adhesive layer, a transparent resin layer and a transparent transparent protective layer are provided in this order. , a decorative sheet characterized in that at least the bright colored layer has an uneven pattern formed by embossing.

Patent Document 3 (Japanese Unexamined Patent Application Publication No. 2007-253506) describes a "decorative sheet having pattern-printed layers on both sides of a resin sheet, in which the register accuracy of the front and back patterns in the width direction and the longitudinal direction of the sheet is 0. "Decorative sheet with an error within .08 mm" is described.

Patent Document 4 (Japanese Patent Application Laid-Open No. 2005-067175) describes, "(A) A planar pattern expressing an appearance pattern in a plane and an uneven shape appearance formed by a cutting-like uneven surface is simulated by its gradation shading. and (B) superimposing and synthesizing the respective images of the planar pattern and the uneven shadow pattern, so that the planar pattern is the appearance pattern on the uneven surface. (C) Forming the synthetic uneven surface pattern on a surface of a base material that does not have the uneven shape formed by the uneven surface. "Method for producing a decorative material with a three-dimensional effect, imparting a pseudo-three-dimensional effect of a cutting-like uneven surface".

JP 2014-100811 A JP 2008-080650 A JP 2007-253506 A JP 2005-067175 A

When unevenness is provided on the surface of the interior material by using a surface processing technique such as embossing, the material constituting the interior material, such as a polymer film, must have a thickness sufficiently larger than the height difference of the unevenness. However, when the polymer film is thickened to a certain extent, it becomes rigid, making it difficult to handle during manufacture, transportation, and installation of the interior material. problems may occur. Therefore, the height difference of the unevenness that can be formed by embossing is not sufficient for imparting an authentic texture to the decorative film or for imparting a three-dimensional design appearance that matches the pattern applied to the decorative film. . In addition, since the interior material is often installed to cover the curved surfaces and corners of the structure, it has sufficient elongation and bending properties, and can be installed without impairing its appearance and strength. is required.

The present disclosure provides a decorative film that has an authentic texture or three-dimensional unevenness on the surface that matches the design of various decorative films and that is excellent in both elongation and bending properties.

According to one embodiment of the present disclosure, a base film layer, a printed layer disposed on the base film layer, and a transparent protective layer covering at least a portion of the printed layer, the UV curable transparent and a three-dimensionally shaped transparent protective layer on which ink is inkjet printed, wherein the transparent protective layer at least partially has a thickness of 7 μm or more, and the decorative film is heated at 20° C. A decorative film is provided that has an elongation at break of 15% or more and does not crack in a 45-degree bending test.

According to another embodiment of the present disclosure, a base film layer, a printing layer disposed on the base film layer, and a transparent protective layer covering at least a portion of the printing layer, the UV curable Provided is a decorative film having texture, comprising a three-dimensional transparent protective layer in which transparent ink is inkjet-printed, wherein the UV-curable transparent ink contains 50% by mass or more of a monofunctional monomer. .

The decorative film of the present disclosure is a three-dimensional transparent protective layer that is formed by inkjet printing a UV curable transparent ink. It has irregularities on its surface and is excellent in both elongation properties and bending properties. Therefore, the decorative film can be suitably used for applications such as interior materials for buildings.

It should be noted that the above description should not be construed as disclosing all embodiments of the invention or all advantages associated with the invention.

1 is a schematic cross-sectional view of a decorative film according to one embodiment of the present disclosure; FIG.

The present invention is described in more detail below for the purpose of illustrating representative embodiments of the invention, but the invention is not limited to these embodiments.

In the present disclosure, "monofunctional monomer" means a compound having only one reactive double bond and generally having a molecular weight of less than 1000.

In the present disclosure, "oligomer" means a compound having multiple units derived from a monomer, generally having a molecular weight of about 500 or more, or about 1000 or more. For example, a urethane acrylate oligomer is a compound containing a plurality of units having urethane bonds and having an acrylate group.

In this disclosure, "texture" means a three-dimensional shape on a surface that can be visually or tactilely perceived by an observer.

In the present disclosure, "transparent" means that a material or article has a total light transmittance of about 85% or more, or about 90% or more in the wavelength range of 400-700 nm. Total light transmittance is determined according to JIS K 7361-1:1997 (ISO 13468-1:1996).

In the present disclosure, "(meth)acrylic" means acrylic or methacrylic, "(meth)acryloyl" means acryloyl or methacryloyl, and "(meth)acrylate" means acrylate or methacrylate.

The textured decorative film of the present disclosure includes a base film layer, a printed layer disposed on the base film layer, and a transparent protective layer covering at least a portion of the printed layer, which comprises a UV curable transparent film. and a three-dimensionally shaped transparent protective layer on which ink is inkjet printed.

In one embodiment, the transparent protective layer at least partially has a thickness of about 7 μm or more, and the decorative film has an elongation at break of about 15% or more at 20° C. and cracks in a 45° bend test. do not have. A transparent protective layer having a three-dimensional shape formed by inkjet printing a UV curable transparent ink has a portion having a thickness of about 7 μm or more, so that it matches the design of a texture or decorative film with a real texture. Three-dimensional unevenness can be imparted to the surface of the decorative film. Since the decorative film has predetermined elongation at break and flexural properties, the elongation and flexural properties of the decorative film are suitable for use in, for example, building interiors.

In another embodiment, the UV curable clear ink contains about 50% by weight or more of monofunctional monomers. A transparent protective layer having a three-dimensional shape formed by inkjet printing a UV curable transparent ink containing 50% by mass or more of a monofunctional monomer is a texture with a real texture or a three-dimensional shape that matches the design of the decorative film. Concavities and convexities can be imparted to the surface of the decorative film, and both elongation properties and bending properties are excellent.

A decorative film according to one embodiment of the present disclosure is shown in schematic cross-section in FIG. The decorative film 10 includes a base film layer 12 , a printed layer 14 disposed on the base film layer 12 , and a transparent protective layer 16 covering at least a portion of the printed layer 14 . The transparent protective layer 16 has a three-dimensional shape obtained by inkjet printing UV curable transparent ink, and the three-dimensional shape of the transparent protective layer 16 imparts a texture to the decorative film. Although the printed layer 14 is completely covered with the transparent protective layer 16 in FIG. 1, a part of the printed layer 14 may be exposed to the outside. The printing layer 14 and the transparent protective layer 16 may each be continuous or discontinuous.

Various resins such as acrylic resins including polymethyl methacrylate (PMMA), polyurethane (PU), polyvinyl chloride (PVC), polycarbonate (PC), polyethylene (PE), polypropylene (PP), etc. can be used as the base film layer. Polyolefin, polyester such as polyethylene terephthalate (PET) and polyethylene naphthalate, fluororesin, ethylene-vinyl acetate copolymer (EVA), ethylene-acrylic acid copolymer, ethylene-ethyl acrylate copolymer, ethylene-vinyl acetate Films comprising copolymers such as acrylonitrile-butadiene rubber (NBR), acrylonitrile-butadiene-styrene copolymer (ABS), or mixtures thereof can be used.

A film containing polyurethane, polyvinyl chloride, polyethylene terephthalate, acrylonitrile-butadiene-styrene copolymer or polycarbonate can be advantageously used as the base film layer from the viewpoint of strength, impact resistance and the like. The base film layer can also function as a receptor layer for printing inks and/or as a protective layer that protects the adherend surface from external punctures, impacts, and the like. When the base film layer functions as a receptor layer for printing ink, it is advantageous in terms of printability, solvent resistance (for example, alcohol resistance), etc. that the base film layer is a polyvinyl chloride film or a polyurethane film. A polyvinyl chloride film can be advantageously used as the base film layer in terms of flame retardancy, flexibility, and the like.

The thickness of the base film layer may vary, but from the standpoint of decorative film strength and handleability, it is generally about 10 μm or more, about 20 μm or more, or about 50 μm or more, about 500 μm or less, about 200 μm or less, or about 100 μm or less. can be The thickness of the base film layer when the base film layer is uneven means the thickness of the thinnest portion of the base film layer. For example, the base film layer may be embossed. The embossing depth, which is generally less than the thickness of the base film layer, can be about 1 μm or greater, about 2 μm or greater, or about 5 μm or greater, about 50 μm or less, about 20 μm or less, or about 10 μm or less.

The base film layer may be transparent, translucent or opaque, and may be colorless or colored. In one embodiment the base film layer is colored white. This embodiment is advantageous in terms of sharpness, color development, etc. of the image produced by the printing layer directly or indirectly placed over the base film layer.

The printed layer is used to impart decorativeness or designability to the decorative film with a picture, pattern, or the like. The printed layer can be formed by printing on the base film layer directly or via another layer using a colorant such as toner or ink. If the base film layer is transparent or translucent, a printing layer can also be formed between the base film layer and the adhesive layer. The printed layer can be formed by using printing techniques such as gravure printing, electrostatic printing, screen printing, inkjet printing, and offset printing. Solvent-based inks or UV curable inks can be used as printing inks.

In one embodiment the printed layer is an inkjet printed layer. In another embodiment, the printed layer is formed by inkjet printing using UV curable ink. Ink jet printing, especially ink jet printing with UV curable inks, enables on-demand manufacturing with short lead times.

The thickness of the printed layer may vary, and may generally be about 1 μm or more, or about 2 μm or more, about 10 μm or less, or about 5 μm or less when solvent-based inks are used. When UV curable ink is used, the thickness can be about 1 μm or more, or about 5 μm or more, about 50 μm or less, or about 30 μm or less.

The printed layer may be continuous or discontinuous. The printed layer may be arranged so as to correspond to the entire surface of the decorative film, or may be arranged so as to correspond to a part or a plurality of parts.

The transparent protective layer covers at least a portion of the printed layer and has a three-dimensional shape formed by inkjet printing a UV curable transparent ink.

As the UV curable transparent ink used for the transparent protective layer, both radical polymerization type and cationic polymerization type can be used. As a UV curable transparent ink, polymerizable monomers and/or polymerizable oligomers, photopolymerization initiators, and other optional components (light stabilizers, polymerization inhibitors, UV absorbers, antifoaming agents, antifouling agents, etc.) Solvent-free inks can be used to advantage. A water-based ink or a solvent-based ink can also be used as the UV curable transparent ink.

In one embodiment, the UV curable transparent ink contains about 50% by weight or more of monofunctional monomers. General UV curable inks contain a relatively large amount of multifunctional monomers that act as cross-linking points in order to obtain sufficient curing with short-term UV irradiation, and the cured ink tends to be rigid and brittle. be. In this embodiment, by using a large amount of a monofunctional monomer of about 50% by mass or more in the transparent protective layer, the surface of the decorative film has a texture with a real texture or three-dimensional unevenness that matches the design of the decorative film. Both excellent elongation and bending properties can be imparted to the decorative film while it is being formed.

In some embodiments, the UV curable clear ink contains about 55 wt% or more, about 60 wt% or more, or about 65 wt% or more, about 90 wt% or less, about 85 wt% or less, or about Contains 80% by mass or less.

In one embodiment, the UV curable transparent ink is a radical polymerizable acrylic ink. A transparent protective layer formed using an acrylic ink is excellent in transparency, strength, weather resistance, etc., and is advantageous, for example, when a decorative film is used as an interior material.

Monofunctional monomers used in acrylic inks include (meth)acrylic monomers having a (meth)acryloyl group, such as methyl (meth)acrylate, ethyl (meth)acrylate, n-butyl (meth)acrylate, and isoamyl (meth)acrylate. ) acrylate, 2-methylbutyl (meth)acrylate, n-hexyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, isooctyl (meth)acrylate, isononyl (meth)acrylate, decyl (meth)acrylate, dodecyl (meth)acrylate , cyclohexyl (meth)acrylate, isobornyl (meth)acrylate and the like; phenoxyalkyl (meth)acrylates such as phenoxyethyl (meth)acrylate; methoxypropyl (meth)acrylate, 2-methoxybutyl (meth)acrylate , alkoxyalkyl (meth)acrylates such as 2-(2-ethoxyethoxy)ethyl (meth)acrylate; cyclic ether-containing (meth)acrylates such as glycidyl (meth)acrylate, tetrahydrofurfuryl (meth)acrylate, cyclic trimethylolpropane formal acrylate, etc. ) acrylate; hydroxyl group-containing (meth) acrylates such as 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, 4-hydroxybutyl (meth) acrylate; (meth) acrylamide, N,N-diethyl (meth) ) Nitrogen-containing (meth)acryloyl compounds such as acrylamide; (meth)acrylic acid; Monofunctional monomers include vinyl compounds such as vinyl acetate, vinyl propionate, styrene, and vinyltoluene; unsaturated nitriles such as acrylonitrile and methacrylonitrile; unsaturated compounds such as crotonic acid, itaconic acid, fumaric acid, citraconic acid, and maleic acid. Also included are carboxylic acids. A (meth)acrylic monomer having a (meth)acryloyl group as the monofunctional monomer is advantageous in terms of strength, transparency, and adhesion to other layers constituting the base film layer or the decorative film, An acrylic monomer having an acryloyl group is more advantageous in terms of curing speed.

In some embodiments, the monofunctional monomers are cycloaliphatic (meth)acrylates such as cyclohexyl (meth)acrylate, isobornyl (meth)acrylate, cyclic (meth)acrylates such as tetrahydrofurfuryl (meth)acrylate, cyclic trimethylolpropane formal acrylate, and the like. Includes ether-containing (meth)acrylates. Cycloaliphatic (meth)acrylates and cyclic ether-containing (meth)acrylates can increase the surface hardness of the cured ink without impairing elongation and bending properties. The monofunctional monomer, based on 100 parts by weight of the monofunctional monomer, the total of alicyclic (meth)acrylate and cyclic ether-containing (meth)acrylate is about 40 parts by weight or more, about 50 parts by weight or more, or about 60 parts by weight Above, about 100 parts by weight or less, about 95 parts by weight or less, or about 85 parts by weight or less.

Polymerizable monomers may include polyfunctional monomers. A polyfunctional monomer can function as a cross-linking agent to increase the strength and durability of the transparent protective layer. By cross-linking using a polyfunctional monomer, the adhesion of the transparent protective layer to the base film layer or other layers of the decorative film can be enhanced in some cases.

Examples of polyfunctional monomers used in acrylic inks include 1,4-butanediol di(meth)acrylate, 1,6-hexanediol di(meth)acrylate, ethylene glycol di(meth)acrylate, cyclohexanedimethanol di( Bifunctional (meth)acrylates such as meth)acrylate, diethylene glycol di(meth)acrylate, dipropylene glycol di(meth)acrylate, polyethylene glycol di(meth)acrylate; glycerol tri(meth)acrylate, trimethylolpropane tri(meth) trifunctional (meth)acrylates such as acrylates, pentaerythritol tri(meth)acrylate; (Meth)acrylates with groups can be used.

In some embodiments, the UV curable clear ink contains about 1 wt% or more, about 3 wt% or more, or about 5 wt% or more, about 50 wt% or less, about 40 wt% or less, or about 30 mass % or less is included.

As the polymerizable oligomer, for example, urethane acrylate, polyester acrylate, epoxy acrylate, etc. can be used. By using a polymerizable oligomer, the printability of the UV curable transparent ink can be enhanced, and the adhesion of the transparent protective layer to the base film layer or other layers of the decorative film can be enhanced. These polymerizable oligomers generally have two or more polymerizable functional groups and can also be used as crosslinkers.

In some embodiments, the UV curable clear ink contains about 1 wt% or more, about 3 wt% or more, or about 5 wt% or more, about 30 wt% or less, about 25 wt% or less, or about 20 mass % or less is included.

As a photopolymerization initiator, a known compound that induces a radical polymerization reaction of (meth)acrylate can be used. Both intramolecular cleavage type and hydrogen abstraction type photopolymerization initiators can be used. 4-(methylthio)phenyl]-2-morpholinopropan-1-one, 2-hydroxy-2-methyl-1-phenylpropan-1-one, 2-benzyl-2-dimethylamino-1-(4-morpholinophenyl )-butan-1-one, 1-[4-(2-hydroxyethoxy)-phenyl]-2-hydroxy-2-methyl-1-propan-1-one, 2,4,6-trimethylbenzoyldiphenylphosphine oxide , 2,6-dimethylbenzoyldiphenylphosphine oxide, benzoyldiethoxyphosphine oxide, bis(2,6-dimethoxybenzoyl)-2,4,4-trimethylpentylphosphine oxide, benzoin alkyl ethers (e.g. benzoin methyl ether, benzoin ethyl ether, benzoin isopropyl ether, benzoin isobutyl ether, n-butyl benzoin ether, etc.), methylbenzoyl formate, 1-(4-isopropylphenyl)-2-hydroxy-2-methylpropan-1-one, 2-hydroxy-2 -methyl-1-phenylpropan-1-one, p-tert-butyltrichloroacetophenone, p-tert-butyldichloroacetophenone, benzyl, acetophenone, thioxanthones (2-chlorothioxanthone, 2-methylthioxanthone, 2,4-diethyl thioxanthone, 2,4-diisopropylthioxanthone), camphorquinone, 3-ketocoumarin, anthraquinones (e.g., anthraquinone, 2-ethylanthraquinone, α-chloroanthraquinone, 2-tert-butylanthraquinone, etc.), acenaphene, 4,4′- dimethoxybenzyl, 4,4'-dichlorobenzyl and the like. Commercially available examples of photoinitiators include those sold under the trade names Irgacure, Darocure, and Versicure by Versicor, available from BASF Japan. Thermal initiators or photoinitiators can be used alone or in combination of two or more.

In some embodiments, the UV curable clear ink comprises about 0.1 wt.% or more, or about 1 wt.% or more, about 15 wt.% or less, or about 10 wt.% or less photoinitiator.

The UV curable transparent ink may optionally contain additives such as light stabilizers, polymerization inhibitors, UV absorbers, antifoaming agents and antifouling agents.

The UV curable transparent ink may further contain reactive siloxane. By including the reactive siloxane in the UV curable transparent ink, the chemical resistance of the transparent protective layer, the bending properties of the decorative film, and the like can be enhanced. Examples of reactive siloxanes include silicone resins having (meth)acryloyl groups in side chains or terminals, and siloxane-containing inorganic oxides whose surfaces are blocked with (meth)acryloyl groups. Siloxane-containing inorganic oxides include silica, silica-zirconia composite oxides, silica-alumina composite oxides and silica-titania composite oxides. By using a siloxane-containing inorganic oxide whose surface is blocked with (meth)acryloyl groups, the surface hardness (for example, pencil hardness) can be further increased.

In some embodiments, the UV curable clear ink contains about 1 wt.% or more, about 3 wt.% or more, or about 5 wt.% or more, about 15 wt.% or less, about 12 wt.% or less, or about Contains 10% by mass or less.

The viscosity of the UV curable transparent ink can be about 5 mPa·s or more, or about 15 mPa·s or more, about 60 mPa·s or less, or about 50 mPa·s or less at 25°C. can be about 1 mPa·s or more, or about 5 mPa·s or more, about 20 mPa·s or less, or about 15 mPa·s or less. By setting the viscosity of the UV curable transparent ink within the above range, the fluidity of the ink droplets is ensured when the ink droplets are ejected, and the shape of the ink droplets is maintained when the ink droplets land. It is possible to form a transparent protective layer having

A transparent protective layer having a three-dimensional shape can be formed by inkjet-printing a UV-curable transparent ink on the base film layer directly or through another layer and curing the ink by irradiating it with ultraviolet rays. The UV curable transparent ink may be printed so as to cover at least a portion of the printed layer, or may be printed so as to cover the entire printed layer. The thickness of the transparent protective layer may be increased by repeatedly printing the UV curable transparent ink locally or over the entire surface.

The thickness of the transparent protective layer may vary, but in some embodiments is at least partially about 7 μm or greater, about 20 μm or greater, or about 30 μm or greater. By providing the transparent protective layer with a portion having a thickness of about 7 μm or more, it is possible to give the surface of the decorative film a texture with a genuine texture or a three-dimensional unevenness that matches the design of the decorative film.

In some embodiments, the maximum thickness of the transparent protective layer is no greater than about 500 microns, no greater than about 300 microns, or no greater than about 100 microns. By setting the maximum thickness of the transparent protective layer to about 500 μm or less, the elongation properties and bending properties of the transparent protective layer can be made suitable.

In some embodiments, the maximum height roughness Rz of the transparent protective layer is about 0.5 μm or more, about 1 μm or more, or about 1.5 μm or more, about 20 μm or less, about 15 μm or less, or about 10 μm or less. . By setting the maximum height roughness Rz of the transparent protective layer within the above range, it is possible to give the surface of the decorative film a texture with a real texture or a three-dimensional unevenness that matches the design of the decorative film.

In some embodiments, the transparent protective layer has a total light transmittance of about 90% or more, about 92% or more, or about 95% or more and a haze of about 2% or less, about 1.5% or less, or about 1.0% or less. When the total light transmittance and haze are within the above ranges, the image provided by the printed layer of the decorative film can be made clearer. Haze is determined according to JIS K 7136:2000 (ISO 14782:1999).

（Ｔｇ_１：成分１のホモポリマーのガラス転移温度
Ｔｇ_２：成分２のホモポリマーのガラス転移温度
・・・
Ｔｇ_ｎ：成分ｎのホモポリマーのガラス転移温度
Ｘ_１：重合の際に添加した成分１のモノマーの質量分率
Ｘ_２：重合の際に添加した成分２のモノマーの質量分率
・・・
Ｘ_ｎ：重合の際に添加した成分ｎのモノマーの質量分率
Ｘ_１＋Ｘ_２＋・・・＋Ｘ_ｎ＝１） In some embodiments, the transparent protective layer has a glass transition temperature (Tg) of about 25° C. or higher, or about 28° C. or higher, and about 40° C. or lower, or about 35° C. or lower. By setting the glass transition temperature of the transparent protective layer within the above range, both excellent elongation properties and bending properties can be imparted to the decorative film. The glass transition temperature (Tg) of the transparent protective layer is determined by the following FOX formula (Fox, TG, Bull. Am. Phys. Soc., 1 (1956), p. 123) as a calculated glass transition temperature.

(Tg ₁ : glass transition temperature of homopolymer of component 1 Tg ₂ : glass transition temperature of homopolymer of component 2 ...
Tg _n : Glass transition temperature of homopolymer of component n X ₁ : Mass fraction of monomer of component 1 added during polymerization X ₂ : Mass fraction of monomer of component 2 added during polymerization ...
X _n : mass fraction of component n monomer added during polymerization X ₁ +X ₂ +...+X _n =1)

The decorative film may further include an adhesive layer disposed on the base film layer opposite the printed layer. FIG. 1 shows an adhesive layer 18 disposed on the base film layer 12 opposite the print layer 14 . The adhesive layer is generally formed using a solvent-based, emulsion-based, pressure-sensitive, heat-sensitive, heat-curable or ultraviolet-curable adhesive such as acrylic, polyolefin, polyurethane, polyester, or rubber. can do.

The thickness of the adhesive layer can generally be greater than or equal to about 3 μm, greater than or equal to about 5 μm, or greater than or equal to about 10 μm, less than or equal to about 100 μm, less than or equal to about 80 μm, or less than or equal to about 50 μm.

In one embodiment the adhesive layer is a pressure sensitive adhesive layer. For the purpose of adjusting the adhesive strength of the pressure-sensitive adhesive layer, the pressure-sensitive adhesive layer may contain elastic microspheres including polyester, polystyrene, acrylic resin, polyurethane, and the like.

A liner may be arranged on the surface of the adhesive layer. Examples of liners include paper such as kraft paper, polymers such as polyethylene, polypropylene, polyester, cellulose acetate, and paper coated with these polymers. These liners may have a release treated surface with silicones, fluorocarbons, and the like. The thickness of the liner can generally be greater than or equal to about 5 μm, greater than or equal to about 15 μm, or greater than or equal to about 25 μm, less than or equal to about 300 μm, less than or equal to about 200 μm, or less than or equal to about 150 μm.

The adhesive layer may have a microstructured surface with communicating channels extending to the outer edge of the adhesive layer. When the decorative film is applied to the adherend, air bubbles sandwiched between the decorative film and the adherend can be discharged to the outside through the communicating passages of the microstructured surface. In this embodiment, the liner may have a relief structure on its release surface that corresponds to the microstructured surface of the adhesive layer. The liner may be the same as that used in forming the microstructured surface of the adhesive layer, or it may be different.

Other layers may be laminated onto the base film layer, such as decorative layers such as metal layers, receptor layers for printed inks, and the like. These layers may be joined by a joining layer. The decoration layer may be arranged so as to correspond to the entire surface of the decoration film, or may be arranged so as to correspond to a part or a plurality of parts.

The metal layer can be formed by depositing a metal such as indium, tin, chromium, etc. on the base film layer or other layers of the decorative film by evaporation, sputtering, or the like. A pattern or picture can also be formed using a metal mask or the like during vapor deposition or sputtering. The thickness of the metal layer can vary and can generally be greater than or equal to about 5 nm, greater than or equal to about 10 nm, or greater than or equal to about 20 nm, less than or equal to about 10 μm, less than or equal to about 5 μm, or less than or equal to about 2 μm.

Various resin films can be used as receptor layers for printing inks. The resin constituting the receptor layer is not particularly limited, but acrylic polymers, polyolefins, polyvinyl acetals, phenoxy resins and the like can be used. The glass transition temperature of the resin forming the receptor layer can generally be about 0° C. or higher and about 100° C. or lower. By setting the glass transition temperature within the above range, a clear image can be obtained by toner transfer or ink printing without impairing the flexibility of the decorative film as a whole. The thickness of the receptor layer can generally be greater than or equal to about 2 μm, greater than or equal to about 5 μm, or greater than or equal to about 10 μm, less than or equal to about 50 μm, less than or equal to about 40 μm, or less than or equal to about 30 μm.

The bonding layer that joins the layers that make up the decorative film is generally solvent-based, emulsion-based, pressure-sensitive, heat-sensitive, heat-curable or ultraviolet-curable, such as acrylic, polyolefin, polyurethane, polyester, or rubber. Includes mold adhesive. The thickness of the bonding layer can generally be greater than or equal to about 1 μm, greater than or equal to about 2 μm, or greater than or equal to about 5 μm, less than or equal to about 50 μm, less than or equal to about 40 μm, or less than or equal to about 30 μm.

In one embodiment, the printed layer has a printed image pattern, the transparent protective layer has a three-dimensional shape pattern by inkjet printing, and the printed image pattern and the three-dimensional shape pattern are synchronized. Since the printed image pattern and the three-dimensional shape pattern of the transparent protective layer are synchronized, the texture can be emphasized both visually and tactilely.

A decorative film in which a printed image pattern and a three-dimensional shape pattern of a transparent protective layer are synchronized is produced by, for example, a step of providing image data of the printed layer and converting the image data of the printed layer into grayscale to generate grayscale image data. a step of inverting the tone of the grayscale image data to generate image data of the transparent protective layer, a step of adjusting the tone curve of the image data of the transparent protective layer as necessary, and an image data of the printing layer Based on the step of forming a print layer on the base film layer by inkjet printing using UV curable CMYK inks, and based on the image data of the transparent protective image, by inkjet printing using UV curable transparent inks and forming a transparent protective layer on the printed layer.

The step of forming the printed layer and the step of forming the transparent protective layer may be performed continuously. The step of forming the printing layer and the step of forming the transparent protective layer may be carried out in one device with multiple inkjet printheads. The inkjet printer can reciprocate the printed material (for example, the base film layer) so that the process of forming the transparent protective layer can be repeated multiple times to form a transparent protective layer with a large unevenness on the surface. A transport device may be provided, and a plurality of inkjet print heads with a transparent protective layer may be provided.

The printed image pattern and the three-dimensional shape pattern of the transparent protective layer are obtained by arranging the inkjet print head for the printed layer and the inkjet print head for the transparent protective layer in series in an inkjet printing apparatus, and the image data of the printed layer and the transparent layer obtained by the above method. By printing the printed layer and the transparent protective layer in succession based on the image data of the protective layer, respectively, it is possible to achieve more accurate synchronization.

The printed image pattern and the three-dimensional shape pattern of the transparent protective layer may be repeated in one decorative film, or may be a non-repeating pattern. By using inkjet printing, not only repeating patterns but also non-repeating patterns can be easily formed. Embossing using an embossing roll cannot form a non-repeating three-dimensional shape pattern longer than the circumference of the embossing roll. By using a non-repetitive pattern, it is possible to increase the degree of design freedom and manufacture a decorative film having a one-of-a-kind design.

In some embodiments, the decorative film has an elongation at break of about 15% or more, about 20% or more, or about 30% or more at 20° C. and does not crack in a 45 degree bend test. The elongation at break is determined by cutting the decorative film to a length of about 150 mm and a width of 25 mm to prepare a sample, and using a tensile tester to perform a tensile test at a test length of 100 mm and a tensile speed of 300 mm/min at 20°C. can do. For the 45-degree bending test, a sample was prepared by cutting the decorative film into a length of about 150 mm and a width of 25 mm, and the sample was attached to an aluminum plate (A5052) having a length of 170 mm, a width of 30 mm, and a thickness of 5 mm, and left overnight. After that, the aluminum plate to which the sample is attached is bent at 45 degrees using a coating film bending tester under the conditions of a mandrel diameter of 3 mm and an auxiliary plate thickness of 3 mm in accordance with JIS K 5600-5-1: 1999. This can be done by visually observing the presence or absence of cracks in the bent portion.

In one embodiment, the decorative film has a pencil hardness of 2B or higher, B or higher, or HB or higher as measured according to JIS K 5600-5-4:1999. When the pencil hardness of the decorative film is within the above range, it is possible to prevent deterioration due to scratches on the surface of the decorative film.

The total thickness of the decorative film can generally be greater than or equal to about 50 microns, greater than or equal to about 60 microns, or greater than or equal to about 70 microns, less than or equal to about 700 microns, less than or equal to about 600 microns, or less than or equal to about 500 microns. The total decorative film thickness does not include the liner thickness.

Decorative films can be adhered to the surfaces of various adherends, and can be applied to, for example, concrete, glass, painted boards, flooring materials, wallpaper, gypsum boards, and the like. The adherend may be a part of a building structure, such as walls, windows, floors, ceilings, columns, and the like.

The following examples illustrate specific embodiments of the present disclosure, but the invention is not limited thereto. All parts and percentages are by weight unless otherwise specified.

Table 1 shows the materials and reagents used in this example.

<Evaluation method>
1. Maximum Surface Depth The maximum depth of the decorative film surface is measured using a digital microscope DSX510 (Olympus Co., Ltd., Shinjuku-ku, Tokyo, Japan). Select the location with the greatest height difference from the profile and measure it as the maximum surface depth.

2. Observation of texture Comparison with 3M (registered trademark) Dynoc (registered trademark) film TE-1650 (3M Japan Co., Ltd., Shinagawa-ku, Tokyo, Japan) when the decorative film is observed at an angle of 10 degrees from the vertical direction of the film surface. If the texture is visually recognizable, it is considered good. If the texture is not visible because the height difference of the unevenness on the surface is smaller than that of TE-1650, it is regarded as defective.

3. Elongation at Break and Yield Point A sample is prepared by cutting the decorative film into a length of about 150 mm and a width of 25 mm. Using a tensile tester (Tensilon universal testing machine, model number: RTC-1210A, A&D Co., Ltd., Toshima-ku, Tokyo, Japan), a test length of 100 mm, a tensile speed of 300 mm / min, and a tensile test at 20 ° C. Measure the elongation at break and yield point.

4.45 degree bending test A sample is prepared by cutting the decorative film into a length of about 150 mm and a width of 25 mm. After removing the liner, the sample is attached to an aluminum plate (A5052) with a length of 170 mm, a width of 30 mm and a thickness of 5 mm. After left overnight, the aluminum plate with the sample attached was subjected to a PI-801 coating film bending tester under the conditions of a mandrel diameter of 3 mm and an auxiliary plate thickness of 3 mm in accordance with JIS K 5600-5-1: 1999. (Tester Sangyo Co., Ltd., Miyoshi-cho, Iruma-gun, Saitama, Japan) is used to bend at 45 degrees. If no visible cracks, ruptures, or peeling from the aluminum plate were observed in the decorative film at the bend, it was judged as good, and if any cracks, ruptures, or peelings from the aluminum plate were visually observed, it was judged as unsatisfactory.

5. Chemical resistance A decorative film is attached to a 5 mm thick acrylic resin substrate. After 2 hours, the sample is immersed in ethanol, 10% NaOH aqueous solution, or 10% hydrochloric acid for 25 hours. After removing the sample from these chemicals, visually inspect the surface of the test piece. If no abnormality is visually observed on the surface of all the chemicals, it is judged as good, and if at least one kind of chemical is visually observed to have corrosion, discoloration, or other abnormality, it is judged as defective.

6. Pencil Hardness A sample is prepared by attaching a decorative film to an aluminum plate (A5052). Using the obtained sample, the scratch hardness by the pencil method is evaluated according to JIS 5600-5-4:1999. Record the hardness of the hardest pencil with no visible scratch marks.

7. Thickness of Transparent Protective Layer The thickness of the transparent protective layer is measured using a thickness measuring device PC-465N (Tester Sangyo Co., Ltd., Miyoshi-cho, Iruma-gun, Saitama, Japan). The sample is sandwiched between the measuring table and the measuring probe, and the measurement is performed three times to obtain the average value. The thickness of the transparent protective layer is obtained by measuring the total thickness of the transparent protective layer and the base film layer and subtracting the thickness of the base film layer.

<Preparation of UV curable transparent inks A to G>
UV curable transparent inks A to G were prepared by mixing the components shown in Table 2. The numerical values in Table 2 are the blending amounts (parts by mass) of each component. The calculated glass transition temperature was determined using the FOX equation based on the components and composition of the UV curable transparent ink.

<Example 1>
Using an inkjet printer UJF-3042FX (Mimaki Engineering Co., Ltd., Tomi City, Nagano Prefecture, Japan), control tack (registered trademark) graphic film 180-10 inkjet material (3M Japan Co., Ltd., Shinagawa-ku, Tokyo, Japan). The decorative film of Example 1 was made by printing UV curable clear ink A with a textured clear carbon fiber pattern. The device profile of the inkjet printer was set to color management off, 600×720 dpi, VD (variable dot size mode), ink limit 100%, and number of prints 6.

<Examples 2 to 5>
Decorative films of Examples 2 to 5 were produced in the same manner as in Example 1, except that the number of printing times was changed to form a thicker transparent protective layer.

<Comparative Example 1>
A decorative film of Comparative Example 1 was prepared in the same manner as in Example 1, except that a commercially available UV curable transparent ink LH-100 (Mimaki Engineering Co., Ltd., Tomi City, Nagano Prefecture, Japan) was used instead of UV curable transparent ink A. was made. LH-100 is composed of multifunctional acrylate monomers such as hexamethylene diacrylate.

<Comparative Example 2>
A decorative film of Comparative Example 2 was produced in the same manner as in Example 1, except that UV curable transparent ink B was used instead of UV curable transparent ink A.

<Examples 6 and 7>
Decorative films of Examples 6 and 7 were prepared in the same manner as in Example 1, except that UV curable transparent inks C and D were used instead of UV curable transparent ink A.

<Example 8>
A decorative film of Example 8 was prepared in the same manner as in Example 1, except that UV curable transparent ink E was used instead of UV curable transparent ink A.

<Examples 9 and 10>
Decorative films of Examples 9 and 10 were prepared in the same manner as in Example 1, except that UV curable transparent inks F and G containing reactive polysiloxane were used instead of UV curable transparent ink A.

Table 3 shows the evaluation results of Examples 1 to 10 and Comparative Examples 1 and 2.

Some of the embodiments of the present invention are described in aspects 1-10 below.
[Aspect 1]
a base film layer;
a printing layer disposed on the base film layer;
A transparent protective layer covering at least part of the printed layer, the transparent protective layer having a three-dimensional shape and being inkjet-printed with a UV-curable transparent ink;
A decorative film having a texture, comprising
The transparent protective layer at least partially has a thickness of 7 μm or more,
The decorative film has an elongation at break of 15% or more at 20° C. and does not crack in a 45° bending test.
[Aspect 2]
a base film layer;
a printing layer disposed on the base film layer;
A transparent protective layer covering at least part of the printed layer, the transparent protective layer having a three-dimensional shape and being inkjet-printed with a UV-curable transparent ink;
A decorative film having a texture, comprising
A decorative film, wherein the UV curable transparent ink contains 50% by mass or more of a monofunctional monomer.
[Aspect 3]
The decorative film according to aspect 2, wherein the monofunctional monomer has a (meth)acryloyl group.
[Aspect 4]
4. The decorative film of any of aspects 1-3, further comprising an adhesive layer disposed on the base film layer opposite the printed layer.
[Aspect 5]
The pencil hardness of the decorative film is JIS K. 5600-5-4:1999, is 2B or greater, according to any of aspects 1-4.
[Aspect 6]
The decorative film according to any one of aspects 1 to 5, wherein the transparent protective layer has a total light transmittance of 90% or more and a haze of 2% or less.
[Aspect 7]
The decorative film according to any one of aspects 1 to 6, wherein the transparent protective layer has a glass transition temperature of 25°C to 40°C.
[Aspect 8]
The decorative film of any of aspects 1-7, wherein the base film layer is a polyvinyl chloride film.
[Aspect 9]
The decorative film of any one of aspects 1-8, wherein the UV curable transparent ink comprises a reactive siloxane.
[Aspect 10]
Any one of aspects 1 to 9, wherein the printed layer has a printed image pattern, the transparent protective layer has a three-dimensional shape pattern formed by inkjet printing, and the printed image pattern and the three-dimensional shape pattern are synchronized. The decorative film as described in kani.

REFERENCE SIGNS LIST 10 decorative film 12 base film layer 14 printing layer 16 transparent protective layer 18 adhesive layer

Claims (9)

a base film layer;
a printing layer disposed on the base film layer;
A transparent protective layer covering at least a part of the printed layer, the transparent protective layer having a three-dimensional shape inkjet-printed with a UV curable transparent ink, for interior and exterior walls of a building, having a texture. A decorative film,
The transparent protective layer at least partially has a thickness of 7 μm or more,
The base film layer has a thickness of 10 μm or more and 200 μm or less,
The decorative film has an elongation at break of 15% or more at 20° C. and does not crack in a 45° bending test. a base film layer;
a printing layer disposed on the base film layer;
A transparent protective layer covering at least a part of the printed layer, the transparent protective layer having a three-dimensional shape inkjet-printed with a UV curable transparent ink, for interior and exterior walls of a building, having a texture. A decorative film,
The base film layer has a thickness of 10 μm or more and 200 μm or less,
The UV curable transparent ink contains 50% by mass or more of a monofunctional monomer,
The monofunctional monomer has a (meth)acryloyl group,
The monofunctional monomer contains 40 parts by mass to 100 parts by mass in total of at least one of an alicyclic (meth)acrylate and a cyclic ether-containing (meth)acrylate based on 100 parts by mass of the monofunctional monomer . the film. 3. The decorative film of claim 1 or 2 , further comprising an adhesive layer disposed on the base film layer opposite the printed layer. The decorative film according to any one of claims 1 to 3 , wherein the decorative film has a pencil hardness of 2B or more when measured in accordance with JIS K 5600-5-4:1999. The decorative film according to any one of claims 1 to 4 , wherein the transparent protective layer has a total light transmittance of 90% or more and a haze of 2% or less. The decorative film according to any one of claims 1 to 5 , wherein the transparent protective layer has a glass transition temperature of 25°C to 40°C. Decorative film according to any one of the preceding claims, wherein the base film layer is a polyvinyl chloride film. The decorative film according to any one of claims 1 to 7 , wherein said UV curable transparent ink comprises reactive siloxane. The printed layer has a printed image pattern, the transparent protective layer has a three-dimensional shape pattern by inkjet printing, and the printed image pattern and the three - dimensional shape pattern are synchronized. A decorative film according to any one of the preceding claims.

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