JP7485553B2 - Decorative film manufacturing method and decorative film - Google Patents

Description

The present invention relates to a decorative film manufacturing method and a decorative film.

Conventionally, decorative films have been used to impart design to automobiles and the like, as disclosed in, for example, Patent Document 1. The decorative film in Patent Document 1 has a laminated structure in which a surface layer having an uneven shape that forms a grain pattern is laminated with other layers such as a base layer, and is attached to an adherend via an adhesive layer.

In this case, it is preferable to prevent swelling caused by air trapped between the decorative film and the adherend. If a release liner having an uneven shape, such as that disclosed in Patent Document 2, is applied to the decorative film of Patent Document 1, the uneven shape of the release liner is transferred to the adhesive layer, and recesses that allow air to escape are formed in the adhesive layer. Therefore, this type of configuration can prevent swelling.

JP 2019-202448 A JP 2006-70273 A

However, when producing a decorative film of the above-mentioned form, if a surface layer and a release liner having an uneven shape are formed and then laminated with other layers, the surface layer and the release liner having an uneven shape must be formed separately in advance, which is time-consuming.

The present invention was made in consideration of such problems, and aims to provide a decorative film manufacturing method and decorative film that can improve productivity.

In order to achieve the above-mentioned object, the decorative film manufacturing method of the present invention involves pressing a laminate in which a skin layer, a base layer, an adhesive layer, and a release liner are stacked along a stacking direction, from the skin layer toward the release liner , thereby forming an uneven shape in the skin layer and deforming the base layer, the adhesive layer, and the release liner to correspond to the uneven shape.

In order to achieve the above-mentioned object, the decorative film of the present invention comprises a skin layer, a base layer, an adhesive layer, and a release liner laminated in this order along the lamination direction, the skin layer having an uneven shape, and the base layer, the adhesive layer, and the release liner having uneven shapes corresponding to the uneven shape.

According to the invention having the above configuration, the surface layer and release liner having an uneven shape are formed simultaneously, which improves productivity.

FIG. 2 is a side view of the decorative film according to the embodiment. FIG. 2 is a side view of the decorative film with the release liner removed. FIG. 2 is a side view showing a laminate to be processed into a decorative film. 1A to 1C are diagrams illustrating a method for manufacturing a decorative film according to a first embodiment. 11A to 11C are diagrams showing articles used in a decorative film manufacturing method according to a second embodiment. 11A to 11C are diagrams illustrating a decorative film manufacturing method according to a second embodiment. 13A to 13C are diagrams illustrating a decorative film manufacturing method according to a third embodiment. 13A to 13C are diagrams showing articles used in a decorative film manufacturing method according to a fourth embodiment. 13A to 13C are diagrams illustrating a decorative film manufacturing method according to a fourth embodiment. FIG. 11 is a side view showing another example of a decorative film different from the embodiment.

Hereinafter, an embodiment of the present invention will be described with reference to the attached drawings. Note that the dimensional ratios in the drawings have been exaggerated for the convenience of explanation and differ from the actual ratios.

First Embodiment
1, the decorative film 100 of the first embodiment has, in this order in the stacking direction, a skin layer 110, a decorative layer 120 (substrate layer), an adhesive layer 130, and a release liner 140. The skin layer 110 has an uneven shape 111, and the decorative layer 120, the adhesive layer 130, and the release liner 140 also have uneven shapes corresponding to the uneven shape 111.

The uneven shape 111 of the skin layer 110 imparts design to the surface of the decorative film 100, forming some kind of pattern. The pattern formed by the uneven shape 111 is, for example, a grain pattern that imitates natural leather, but is not limited to this, and may be, for example, cloth grain, stone grain, sand grain, wood grain, lines, hairlines, etc., or may be letters, symbols, geometric figures, designs, etc. Furthermore, the pattern formed by the uneven shape 111 may be regular or irregular.

The skin layer 110 is light-transmitting, and the decorative layer 120 is visible through the skin layer 110. As long as the decorative layer 120 is visible, there is no particular limitation on the degree of transmittance of the skin layer 110 in the visible light range.

The material forming the skin layer 110 is, for example, a resin such as polyvinylidene fluoride (PVDF), but is not limited to this, and may be other resins such as ethylene tetrafluoroethylene (ETFE). The thickness of the skin layer 110 is, for example, 5 μm to 100 μm, but is not limited to this.

The decorative layer 120 includes, for example, color and patterns, which provide a decorative effect. The material from which the decorative layer 120 is formed is, for example, polyvinyl chloride (PVC) resin, acrylic resin, etc., but is not limited to these. The thickness of the decorative layer 120 is, for example, 50 μm to 400 μm, but is not limited to this.

The adhesive layer 130 is formed from an adhesive such as an acrylic adhesive, a urethane adhesive, or a silicone adhesive, but the material from which the adhesive layer 130 is formed is not limited to these. The thickness of the adhesive layer 130 is, for example, 20 μm to 80 μm, but is not limited to this.

The release liner 140 is disposed so as to be releasable from the adhesive layer 130. The release liner 140 has a configuration in which a release agent layer is provided on the surface of a film substrate or a paper substrate, for example, but there is no particular limitation on the configuration. The thickness of the release liner 140 is, for example, 30 μm to 100 μm, but is not limited to this.

As shown in FIG. 2, the decorative film 100 is used by removing the release liner 140, and is attached to an adherend via the adhesive layer 130. The surface of the adhesive layer 130 facing the release liner 140 has an inverted shape of the uneven shape of the release liner 140, and recesses 150 are formed.

When the decorative film 100 is applied to an adherend, the recesses 150 allow air between the adherend and the decorative film 100 to escape, suppressing swelling of the decorative film 100. The decorative film 100 is used, for example, to decorate the interior and exterior of a vehicle such as an automobile, but the adherend to be decorated is not particularly limited and may be, for example, a home appliance or miscellaneous goods.

Next, we will explain the decorative film manufacturing method.

As shown in FIG. 3, in the decorative film manufacturing method of the embodiment, the decorative film 100 is produced by creating irregularities in a flat sheet-like laminate 500. The laminate 500 has a different shape from the decorative film 100, but has a structure in which layers made of the same material as the decorative film 100 are laminated, and has a skin layer 110, a decorative layer 120, an adhesive layer 130, and a release liner 140 in this order in the lamination direction. Unlike the decorative film 100, each of these layers has a flat shape.

As shown in FIG. 4, in this embodiment, unevenness is created in the laminate 500 by a pair of opposing rollers R1 and R2, producing the decorative film 100. Specifically, the rollers R1 and R2 press the laminate 500 in the stacking direction of the layers that make it up, thereby forming an uneven shape 111 in the skin layer 110 and deforming the decorative layer 120, adhesive layer 130, and release liner 140 to correspond to the uneven shape 111, producing the decorative film 100.

Roller R1 has an uneven surface R10 on its outer periphery, which is the inverse of uneven surface 111, and roller R2 has a smoother, arc-shaped outer periphery compared to roller R1. The laminate 500 is supplied between rollers R1 and R2 with the skin layer 110 side facing roller R1 and the release liner 140 side facing roller R2.

At least one of the rollers R1 and R2 has an internal heat source, such as a heater, and applies heat to the laminate 500 to soften it while pressing it. The rollers R1 and R2 are preferably made of metal, but their materials are not particularly limited.

The laminate 500 is long and is continuously fed between the rollers R1 and R2, and the rollers R1 and R2 continuously press the laminate 500. The laminate 500 is transported, for example, by a roll-to-roll method.

Next, the effects of this embodiment will be described.

In this embodiment, the skin layer 110 having the uneven shape 111 is formed, and at the same time, the release liner 140 having the uneven shape corresponding thereto is formed, which eliminates the need to form them separately and improves productivity.

In addition, in this embodiment, the long laminate 500 is continuously fed between the rollers R1 and R2, which continuously press the laminate 500 to process it into the decorative film 100. This increases the productivity of the decorative film 100.

Second Embodiment
5, the decorative film manufacturing method of the second embodiment uses a sheet-shaped laminate 500A. The laminate 500A has a different shape from the laminate 500 of the first embodiment, but has a structure in which layers of the same material as the laminate 500 are laminated, and has a surface layer 110, a decorative layer 120, an adhesive layer 130, and a release liner 140 in this order in the lamination direction.

The laminate 500A is placed between an upper mold P1 and a lower mold P2 that are relatively close to each other and spaced apart. The upper mold P1 has an uneven shape P10 on the surface facing the lower mold P2. The surface of the lower mold P2 that faces the upper mold P1 is a smooth flat surface compared to the surface of the upper mold P1 on which the uneven shape P10 is provided. The laminate 500A is placed between the upper mold P1 and the lower mold P2 with the skin layer 110 side facing the upper mold P1 and the release liner 140 side facing the lower mold P2.

As shown in FIG. 6, the upper mold P1 and the lower mold P2 are close to each other and press the laminate 500A in the stacking direction of each layer that constitutes it. This produces the decorative film 100A. At least one of the upper mold P1 and the lower mold P2 has an internal heat source, such as a heater, and applies heat to the laminate 500A to soften it while pressing it.

Unlike the long decorative film 100 of the first embodiment, the decorative film 100A is in the form of a sheet of paper, but the materials of the layers that are stacked and the uneven shapes of each layer are the same as those of the first embodiment.

In this embodiment, as in the first embodiment, the surface layer 110 and the release liner 140 are simultaneously textured, eliminating the need to form them separately and improving productivity.

In addition, by using the sheet-like laminate 500A as in this embodiment, it is possible to produce only the decorative film 100A required, thereby reducing inventory.

Third Embodiment
As shown in FIG. 7, the decorative film manufacturing method of the third embodiment differs from the first embodiment in that a process paper 1000 having an uneven surface 1001 is used.

The process paper 1000 has a configuration in which the uneven shape 1001 is formed on the surface of a paper base material such as fine paper, medium quality paper, glassine paper, art paper, coated paper, and cast coated paper, but is not limited to this. The process paper 1000 may have a configuration in which the uneven shape 1001 is formed on the surface of a resin film that has good heat resistance, for example. The process paper 1000 may also have a release agent layer on the surface on which the uneven shape 1001 is formed. The thickness of the process paper 1000 is, for example, 5 μm to 300 μm, but is not limited to this.

The uneven shape 1001 is an inverted shape of the uneven shape 111 formed in the decorative film 100, and is formed, for example, by embossing, but there is no particular limit to how it is formed. For example, the uneven shape 1001 may be formed by separately attaching convex portions to the surface of a smooth substrate.

The process paper 1000 is fed between rollers R3 and R4 together with the laminate 500 similar to that of the first embodiment. Both rollers R3 and R4 have an arc-shaped outer peripheral surface that is smoother than the surface of the process paper 1000 on which the uneven shape 1001 is provided. The rollers R3 and R4 are preferably made of metal, but their material is not particularly limited.

The process paper 1000 and the laminate 500 are fed between the rollers R3 and R4 so that the uneven shape 1001 of the process paper 1000 faces the surface layer 110 of the laminate 500. When the process paper 1000 and the laminate 500 pass between the rollers R3 and R4, they are pressed in the thickness direction by the rollers R3 and R4, and the surface of the process paper 1000 having the uneven shape 1001 is pressed against the surface layer 110 of the laminate 500. As a result, the uneven shape 111 is formed on the surface layer 110, and the decorative layer 120, the adhesive layer 130, and the release liner 140 are deformed in response to the uneven shape 111, and the decorative film 100 is produced.

The process paper 1000 and the laminate 500 have a long shape, and are continuously fed between the rollers R3 and R4, and pressed by the rollers R3 and R4 continuously. At least one of the rollers R3 and R4 has a heat source, such as a heater, inside, and applies heat to the laminate 500 to soften it while pressing it.

The process paper 1000 has the strength and heat resistance to maintain the uneven shape 1001 against the force and heat applied from the rollers R3 and R4. The heat resistance temperature of the process paper 1000 is, for example, 150°C or higher, preferably 170°C or higher, but is not limited thereto. The process paper 1000 and the laminate 500 are each transported, for example, by a roll-to-roll method.

In this embodiment, a process paper 1000 is used as a processing means for creating unevenness in the laminate 500, which is relatively inexpensive compared to the roller with an uneven shape formed on its outer circumferential surface as in the first embodiment. Therefore, in addition to the effects of the first embodiment, this embodiment has the effect of reducing manufacturing costs.

In addition, when using a roller with an uneven surface formed on its outer periphery as in the first embodiment, the roller must be changed in order to change the uneven surface 111 formed on the decorative film 100. In that case, the roller must be removed from and reattached to the manufacturing device, and this replacement work is extensive and time-consuming.

On the other hand, in this embodiment, to change the uneven shape 111 formed on the decorative film 100, it is sufficient to change the process paper 1000, and there is no need to replace the rollers, which is time-consuming, and therefore productivity can be improved.

In addition, as in the first embodiment, when the uneven shape R10 is formed on the surface of the roller R1, the circumferential dimension of one pattern of the pattern formed thereby is at most equal to the length of the circumference of the roller R1 and is limited within that length range.

On the other hand, if a continuous, long process paper 1000 is used as in this embodiment, the pattern dimensions are not limited as with the roller R1 in the first embodiment, so a longer pattern can be used.

Fourth Embodiment
As shown in Fig. 8, the decorative film manufacturing method of the fourth embodiment is different from that of the second embodiment in that a process sheet 1000A is used. In addition, in this embodiment, an upper mold P3 different from that of the second embodiment is used. In other respects, this embodiment is similar to the second embodiment.

The process paper 1000A has a different shape from the process paper 1000 of the third embodiment, being in the form of a sheet of paper, but the material and the uneven shape 1001 formed on the surface are the same as those of the process paper 1000 of the third embodiment.

The surface of the upper die P3 facing the lower die P2 is smoother than the surface of the process paper 1000A on which the uneven shape 1001 is formed. In other respects, the upper die P3 is similar to the upper die P1 of the second embodiment.

As shown in FIG. 9, in this embodiment, the upper mold P3 and the lower mold P2 are brought close to each other and press the process paper 1000A and the laminate 500A to produce the decorative film 100A. The decorative film 100A itself that is produced is the same as in the second embodiment.

In this embodiment, since the process paper 1000A is used, in addition to the effect of the second embodiment, the effect of reducing manufacturing costs can be obtained, as in the third embodiment.

In the third embodiment, the transfer is performed continuously using a continuous process paper 1000, but in this embodiment, the transfer is performed for each sheet-shaped process paper 1000A and each laminate 500A. This allows the transfer to be performed in small quantities while changing the process paper 1000A depending on the type of decorative film 100A required, making it suitable for high-mix low-volume production.

In addition, when producing decorative films 100A with different concave and convex shapes, the process paper 1000A can be changed, eliminating the need to replace the upper mold P3, which is time-consuming, and thus improving productivity.

The present invention is not limited to the above-described embodiment, and various modifications can be made within the scope of the claims. For example, the decorative film or laminate may further include layers other than those shown in Figures 1 and 3.

In the third embodiment, the configuration in which the process paper 1000 is wrapped around the outer periphery of the roller R3 is also included in the scope of the present invention.

The uneven shape formed on the decorative film is also not limited to the above embodiment, but varies depending on the design of the decorative film. For example, as shown in FIG. 10, uneven shape 111B having wider convex portions and narrower concave portions compared to the above embodiment is also included in the present invention.

The decorative film 100B shown in FIG. 10 can also be produced by a manufacturing method similar to that of the above embodiment, and in this case, the surface shapes of the roller, upper die, and process paper used in the manufacturing process are the inverse shapes of the uneven shape 111B.

Furthermore, the scope of the present invention is not limited to configurations in which the uneven shape is formed only by convex portions and concave portions with a fixed width, as in the above embodiment and the example shown in FIG. 10, but also includes configurations in which the uneven shape is formed by convex portions and concave portions with different widths.

100, 100A, 100B Decorative film,
110 epidermis layer,
111, 111B uneven shape,
120 Decorative layer (substrate layer),
130 adhesive layer,
140 Release liner,
150 recessed portion,
500, 500A laminate,
1000, 1000A process paper,
P1, P3 Upper mold,
P2 Lower die,
R1, R2, R3, R4 Roller.

Claims (5)

A laminate in which a surface layer, a base layer, a pressure-sensitive adhesive layer, and a release liner are laminated in a lamination direction is pressed from the surface layer toward the release liner ,
A method for producing a decorative film, comprising forming an uneven shape on the surface layer, and deforming the base layer, the pressure-sensitive adhesive layer, and the release liner to correspond to the uneven shape. The decorative film manufacturing method according to claim 1, in which the long laminate is continuously fed between a pair of rollers facing each other, and the pressing is continuously performed by the rollers. The decorative film manufacturing method according to claim 1, in which the pressing is performed for each of the laminated sheets. The decorative film manufacturing method according to any one of claims 1 to 3, in which a process paper having a surface with an inverted uneven shape of the uneven shape is used, and the surface of the process paper is pressed against the skin layer to perform the pressing. a surface layer, a base layer, a pressure-sensitive adhesive layer, and a release liner are laminated in this order along a lamination direction;
A decorative film, wherein the surface layer has an uneven shape, and the base layer, the pressure-sensitive adhesive layer, and the release liner also have uneven shapes corresponding to the uneven shape.