JPWO2020153137A1 - Structure, decorative film, method of manufacturing the structure, and method of manufacturing the decorative film - Google Patents

Abstract

The structure according to one form of the present technology includes a decorative portion and a member. The decorative portion has a first surface, a second surface, a metal layer, and a light-shielding portion. The second surface is a surface opposite to the first surface. The metal layer has fine cracks. The light-shielding portion is formed in the gap between the fine cracks or at least one of the metal layer and the second surface. The member has a decorated area to which the decorated portion is adhered so that the first surface faces the surface side.

Description

The present technology relates to a structure, a decorative film, a method for manufacturing a structure, and a method for manufacturing a decorative film, which are applicable to electronic devices, vehicles, and the like.

Conventionally, as housing parts for electronic devices and the like, members having a metallic appearance but capable of transmitting electromagnetic waves such as millimeter waves have been devised. For example, Patent Document 1 discloses an exterior component for mounting an automobile radar on an automobile emblem. For example, indium is vapor-deposited on a resin film, and this film is attached to the surface layer of the emblem by the insert molding method. This makes it possible to manufacture exterior parts that have a metallic luster decoratively and do not have an absorption region in the electromagnetic wave frequency band due to the island-like structure of indium (paragraph [0006] of the specification of Patent Document 1 and the like). ).

However, the method of forming an island-like structure of indium has a problem that it is difficult to form a uniform film thickness as a whole when the vapor deposition area is large. Further, there is a problem that the island-shaped structure is easily destroyed by the temperature of the resin poured into the housing component (paragraphs [0007] [0008] of the specification of Patent Document 1 and the like).

In order to solve this problem, Patent Document 1 discloses the following techniques. That is, a sea-island structure with a metal region as an island and a non-metal region surrounding this island as the sea is artificially formed with regularity. Then, each metal region is insulated from each other by a non-metal region, and the area of the metal region and the distance from the adjacent metal region are appropriately controlled. As a result, an electromagnetic wave-transmitting material comparable to the film on which indium is vapor-deposited can be obtained (paragraph [0013] of the specification of Patent Document 1 and the like).

Japanese Unexamined Patent Publication No. 2010-251899

As described above, there is a demand for a technique for manufacturing a member having a metallic luster, which can transmit radio waves and has a higher design.

In view of the above circumstances, the purpose of this technology is to provide a highly designed structure, decorative film, structure manufacturing method, and decorative film that has a metallic appearance but is capable of transmitting radio waves. The purpose is to provide a manufacturing method.

In order to achieve the above object, the structure according to one embodiment of the present technology includes a decorative portion and a member.
The decorative portion has a first surface, a second surface, a metal layer, and a light-shielding portion.
The second surface is a surface opposite to the first surface.
The metal layer has fine cracks.
The light-shielding portion is formed in the gap between the fine cracks or at least one of the metal layer and the second surface.
The member has a decorated area to which the decorated portion is adhered so that the first surface faces the surface side.

In this structure, a light-shielding portion is formed in the gap between fine cracks or at least one of the metal layer and the second surface. This makes it possible to suppress the light that passes through the gaps between the fine cracks. As a result, it is possible to realize a highly designed structure capable of transmitting radio waves while having a metallic appearance.

The light-shielding portion may include a gap light-shielding portion formed in the gaps of the fine cracks.

The light-shielding portion may include a light-shielding layer formed between the metal layer and the second surface.

The light-shielding portion includes a gap light-shielding portion formed in the gap between the fine cracks, and a light-shielding layer located between the metal layer and the second surface and integrally formed with the gap light-shielding portion. May include.

The decoration portion may include a decoration function portion formed in at least one of the gaps between the fine cracks or the metal layer and the second surface and having a decoration function.

The decoration function unit may have a decoration function utilizing at least one of transmission and reflection of light.

The decoration function unit may include a gap decoration function unit formed in the gaps of the fine cracks.

The decorative functional unit may include a decorative functional layer formed between the metal layer and the second surface.

The decoration function unit is located between the gap decoration function unit formed in the gap between the fine cracks and the metal layer and the second surface, and is integrated with the gap decoration function unit. It may include a decorative functional layer to be configured.

The metal layer may be any of aluminum, titanium, chromium, and an alloy containing at least one of these.

The metal layer may have a thickness of 30 nm or more and 300 nm or less.

The fine cracks may be included in the range of pitch of 1 μm or more and 500 μm or less.

The structure may be configured as at least a part of a housing component, vehicle, or building.

The decorative portion may have a fixing layer for immobilizing the fine cracks.

The decorative film according to one embodiment of the present technology includes a base film and the decorative portion formed on the base film.

A method for manufacturing a structure according to an embodiment of the present technology includes forming a metal layer on a base film by vapor deposition.
By stretching the base film, fine cracks are formed in the metal layer.
A decorative film including a metal layer on which the fine cracks are formed and a light-shielding portion formed on at least one of the gaps between the fine cracks or the surface opposite to the metal layer and the design surface. It is formed.
A transfer film is formed by adhering a carrier film to the decorative film.
Molded parts are formed so that the decorative film is transferred from the transfer film by an in-mold molding method, a hot stamping method, or a vacuum forming method.

In the method for manufacturing a structure according to another embodiment of the present technology, the metal layer in which the fine cracks are formed and the gap between the fine cracks or the surface on the opposite side of the metal layer and the design surface are used. A transfer film including a light-shielding portion formed on at least one of them is formed. Further, the molded part is formed so that the metal layer and the light-shielding portion peeled off from the base film are transferred by the in-mold molding method, the hot stamping method, or the vacuum forming method.

In the method for manufacturing a structure according to another embodiment of the present technology, a molded part is integrally formed with the decorative film by an insert molding method.

In the step of forming the fine cracks, the base film may be biaxially stretched at a stretch ratio of 5% or less in each axial direction.

A method for producing a decorative film according to an embodiment of the present technology includes forming a metal layer on a base film by vapor deposition.
By stretching the base film, fine cracks are formed in the metal layer.
A light-shielding portion is formed in the gap between the fine cracks or at least one of the metal layer and the surface opposite to the design surface.

It is a schematic diagram which shows the structural example of the mobile terminal as an electronic device which concerns on one Embodiment. It is a schematic cross-sectional view which shows the structural example of the metal decoration part shown in FIG. It is a photograph which magnified the surface state of a metal layer with a microscope. It is a photograph which magnified the surface state of a metal layer with a microscope. It is a schematic diagram which shows the structural example of the vacuum vapor deposition apparatus. It is a schematic diagram which shows the structural example of the biaxial stretching apparatus. It is a schematic diagram which shows the other structural example of a light-shielding part. It is a schematic diagram which shows the other structural example of a light-shielding part. It is a schematic cross-sectional view which shows the other structural example of a metal decoration part. It is a schematic diagram which shows the other structural example of the decoration function part. It is a schematic diagram which shows the other structural example of the decoration function part. It is a schematic diagram which shows the structural example when the light-shielding part and the decorative function part are combined. It is a schematic diagram for demonstrating the in-mold molding method. It is a schematic diagram for demonstrating an insert molding method. It is a schematic diagram which shows the structural example of the transfer film including a base film and a metal layer. It is sectional drawing which shows the structural example of the glossy film which concerns on other embodiment. It is a figure which shows the relationship between the thickness of the coating layer formed as a support layer, and the pitch of fine cracks.

Hereinafter, embodiments of the present technology will be described with reference to the drawings.

[Electronic device configuration]
FIG. 1 is a schematic diagram showing a configuration example of a mobile terminal as an electronic device according to an embodiment of the present technology. 1A is a front view showing the front side of the mobile terminal 100, and FIG. 1B is a perspective view showing the back side of the mobile terminal 100.

The mobile terminal 100 has a housing portion 101 and an electronic component (not shown) housed in the housing portion 101. As shown in FIG. 1A, a telephone unit 103, a touch panel 104, and a face-to-face camera 105 are provided on the front surface 102, which is the front side of the housing 101. The calling unit 103 is provided for talking to the other party of the telephone, and has a speaker unit 106 and a voice input unit 107. The voice of the other party is output from the speaker unit 106, and the voice of the user is transmitted to the other party via the voice input unit 107.

Various images and GUIs (Graphical User Interfaces) are displayed on the touch panel 104. The user can view still images and moving images via the touch panel 104. Further, the user inputs various touch operations via the touch panel 104. The face-to-face camera 105 is used when photographing a user's face or the like. The specific configuration of each device is not limited.

As shown in FIG. 1B, the back surface portion 108, which is the back surface side of the housing portion 101, is provided with a metal decoration portion 10 decorated so as to have a metallic appearance. The metal decoration portion 10 can transmit radio waves while having a metallic appearance.

As will be described in detail later, the decorated area 11 is formed in a predetermined area of the back surface portion 108. The metal decoration portion 10 is formed by adhering the decoration film 12 to the decoration area 11. Therefore, the decorated area 11 corresponds to the area where the metal decoration portion 10 is formed.

In the present embodiment, the decorative film 12 corresponds to the decorative portion. Further, the housing portion 101 on which the decorated region 11 is formed corresponds to the member. The structure according to the present technology is configured as a housing component by the housing portion 101 having the decorated area 11 and the decorative film 12 adhered to the decorated area 11. The structure according to the present technology may be used as a part of the housing component.

In the example shown in FIG. 1B, the metal decorative portion 10 is partially formed at substantially the center of the back surface portion 108. The position where the metal decoration portion 10 is formed is not limited and may be appropriately set. For example, the metal decorative portion 10 may be formed on the entire back surface portion 108. This makes it possible to give the entire back surface portion 108 a uniformly metallic appearance.

By making the other parts around the metal decoration part 10 have an appearance substantially equal to that of the metal decoration part 10, it is possible to give the entire back surface part 108 a uniform metallic appearance. In addition, it is possible to improve the design by giving the portion other than the metal decorative portion 10 another appearance such as wood grain. The position and size of the metal decorative portion 10, the appearance of other portions, and the like may be appropriately set so that the user can exhibit the desired design.

The decorative film 12 adhered to the decorated area 11 has a design surface 12a. The design surface 12a is a surface that can be visually recognized by a user who uses the mobile terminal 100, and is a surface that is one of the elements constituting the appearance (design) of the housing portion 101. In the present embodiment, the surface of the back surface portion 108 on the front surface side is the design surface 12a of the decorative film 12. That is, the surface opposite to the adhesive surface 12b (see FIG. 2) bonded to the decorated area 11 is the design surface 12a.

In the present embodiment, the design surface 12a corresponds to the first surface of the decorative portion. Further, the adhesive surface 12b (see FIG. 2) on the side opposite to the design surface 12a corresponds to the second surface on the side opposite to the first surface. The decorative film 12 is adhered to the decorated region 11 so that the design surface 12a is on the front side.

As an electronic component housed in the housing section 101, in the present embodiment, an antenna section 15 (see FIG. 2) capable of communicating with an external reader / writer or the like via radio waves is housed. The antenna unit 15 includes, for example, a base substrate (not shown), an antenna coil 16 formed on the base substrate (see FIG. 2), a signal processing circuit unit electrically connected to the antenna coil 16 (not shown), and the like. Have. The specific configuration of the antenna unit 15 is not limited. The electronic components accommodated in the housing portion 101 are not limited, and various electronic components such as IC chips and capacitors may be accommodated.

FIG. 2 is a schematic cross-sectional view showing a configuration example of the metal decoration portion 10. As described above, the metal decoration portion 10 is composed of a decoration region 11 formed in a region corresponding to the position of the antenna portion 15 and the like, and a decoration film 12 adhered to the decoration region 11. ..

The decorative film 12 has a base film 19, a metal layer 20, a sealing resin 21, and an adhesive layer 18.

The base film 19 is made of a transparent and stretchable material, and a resin film is typically used. As the material of the base film 19, for example, PET (polyethylene terephthalate), PC (polycarbonate), PMMA (polymethyl methacrylate), PP (polypropylene) and the like are used. Other materials may be used.

Since the base film 19 is a layer in contact with the metal, for example, when a vinyl chloride-based material is used, the liberated chlorine may accelerate the corrosion of the metal. Therefore, by selecting a non-vinyl chloride-based material as the base film 19, it is possible to prevent metal corrosion. Of course, it is not limited to this.

The surface of the base film 19, that is, the surface of the base film 19 opposite to the surface of the housing portion 101 is the design surface 12a of the decorative film 12. A protective layer, a printed image, or the like may be formed on the base film 19. In this case, the surface of the protective layer, the printing layer, or the like becomes the design surface 12a of the decorative film 12. Of course, the base film 19 may be provided with a function as a protective layer. Further, the base film 19 may be provided with a decoration function by printing, coloring or the like. This makes it possible to improve the design.

In the present disclosure, the decorative function includes an arbitrary function for realizing a predetermined design.
For example, there are arbitrary decoration functions such as a decoration function that expresses a predetermined color by using light transmission and reflection, and a decoration function that makes a predetermined pattern or pattern visually visible by printing or the like. Be done. Of course, the decoration function that visually recognizes a predetermined pattern or the like by using printing or the like can be said to be a decoration function that utilizes the transmission or reflection of light.

The metal layer 20 is formed to give the decorated area 11 a metallic appearance. The metal layer 20 is a layer formed on the base film 19 by vacuum deposition, and a large number of fine cracks (hereinafter referred to as fine cracks) 22 are formed.

Due to the fine cracks 22, a plurality of discontinuous surfaces are formed in the metal layer 20, and the surface resistance values are substantially insulative. Therefore, it is possible to sufficiently suppress the generation of eddy current when the radio wave hits the housing portion 101. As a result, the reduction of electromagnetic wave energy due to eddy current loss can be sufficiently suppressed, and high radio wave transparency is realized.

The film thickness of the metal layer 20 is set, for example, in the range of 30 nm or more and 300 nm or less. If the film thickness is too small, light is transmitted and the reflectance in the visible light region is lowered. If the film thickness is too large, the surface shape tends to be rough and the reflectance is lowered. Further, the smaller the film thickness, the larger the amount of decrease in reflectance after the high temperature and high humidity test (for example, after 75 ° C. 90% RH48H). RH is a relative humidity (Relative Humidity).

By setting the film thickness in the above range in consideration of these points, it was possible to realize a radio wave transmitting surface maintaining a high reflectance. In particular, by setting the film thickness in the range of 30 nm or more and 150 nm or less, high reflectance was sufficiently maintained and high radio wave transmission was exhibited. Of course, the film thickness of the metal layer 20 may be appropriately set so as to exhibit desired characteristics without being limited to these ranges. Further, for example, the optimum numerical range may be set again in the range of 30 nm or more and 300 nm or less.

The sealing resin 21 functions as a protective layer (hard coat layer) that protects the metal layer 20. The sealing resin 21 is formed by applying, for example, a UV curable resin, a thermosetting resin, a two-component curable resin, or the like. By forming the sealing resin 21, for example, smoothing, antifouling, peeling prevention, scratch prevention and the like are realized. The protective layer may be coated with an acrylic resin or the like. By selecting a non-vinyl chloride-based material as the sealing resin 21, it is advantageous to prevent metal corrosion.

Further, the sealing resin 21 also has a function of immobilizing the fine cracks 22 in the metal layer 20 to prevent re-adhesion. That is, the sealing resin 21 also functions as a fixed layer. This makes it possible to exhibit sufficient radio wave transmission and maintain radio wave transmission for a long time. A layer that functions as a protective layer and a layer that functions as a fixed layer may be separated from each other and may be formed on the metal layer 20 as a cover layer having a two-layer structure.

The adhesive layer 18 is a layer for adhering the decorative film 12 to the decorated region 11. The adhesive layer 18 is formed by applying an adhesive material to the surface of the sealing resin 21 opposite to the side covering the metal layer 20 (the surface on the housing portion 101 side). The type of adhesive material, application method, etc. are not limited. The surface of the adhesive layer 18 that is adhered to the decorated area 11 is the adhesive surface 12b of the decorative film 12.

In the present embodiment, when the decorative film 12 is formed, the glossy film 23 composed of the base film 19 and the metal layer 20 is first formed. After that, the sealing resin 21 and the adhesive layer 18 are formed on the glossy film 23. The order in which each layer is formed is not limited to this.

3 and 4 are photographs taken by magnifying the surface state of the metal layer 20 of the glossy film 23 with a microscope. The photograph M2 shown in FIG. 4 was taken including a scale (scale), but in order to make the scale easier to recognize, a line is reinforced from the top of the photograph. Of course, the photographs of FIGS. 3 and 4 are examples of the glossy film 23 according to the present technology.

In the glossy film 23 shown in the photograph M1 of FIG. 3, an aluminum layer to which oxygen is added as a predetermined element is formed as a metal layer 20 on the base film 19. Then, the base film 19 is biaxially stretched under the conditions of a stretching ratio (stretching amount with respect to the original size) of 2% and substrate heating of 130 ° C. to form fine cracks 22.

As shown in Photo M1, fine cracks 22 are formed in the metal layer 20 in a mesh pattern along the biaxial direction. That is, the fine cracks 22 are formed so as to intersect each other along two directions substantially orthogonal to each other.

In the glossy film 23 shown in the photograph M2 of FIG. 4, a metal layer 20 in which a high hardness layer made of chromium and a high reflection layer made of aluminum are laminated is formed on the base film 19. Then, the base film 19 is biaxially stretched under the conditions of a stretch ratio of 2% and substrate heating of 130 ° C. to form fine cracks 22.

As shown in Photo M2, fine cracks 22 are irregularly formed in the metal layer 20. Irregular formation means that there is no regularity in the formation mode of the fine cracks 22, and it can be said that the fine cracks 22 are randomly formed.

As shown in Photo M2, there is no regularity in the direction of the fine cracks 22, and innumerable cracks 22 are formed in random directions. It can be said that the shape of the region surrounded by the fine cracks 22 is not regular, and innumerable regions having a random shape are formed by the fine cracks 22.

The pitch (crack interval) of the fine cracks 22 is set, for example, in the range of 1 μm or more and 500 μm or less. When the pitch is reduced, the area of the gaps (voids) of the fine cracks 22 increases relatively. When the pitch is increased, the area of the gaps between the fine cracks 22 is relatively reduced.

For example, if the pitch is too small, a large amount of light is scattered on the surface of the metal layer 20, which affects the design. On the other hand, if the pitch was too large, a decrease in radio wave transmission was observed. By setting the pitch in the range of 1 μm or more and 500 μm or less, it was possible to realize radio wave transmission while maintaining high designability. For example, it is possible to sufficiently transmit an electromagnetic wave (wavelength of about 12.2 cm) at 2.45 GHz of WiFi or Bluetooth (registered trademark).

Of course, the pitch is not limited to this range, and the pitch of the fine cracks 22 may be appropriately set so that the desired characteristics are exhibited. For example, by setting the pitch in the range of 50 μm or more and 200 μm or less, high reflectance and high radio wave transmission were sufficiently exhibited. In addition, for example, the optimum numerical range may be set again in the range of 1 μm or more and 500 μm or less.

When the surface resistance of the metal layer 20 of the photographs M1 and M2 was evaluated by a 4-probe resistor, the insulating property was shown. Moreover, when the surface reflectance (average reflectance) in the visible light region (400 nm to 700 nm) was measured using a spectrophotometer (U-4100 "manufactured by Hitachi, Ltd."), the value was 70% or more. .. That is, it has become possible to realize a metal layer 20 having a metallic luster surface having a high reflectance and having sufficient radio wave transmission.

When the base film 19 is formed on the surface side of the metal layer 20, or when a protective layer such as a sealing resin or a hard coat layer is formed, the surface reflectance of the design surface 12a is reduced by about 5%. There can be. Even in consideration of this, by using the decorative film 12 according to the present technology, it is possible to set the surface reflectance to a high value of 65% or more.

The case where the fine cracks 22 are regularly formed as shown in FIG. 3 and the case where the fine cracks 22 are irregularly formed as shown in FIG. 4 are compared. Then, it was found that it is possible to reduce the visibility (conspicuousness) of the fine cracks 22 when they are formed irregularly. It is considered that this is because the fine cracks 22 are conspicuous when the directions of the fine cracks 22 are aligned.

Therefore, for example, by forming the glossy film 23 so that the fine cracks 22 are irregularly formed, it is possible to improve the designability of the design surface 12a.

FIG. 5 is a schematic diagram showing a configuration example of a vacuum vapor deposition apparatus. The vacuum vapor deposition apparatus 200 has a film transfer mechanism 201, a partition wall 202, a mounting table 203, and a heating source (not shown) arranged in a vacuum chamber (not shown).

The film transport mechanism 201 has a first roll 205, a rotary drum 206, and a second roll 207. When the rotary drum 206 rotates clockwise, the base film 19 is conveyed from the first roll 205 to the second roll 207 along the peripheral surface of the rotary drum 206. When the rotary drum 206 rotates counterclockwise, the base film 19 is conveyed from the second roll 207 toward the first roll 205.

The mounting table 203 is arranged at a position facing the rotating drum 206. On the mounting table 203, a crucible 208 containing a metal material constituting the metal layer 20 formed on the base film 19 is arranged. The region of the rotating drum 206 facing the crucible 208 is the film formation region 210. The partition wall 202 regulates the fine particles 91 of the film forming material 90 that travel at an angle toward a region other than the film forming region 210.

The base film 19 is conveyed in a state where the rotating drum 206 is sufficiently cooled. For example, the rotary drum 206 is rotated clockwise, and the base film 19 is conveyed from the first roll 205 to the second roll 207.

Along with the transport of the base film 19, the metal material in the crucible 208 is heated by a heating source (not shown) such as a heater, a laser or an electron gun. As a result, steam containing fine particles 91 is generated from the crucible 208. The metal layer 20 is formed on the base film 19 by depositing the fine particles 91 of the metal material contained in the steam on the base film 19 advancing through the film forming region 210.

For example, crucible 208 contains aluminum as a metal material. Further, an oxygen introduction mechanism (not shown) is arranged on the upstream side (unwinding roll 205 side) of the film forming region 210. Oxygen is blown toward the base film 19 by the oxygen introduction mechanism in accordance with the transportation of the base film 19 and the heating of the crucible 208 by the heating source. This makes it possible to easily form the metal layer 20 made of the oxygen-added aluminum layer illustrated in FIG.

As another example, first, the crucible 208 containing the chromium constituting the high hardness layer is placed on the mounting table 203. Then, the rotary drum 206 is rotated clockwise, and the base film 19 is conveyed from the first roll 205 to the second roll 207. The crucible 208 is heated in accordance with the transportation of the base film 19, and a high-hardness layer made of chromium is formed on the base film 19.

Next, the crucible 208 containing aluminum, which is a metal constituting the highly reflective layer, is placed on the mounting table 203. The rotary drum 206 is rotated counterclockwise, and the base film 19 on which the high hardness layer is formed is conveyed from the second roll 207 to the first roll 205. By heating the aluminum in the crucible 208 in accordance with the transportation, a high-reflection layer is formed on the high-hardness layer. This makes it possible to easily form the metal layer 20 in which the high hardness layer made of chromium and the high reflection layer made of aluminum are laminated as illustrated in FIG.

In the example shown in FIG. 5, continuous vacuum vapor deposition by the roll-to-roll method is possible, so that it is possible to significantly reduce the cost and improve the productivity. Of course, this technique can also be applied when a batch type vacuum vapor deposition apparatus is used.

FIG. 6 is a schematic view showing a configuration example of a biaxial stretching device. The biaxial stretching device 250 includes a base member 251 and four stretching mechanisms 252 arranged on the base member 251 and having substantially the same configuration as each other. The four stretching mechanisms 252 are arranged so as to face each other on each axis, two on each of the two axes (x-axis and y-axis) orthogonal to each other. Hereinafter, description will be made with reference to the stretching mechanism 252a that stretches the glossy film 23'in the direction opposite to the arrow in the y-axis direction.

The stretching mechanism 252a has a fixed block 253, a movable block 254, and a plurality of clips 255. The fixing block 253 is fixed to the base member 251. A drawing screw 256 extending in the drawing direction (y direction) is penetrated through the fixing block 253.

The movable block 254 is movably arranged on the base member 251. The movable block 254 is connected to a draw screw 256 that penetrates the fixing block 253. Therefore, by operating the draw screw 256, the movable block 254 can move in the y direction.

The plurality of clips 255 are arranged along a direction (x direction) orthogonal to the stretching direction. A slide shaft 257 extending in the x direction penetrates each of the plurality of clips 255. Each clip 255 can be repositioned in the x direction along the slide shaft 257. Each of the plurality of clips 255 and the movable block 254 are connected by a connecting link 258 and a connecting pin 259.

The draw ratio is controlled by the amount of operation of the draw screw 256. Further, the stretching ratio can be controlled by appropriately setting the number and position of the plurality of clips 255, the length of the connecting link 258, and the like. The configuration of the biaxial stretching device 250 is not limited. The biaxial stretching device 250 according to the present embodiment biaxially stretches the film with a fully cut single sheet, but it is also possible to continuously biaxially stretch the film with a roll. For example, continuous biaxial stretching is possible by applying tension in the traveling direction between the rolls and tension perpendicular to the traveling direction by the clip 255 provided between the rolls that moves in synchronization with the traveling.

A vacuum-deposited glossy film 23'is arranged on the base member 251 and a plurality of clips 255 of the stretching mechanism 252 are attached to each of the four sides. In a state where the glossy film 23'is heated by a temperature-controlled heating lamp or temperature-controlled hot air (not shown), four drawing screws 256 are operated to perform biaxial stretching. In the present embodiment, the base film 19 is biaxially stretched under the conditions of a stretch ratio of 2% in each axial direction and substrate heating of 130 ° C. As a result, as shown in FIG. 3, a mesh-like fine crack 22 is formed along the direction orthogonal to the stretching direction (biaxial direction). Alternatively, as shown in FIG. 4, fine cracks 22 are irregularly formed.

If the stretch ratio is too low, proper fine cracks 22 are not formed, and the metal layer 20 has conductivity. In this case, sufficient radio wave transmission is not exhibited due to the influence of eddy current and the like. On the other hand, if the stretching ratio is too large, the damage to the base film 19 after stretching becomes large. As a result, when the decorative film 12 is adhered to the decorated area 11, the yield may be deteriorated due to air biting, wrinkles, and the like. Further, the design of the metal decorative portion 10 may be deteriorated due to the deformation of the base film 19 or the metal layer 20 itself. This problem can also occur when the metal layer 20 is stripped from the base film 19 and transferred.

In the glossy film 23 according to the present embodiment, the fine cracks 22 can be appropriately formed with a low draw ratio of 2% or less in the direction of each axis. This makes it possible to sufficiently prevent damage to the base film 19 and improve the yield. Further, the design of the metal decorative portion 10 to which the decorative film 12 is adhered can be maintained high. Of course, the stretch ratio can be set as appropriate, and a stretch ratio of 2% or more may be set as long as the above-mentioned problems do not occur. For example, if the draw ratio is in the range of 5% or less, it is possible to properly form the fine cracks 22 with a high yield without causing the above-mentioned problems. Of course, a value larger than 5% may be set.

[Regarding the gaps and design of fine cracks]
Here, the inventor examined the gaps between the fine cracks 22 and the designability on the design surface 12a. Specifically, the light transmission of the gaps between the fine cracks 22 and the design property of the design surface 12a were examined.

For example, in the decorative film 12 illustrated in FIG. 2, the sealing resin 21 is made of a transparent material having high light transmittance. As a result, the gap between the fine cracks 22 becomes a region having light transmission. In this case, when the design surface 12a is irradiated with light from the outside side, the light is transmitted through the gaps of the fine cracks 22, so that the reflectance of the design surface 12a may decrease. As a result, it may be difficult to achieve a metallic luster with high design.

Further, when the light generated on the inner side of the housing portion 101 is emitted to the outer side, there is a possibility that the light passes through the gaps of the fine cracks 22 and leaks. In this case, the design may be deteriorated due to the influence of the leaked light emitted from the gaps of the fine cracks 22.

From such a study, the inventor newly devised to realize the following points in order to improve the design.
(A) Sufficiently suppress the light transmitted through the gaps of the fine cracks 22 (B) Control the influence of the light incident on the gaps of the fine cracks 22 on the design (C) Combine these two points. Hereinafter, these points (A) to (C) will be described.

[About point A]
In order to realize the point A, the inventor constitutes a light-shielding portion that shields light from the gaps of the fine cracks 22 or at least one of the metal layer 20 and the adhesive surface 12b (second surface). Was newly devised. In particular, a light-shielding portion that blocks light in the visible light region is configured.

The light shielding in the present disclosure is not limited to the case where light is completely blocked as in the case of complete shading, and also includes the case where light transmission is allowed within a range that does not impair the effect of the present technology. Further, shading in the present disclosure is a concept including absorbing light and reflecting light. For example, the shading in the present disclosure can be expressed as having a light transmittance of a predetermined threshold value (for example, 10%) or less. Of course, it is not limited to this.

In the decorative film 12 illustrated in FIG. 2, the sealing resin 21 is formed of a light-shielding material having a light-shielding property. This makes it possible to fill the gaps in the fine cracks 22 with a light-shielding material. Further, it is possible to realize a layer made of a light-shielding material between the metal layer 20 and the adhesive surface 12b.

As shown in FIG. 2, hereinafter, the light-shielding material formed in the gaps of the fine cracks 22 is referred to as a gap light-shielding portion 31. The layer of the light-shielding material formed between the metal layer 20 and the adhesive surface 12b is referred to as a light-shielding layer 32.

For example, a glossy film 23 is formed, and fine cracks 22 are formed by stretching. After that, the sealing resin 21 is formed by applying a resin made of a light-shielding material so as to cover the metal layer 20. This makes it possible to easily integrally form the gap light-shielding portion 31 and the light-shielding layer 32. In the example shown in FIG. 2, the light-shielding portion 30 is configured by the gap light-shielding portion 31 and the sealing resin 21 that functions as the light-shielding layer 32.

By configuring the light-shielding portion 30, it is possible to sufficiently suppress the light transmitted through the gaps of the fine cracks 22, and it is possible to realize a metallic luster having a high reflectance. Further, it is possible to sufficiently suppress unnecessary light leakage from the inside of the housing portion 101. As a result, it is possible to realize a very high design.

As shown in FIG. 2, the sealing resin 21 is formed so as to fill the gaps between the fine cracks 22 in the metal layer 20, and the sealing resin 21 is formed so as to be the same layer as the metal layer 20. It is also possible to say that it is in a state of being.

7 and 8 are schematic views showing another configuration example of the light-shielding portion. For example, as shown in FIG. 7A, the sealing resin 21 that functions as the light-shielding portion 30 can be provided with an adhesive function. As a result, the adhesive layer 18 can be omitted, and the manufacturing process can be simplified.

As shown in FIG. 7B, only the gap light-shielding portion 31 may be configured as the light-shielding portion 30. For example, a glossy film 23 is formed, and fine cracks 22 are formed by stretching. After that, by applying a light-shielding material so as to fill the gaps of the fine cracks 22, the gap light-shielding portion 31 is formed. After that, the sealing resin 21 is formed by applying the resin so as to cover the metal layer 20 and the gap shading portion 31. The sealing resin 21 is made of a material that does not have a light-shielding property.

Even with such a configuration, the light-shielding portion 30 can sufficiently suppress the light transmitted through the gaps of the fine cracks 22, and can sufficiently suppress unnecessary light leakage from the inside. As a result, it is possible to realize a very high design. When the sealing resin 21 is formed of the light-shielding material, it can function as the light-shielding layer 32.

As shown in FIG. 7B, the state in which the gap light-shielding portion 31 is formed in the gap of the fine crack 22 is also referred to as the state in which the gap light-shielding portion 31 is formed so as to be the same layer as the metal layer 20. It is possible.

As shown in FIG. 7C, only the light-shielding layer 32 may be configured as the light-shielding portion 30. For example, after the fine cracks 22 are formed by stretching, the sealing resin 21 is formed so as to cover the metal layer 20. The light-shielding layer 32 is formed by applying a light-shielding material to the surface of the sealing resin 21 opposite to the side covering the metal layer 20. An adhesive layer 18 is formed on the light-shielding layer 32.

When only the light-shielding layer 32 is formed, it is difficult to prevent the light irradiating the design surface 12a from the outside from passing through the gaps of the fine cracks 22. On the other hand, it is possible to sufficiently suppress unnecessary light leakage from the inside. That is, it is possible to sufficiently suppress the light that passes through the gaps of the fine cracks 22 from the inner side. As a result, it is possible to improve the design.

As shown in FIG. 8A, the gap light-shielding portion 31 and the light-shielding layer 32 may be separately configured as the light-shielding portion 30. For example, after the fine cracks 22 are formed by stretching, the gap light-shielding portion 31 is formed by applying a light-shielding material so as to fill the gaps of the fine cracks 22. After that, after the sealing resin 21 is formed, the light-shielding layer 32 is formed by applying a light-shielding material to the surface of the sealing resin 21 opposite to the side covering the metal layer 20. Even with such a configuration, it is possible to realize high designability.

In the example shown in FIG. 8B, the adhesive layer 18 is formed on the surface of the base film 19 opposite to the surface on which the metal layer 20 is formed. Then, the base film 19 side of the decorative film 12 is adhered to the decorated region 11 of the housing portion 101. Therefore, the surface of the sealing resin 21 opposite to the side covering the metal layer 20 is the design surface 12a of the decorative film 12.

In such a configuration, the base film 19 is formed of a light-shielding material. This makes it possible to easily form the light-shielding layer 32 as the light-shielding portion 30. As a result, it is possible to sufficiently suppress unnecessary light leakage from the inside, and it is possible to realize high designability.

The adhesive layer 18 and the sealing resin 21 may be omitted depending on the molding conditions of the housing portion 101 and the like. In this case, the glossy film 23 is adhered to the decorated area 11 as a decorative film according to the present technology.

In FIG. 8B, the light-shielding portion 30 is realized by the base film 19. Of course, the present invention is not limited to this, and as shown in FIG. 8C, the gap light-shielding portion 31 and the light-shielding layer 32 may be newly added.

For example, after the fine cracks 22 are formed by stretching, the gap light-shielding portion 31 is formed by applying a light-shielding material so as to fill the gaps of the fine cracks 22. Further, the light-shielding layer 32 is formed by applying the light-shielding material to the surface of the base film 19 opposite to the surface on which the metal layer 20 is formed. Even with such a configuration, it is possible to realize a high degree of design. Of course, only one of the gap light-shielding portion 31 and the light-shielding layer 32 may be formed.

Any material may be used as the light-shielding material used to realize the light-shielding portion 30 (gap light-shielding portion 31, light-shielding layer 32). Of course, when the light-shielding portion 30 is realized by an element having other functions such as the sealing resin 21 and the base film 19, the material may be appropriately selected so as to exhibit the other functions.

As described with reference to FIGS. 2, 7, and 8, a light-shielding portion 30 is configured in the gaps of the fine cracks 22 or at least one of the metal layer 20 and the adhesive surface 12b (second surface). do. Specifically, the light-shielding portion 30 formed on at least one of the gap between the metal layer 20 on which the fine crack 22 is formed and the gap between the fine crack 22 or the metal layer 20 and the adhesive surface 12b (second surface). The decorative film 12 including the above is formed. This makes it possible to suppress the light that passes through the gaps of the fine cracks 22. As a result, it is possible to realize a highly designed housing portion 101 that has a metallic appearance and is capable of transmitting radio waves.

[About point B]
In order to realize the point B, the inventor has provided a decoration function portion having a decoration function in at least one of the gaps of the fine cracks 22 or between the metal layer 20 and the adhesive surface 12b (second surface). I devised a new composition. Specifically, it constitutes a decoration function unit having a decoration function using at least one of transmission or reflection of light.

As a decoration function unit having a decoration function utilizing light transmission or reflection, in order to realize a predetermined design property, the transmitted light transmitted through the decoration function unit or the reflected light reflected by the decoration function unit is used. Includes any configuration that can be made to work.

For example, a light-transmitting member, a layer, or the like colored with a predetermined color can function as a decorative function unit capable of expressing the color. Further, it has a laminated structure, and causes interference by the other layer with respect to the light emitted from one layer by transmission or reflection. By utilizing this interference of light, it is possible to realize a predetermined design such as color adjustment. A member, a layer, or the like having such a laminated structure can function as a decorative functional unit. Further, the print layer and the like can also function as a decorative function unit.

In the decorative film 12 illustrated in FIG. 9, the sealing resin 21 is formed as the decorative functional portion 40 having the decorative function. This makes it possible to fill the gaps in the fine cracks 22 with a material having a decorative function. Further, it is possible to realize a layer made of a material having a decorative function between the metal layer 20 and the adhesive surface 12b.

As shown in FIG. 9, hereinafter, the material having the decoration function portion formed in the gap of the fine crack 22 is referred to as the gap decoration function portion 41. The layer having a decorative function diagram formed between the metal layer 20 and the adhesive surface 12b is referred to as a decorative functional layer 42. In the configuration illustrated in FIG. 9, in the decorative film 12 illustrated in FIG. 2, the light-shielding portion 30 (gap light-shielding portion 31, light-shielding layer 32) is replaced with the decoration function unit 40 (gap decoration function unit 41, decoration). It corresponds to the one replaced with the functional layer 42). Of course, it is not limited to this configuration.

For example, a glossy film 23 is formed, and fine cracks 22 are formed by stretching. After that, the sealing resin 21 is formed by applying a resin made of a material having a decorative function so as to cover the metal layer 20. This makes it possible to easily integrally and easily form the gap decoration function portion 41 and the decoration function layer 42. In the example shown in FIG. 9, the decoration function unit 40 is configured by the gap decoration function unit 41 and the sealing resin 21 that functions as the decoration function layer 42.

By configuring the decoration function unit 40, the light incident on the gaps of the fine cracks 22 from the outside side and the light incident on the gaps of the fine cracks 22 from the inside side are positively used to improve the design. Is possible.

For example, it is possible to improve the designability of the design surface 12a by using the transmitted light transmitted through the decoration function unit 40 (gap decoration function unit 41, decoration function layer 42). Further, it is possible to improve the designability of the design surface 12a by utilizing the reflected light reflected by the decoration function unit 40 (gap decoration function unit 41, decoration function layer 42). In addition, it is also possible to reflect the light transmitted through the gap decoration function unit 41 by the decoration function layer 42 and transmit the light through the gap decoration function unit 41 again.

Specifically, as a design example (design example), a design in which the fine cracks 22 are colored or a design in which the decorated light is transmitted from the fine cracks 22 can be considered. Of course, it is not limited to such a design.

By configuring the decorative function unit 40 in this way, it is possible to control the influence of the light incident on the gaps of the fine cracks 22 on the design. As a result, it is possible to realize a very high design. Since the decorative function portion 40 is formed on the same layer or the back layer (inner layer) with respect to the metal layer 20, it is easy to arrange the metal layer 20 on the front surface side (design surface side). Become. As a result, it becomes possible to realize a metallic luster having a high reflectance.

10 and 11 are schematic views showing another configuration example of the decorative function unit. The configurations illustrated in FIGS. 10 and 11 correspond to the decorative film 12 illustrated in FIGS. 7 and 8 in which the light-shielding portion 30 is replaced with the decorative functional portion 40. Hereinafter, these configurations will be described again.

For example, as shown in FIG. 10A, the sealing resin 21 that functions as the decorative function unit 40 can be provided with an adhesive function. As a result, the adhesive layer 18 can be omitted, and the manufacturing process can be simplified.

As shown in FIG. 10B, only the gap decoration function unit 41 may be configured as the decoration function unit 40. For example, a glossy film 23 is formed, and fine cracks 22 are formed by stretching. After that, by applying a material having a decorating function so as to fill the gaps of the fine cracks 22, the gap decorating function portion 41 is formed. After that, the sealing resin 21 is formed by applying the resin so as to cover the metal layer 20 and the gap decoration function portion 41. The sealing resin 21 is made of a material that does not have a decorative function.

Even in such a configuration, the decorative function unit 40 positively utilizes the light incident on the gaps of the fine cracks 22 from the outside side and the light incident on the gaps of the fine cracks 22 from the inside side to improve the design. It will be possible to improve. When the sealing resin 21 is formed of a material having a decorative function, it can function as the decorative functional layer 42.

As shown in FIG. 10C, only the decoration function layer 42 may be configured as the decoration function unit 40. For example, after the fine cracks 22 are formed by stretching, the sealing resin 21 having light transmission is formed so as to cover the metal layer 20. The decorative functional layer 42 is formed by applying a material having a decorative function to the surface of the sealing resin 21 opposite to the side covering the metal layer 20. An adhesive layer 18 is formed on the decorative functional layer 42.

Even with such a configuration, it is possible to improve the design by positively utilizing the light incident on the gaps of the fine cracks 22 from the outside side and the light incident on the gaps of the fine cracks 22 from the inside side. ..

As shown in FIG. 11A, the gap decoration function unit 41 and the decoration function layer 42 may be separately configured as the decoration function unit 40. For example, after the fine cracks 22 are formed by stretching, the gap decoration function portion 41 is formed by applying a material having a decorative function so as to fill the gaps of the fine cracks 22. After that, after the sealing resin 21 is formed, the decorative functional layer 42 is formed by applying a material having a decorative function to the surface of the sealing resin 21 opposite to the side covering the metal layer 20. Even with such a configuration, it is possible to realize high designability.

In the example shown in FIG. 11B, the adhesive layer 18 is formed on the surface of the base film 19 opposite to the surface on which the metal layer 20 is formed. Then, the base film 19 side of the decorative film 12 is adhered to the decorated region 11 of the housing portion 101. Therefore, the surface of the sealing resin 21 opposite to the side covering the metal layer 20 is the design surface 12a of the decorative film 12.

In such a configuration, the base film 19 is formed of a material having a decorative function. This makes it possible to easily form the decoration function layer 42 as the decoration function unit 40. As a result, it is possible to improve the design by positively utilizing the light incident on the gaps of the fine cracks 22 from the outside side and the light incident on the gaps of the fine cracks 22 from the inside side.

The adhesive layer 18 and the sealing resin 21 may be omitted depending on the molding conditions of the housing portion 101 and the like. In this case, the glossy film 23 is adhered to the decorated area 11 as a decorative film according to the present technology.

In FIG. 11B, the decorative function unit 40 is realized by the base film 19. Of course, the present invention is not limited to this, and as shown in FIG. 11C, the gap decoration function portion 41 and the decoration function layer 42 may be newly added.

For example, after the fine cracks 22 are formed by stretching, the gap decoration function portion 41 is formed by applying a material having a decorative function so as to fill the gaps of the fine cracks 22. Further, the decorative functional layer 42 is formed by applying a material having a decorative function to the surface of the base film 19 opposite to the surface on which the metal layer 20 is formed. Even with such a configuration, it is possible to realize a high degree of design. Of course, only one of the gap decoration function portion 41 and the decoration function layer 42 may be formed.

Any material may be used as the material having a decoration function used to realize the decoration function unit 40 (gap decoration function unit 41, decoration function layer 42). Of course, when the decorative function unit 40 is realized by an element having other functions such as the sealing resin 21 and the base film 19, the material may be appropriately selected so as to exhibit the other functions.

As described with reference to FIGS. 9, 10 and 11, the decorative functional unit 40 is located in the gap between the fine cracks 22 or at least one of the metal layer 20 and the adhesive surface 12b (second surface). To configure. Specifically, a decorative function configured on at least one of the gap between the metal layer 20 on which the fine crack 22 is formed and the gap between the fine crack 22 or the metal layer 20 and the adhesive surface 12b (second surface). The decorative film 12 including the portion 40 is formed. As a result, it is possible to improve the design by positively utilizing the light incident on the gaps of the fine cracks 22 from the outside side and the light incident on the gaps of the fine cracks 22 from the inside side. As a result, it is possible to realize a highly designed housing portion 101 that has a metallic appearance and is capable of transmitting radio waves.

[About point C]
FIG. 12 is a schematic diagram showing a configuration example when the light-shielding portion 30 and the decorative function portion 40 are combined. In the example shown in FIG. 12A, for example, after the fine cracks 22 are formed by stretching, the gap decorating function portion 41 is decorated by applying a material having a decorative function so as to fill the gaps of the fine cracks 22. It is formed as a functional unit 40. After that, after the sealing resin 21 is formed, the light-shielding layer 32 is formed as the light-shielding portion 30 by applying the light-shielding material to the surface of the sealing resin 21 opposite to the side covering the metal layer 20.

By combining the light-shielding portion 30 and the decorative function portion 40 in this way, it is possible to sufficiently suppress unnecessary light leakage from the inside of the housing portion 101. Further, it is possible to control the influence of the light incident on the gap of the fine crack 22 from the outside side on the design. As a result, it is possible to realize a high degree of design.

The sealing resin 21 may be formed of a material having a decorative function, and a light-shielding layer 32 may be formed on the back layer (inner layer) thereof. In this case, the gap decoration function portion 41, the decoration function layer 42, and the light-shielding layer 32 can be easily formed. Alternatively, after the gap decoration function portion 41 is formed, the sealing resin 21 may be formed as the light-shielding layer 32 by the light-shielding material.

Further, a combination of the decorative functional layer 42 and the light-shielding layer 32 is also conceivable. For example, the decorative functional layer 42 is formed on the back layer (inner layer) of the sealing resin 21. Then, the light-shielding layer 32 may be formed on the back layer (inner layer) of the decorative functional layer 42. In addition, any configuration may be adopted.

In the example shown in FIG. 12B, for example, after the fine cracks 22 are formed by stretching, the gap decorating function portion 41 is decorated by applying a material having a decorative function so as to fill the gaps of the fine cracks 22. It is formed as a functional unit 40. Further, by applying a light-shielding material to the surface of the base film 19 opposite to the surface on which the metal layer 20 is formed, the light-shielding layer 32 is formed as the light-shielding portion 30. Even with such a configuration, it is possible to realize high designability.

The base film 19 may be formed of a material having a decorative function, and the light-shielding layer 32 may be formed on the back layer (inner layer) thereof. In this case, the gap decoration function portion 41, the decoration function layer 42, and the light-shielding layer 32 can be easily formed. Alternatively, the base film 19 may be formed of a light-shielding material, and the gap decoration function portion 41 may be formed in the gaps of the fine cracks 22.

Further, a combination of the decorative functional layer 42 and the light-shielding layer 32 is also conceivable. For example, the decorative functional layer 42 is formed on the back layer (inner layer) of the base film 19. Then, the light-shielding layer 32 may be formed on the back layer (inner layer) of the decorative functional layer 42. In addition, any configuration may be adopted.

As described with reference to FIG. 12, the light-shielding portion 30 is formed in the gap between the fine cracks 22 or at least one of the metal layer 20 and the adhesive surface 12b (second surface). Further, the decorative function portion 40 is formed in the gap between the fine cracks 22 or at least one of the metal layer 20 and the adhesive surface 12b (second surface). That is, the light-shielding portion 30 and the decorative function portion 40 are combined. This makes it possible to realize a highly designed housing portion 101 that has a metallic appearance and is capable of transmitting radio waves.

FIG. 13 is a schematic diagram for explaining the in-mold molding method. In-mold molding is performed by a molding apparatus 300 having a cavity type 301 and a core type 302 as shown in FIG. As shown in FIG. 13A, the cavity type 301 is formed with a recess 303 corresponding to the shape of the housing portion 101. The transfer film 50 is arranged so as to cover the recess 303. The transfer film 50 is formed by adhering the decorative film 12 shown in FIG. 2 or the like to the carrier film 51. The transfer film 50 is supplied from the outside of the molding apparatus 300, for example, by a roll-to-roll method.

As shown in FIG. 13B, the cavity type 301 and the core type 302 are clamped, and the molding resin 55 is injected into the recess 303 via the gate portion 306 formed in the core type 302. The cavity type 301 is formed with a sprue portion 508 to which the molding resin 55 is supplied and a runner portion 509 connected to the sprue portion 508. When the cavity type 301 and the core type 302 are clamped, the runner portion 509 and the gate portion 306 are connected to each other. As a result, the molding resin 55 supplied to the sprue portion 508 is injected into the recess 303. The configuration for injecting the molding resin 55 is not limited.

As the molding resin 55, for example, a general-purpose resin such as ABS (acrylonitrile, butadiene, styrene) resin, a PC resin, an engineering plastic such as a mixed resin of ABS and PC, and the like are used. Not limited to these, the material and color (transparency) of the molding resin may be appropriately selected so that a desired housing portion (housing component) can be obtained.

The molding resin 55 is injected into the recess 303 in a state of being melted at a high temperature. The molding resin 55 is injected so as to press the inner surface of the recess 303. At this time, the transfer film 50 arranged in the recess 303 is pressed by the molding resin 55 and deformed. The heat of the molding resin 55 melts the adhesive layer 18 formed on the transfer film 50, and the decorative film 12 is adhered to the surface of the molding resin 55.

After the molding resin 55 is injected, the cavity type 301 and the core type 302 are cooled and the clamp is released. The molding resin 55 to which the decorative film 12 is transferred is attached to the core mold 302. By taking out the molded resin 55, the housing portion 101 in which the metal decorative portion 10 is formed in a predetermined region is manufactured. When the clamp is released, the carrier film 51 is peeled off.

By using the in-mold molding method, the alignment of the decorative film 12 becomes easy, and the metal decorative portion 10 can be easily formed. Further, the degree of freedom in designing the shape of the housing portion 101 is high, and the housing portion 101 having various shapes can be manufactured.

The antenna portion 15 housed inside the housing portion 101 may be attached by an in-mold molding method at the time of molding the housing portion 101. Alternatively, after molding the housing portion 101, the antenna portion 15 may be attached to the inside of the housing portion 101. Further, the antenna portion 15 may be built in the housing.

FIG. 14 is a schematic diagram for explaining an insert molding method. In insert molding, the decorative film 12 is arranged as an insert film in the cavity mold 351 of the molding apparatus 350. Then, as shown in FIG. 14B, the cavity mold 351 and the core mold 352 are clamped, and the molding resin 55 is injected into the cavity mold 351 via the gate portion 356. As a result, the housing portion 101 is integrally formed with the decorative film 12. Even if the insert molding method is used, the metal decorative portion 10 can be easily formed. Further, it is possible to manufacture the housing portion 101 having various shapes. The configuration of the molding apparatus that performs in-mold molding and insert molding is not limited.

FIG. 15 is a schematic view showing a configuration example of a transfer film including a base film and a metal layer. The transfer film 450 has a base film 419, a release layer 481, a hard coat layer 482, a metal layer 420, a sealing resin 421, and an adhesive layer 418. The release layer 481 and the hard coat layer 482 are formed on the base film 419 in this order.

Therefore, the metal layer 420 is formed on the base film 419 on which the release layer 481 and the hard coat layer 482 are formed. Then, by stretching the base film 419, fine cracks 422 are formed in the metal layer 420.

In the example shown in FIG. 15, the sealing resin 421 is configured as a light-shielding portion or a decorative function portion. Of course, it is not limited to such a configuration.

As shown in FIG. 15B, when the housing portion 101 is formed by the in-mold molding method, the base film 419 and the release layer 481 are peeled off, and include the metal layer 420 and the light-shielding portion (or the decorative function portion). The decorative portion 412 is adhered to the decorated area 411. In this way, the base film 419 may be used as the carrier film. The base film 419 on which the release layer 481 is formed can also be regarded as the base film according to the present technology. Further, the decorative portion 412 peeled off from the base film 419 can also be referred to as a decorative film.

In the example shown in FIG. 15, the vapor deposition start surface of the metal layer 420 is the surface on the design surface 412a side, and the vapor deposition end surface is the surface on the adhesive surface 412b side. Instead of this configuration, a transfer film may be created so that the vapor deposition end surface is the surface on the design surface 412a side and the vapor deposition start surface is the surface on the adhesive surface 412b side.

Using the transfer films 50 and 450 shown in FIGS. 13 and 15, a decorative film (decorative portion) including a metal layer 20 and a light-shielding portion (or a decorative functional portion) in the decorated region 11 by a hot stamping method. ) 12 may be transferred to form a housing portion 101. In addition, the decorative film 12 may be adhered to the housing portion 101 by any method such as pasting. Further, vacuum forming, compressed air forming, or the like may be used.

The metal material to which this technique can be applied is not limited to aluminum, and other metal materials such as silver (Ag) may be used. For example, by adding oxygen, it becomes possible to appropriately form the fine cracks 22 with a stretching ratio of 2% or less, and it becomes possible to realize a metal layer 20 having a reflectance of 70% or more.

Further, as the metal material, aluminum, titanium, chromium, and an alloy containing at least one of these can be used. These metals are so-called valve metals, and it is possible to fully exert the effect of preventing oxidation by the oxide film. As a result, it is possible to maintain high designability for a long period of time.

The element to be added is not limited to oxygen, and for example, nitrogen (N) may be added. For example, instead of the oxygen introduction mechanism, a nitrogen introduction mechanism may be arranged and nitrogen may be sprayed as the introduction gas. For example, the supply amount may be appropriately set in the range from the addition amount at which the surface of the metal film becomes insulated after the stretching step to the nitriding of the metal layer. For example, high designability is exhibited by making the addition concentration of nitrogen different in the film thickness direction. Further, by setting the ratio of the metal not compounded with nitrogen in the vicinity of both sides of the metal layer to a predetermined threshold value or more, it is possible to prevent the progress of nitriding. In addition, other elements may be added.

When a thin film having an island-like structure of In or Sn is used as the metal film that transmits radio waves, the reflectance is about 50% to 60%. This is due to the optical constants of the material, and it is very difficult to achieve a reflectance of 70% or more as in the glossy film 23 according to the present embodiment. Moreover, since In is a rare metal, material cost is high.

Further, even when cracks are generated in a metal film such as nickel or copper by performing afterbaking using electroless plating, it is difficult to achieve a reflectance of 70% or more. It is also conceivable to alloy silicon and metal to increase the surface resistivity to generate radio wave transmission, but even in this case, it is difficult to achieve a reflectance of 70% or more.

Further, in the present embodiment, since a film of a metal material is formed by vacuum vapor deposition, a material such as Al or Ti, which is difficult to form a film on a resin by wet plating such as electroless plating, can be used. Therefore, a metal material having a very wide selection range of usable metal materials and having a high reflectance can be used. Further, since the fine cracks 22 are formed by biaxial stretching, it is possible to form the metal layer 20 with high adhesion in vacuum deposition. As a result, it is possible to properly mold the housing portion 101 without the metal layer 20 flowing down during in-mold molding or insert molding. Further, the durability of the metal decoration portion 10 itself can be improved.

Further, in the present embodiment, since it is possible to use a simple thin-film deposition process with a simple thin-film deposition source configuration, it is possible to suppress equipment costs and the like. The method for forming the metal layer to which oxygen or nitrogen is added is not limited to the case where the gas is blown toward the film transport mechanism 201. For example, the metal material in the crucible may contain oxygen or the like.

This technology can be applied to almost all electronic devices in which a built-in antenna or the like is housed. For example, such electronic devices include mobile phones, smartphones, personal computers, game machines, digital cameras, audio devices, TVs, projectors, car navigation systems, GPS terminals, wearable information devices (glasses type, wristband type) and other electronic devices. Examples include a remote controller, a mouse, an operating device such as a touch pen, and an electronic device provided in a vehicle such as an in-vehicle radar and an in-vehicle antenna. It can also be applied to IoT devices connected to the Internet or the like.

Further, this technology is not limited to housing parts such as electronic devices, and can be applied to vehicles and buildings. That is, a structure including a decorative portion according to the present technology and a member having a decorated region to which the decorative portion is adhered may be used for all or a part of a vehicle or a building. This makes it possible to realize a vehicle or a building having a wall surface or the like capable of transmitting radio waves while having a metallic appearance, and it is possible to exhibit a very high design. The vehicle includes any vehicle such as a car, a bus, and a train. Buildings include any building such as detached houses, apartment houses, facilities, bridges, etc.

<Other embodiments>
The present technology is not limited to the embodiments described above, and various other embodiments can be realized.

It is also possible to equip the housing portion 101 illustrated in FIG. 2 and the like with the functions of a light-shielding portion and a decorative function portion. Even in this case, it is possible to realize high designability.

With respect to the application of this technique, the method of forming the fine crack 22 is not limited. For example, even when a thin film having an island-like structure of In or Sn is used, or when cracks are generated in a metal film such as nickel or copper by performing afterbaking using electroless plating, the present technology It is possible to improve the design by forming the light-shielding portion and the decorative function portion.

FIG. 16 is a cross-sectional view showing a configuration example of a glossy film according to another embodiment. In this glossy film 523, a support layer 550 having a tensile breaking strength smaller than that of the metal layer 520 is provided as a layer for supporting the metal layer 520. This made it possible to reduce the draw ratio required to form the fine cracks 522. For example, it is possible to form the fine crack 522 with a draw ratio smaller than the draw ratio required to break the metal layer 520 itself (mainly a high hardness layer or the like). It is considered that this is because, as shown in FIGS. 16A and 16B, the metal layer 520 breaks following the breakage of the surfaces of the support layers 550A and B having low tensile breaking strength.

As shown in FIG. 16A, a base film having a low tensile breaking strength may be used as the support layer 550A. For example, biaxially stretched PET has a tensile breaking strength of about 200 to about 250 MPa, which is often higher than the tensile breaking strength of the metal layer 520.

On the other hand, the tensile breaking strengths of unstretched PET, PC, PMMA, and PP are as follows.
Unstretched PET: Approximately 70 MPa
PC: Approximately 69 to 72 MPa
PMMA: Approximately 80MPa
PP: Approximately 30 to 72 MPa
Therefore, by using a base film made of these materials as the support layer 550A, it is possible to appropriately form fine cracks 522 with a low draw ratio. By selecting a non-vinyl chloride-based material as the support layer 550A, it is advantageous to prevent metal corrosion.

As shown in FIG. 16B, a coating layer may be formed on the base film 519 as the support layer 550B. For example, by coating an acrylic resin or the like to form a hard coat layer, the hard coat layer can be easily formed as a support layer 550B.

By forming a coating layer having a small tensile breaking strength between the base film 519 having a high tensile breaking strength and the metal layer 520, the durability of the glossy film 523B is maintained high, and the fine cracks 522 due to a low elongation rate are formed. The formation can be realized. It is also effective when PET must be used in the manufacturing process. The fracture of the surface of the base film or the hard coat layer that functions as the support layers 550A and B shown in FIGS. 16A and 16B is very small, about the width of the fine crack 522. Therefore, it does not cause air biting or deterioration of design.

FIG. 17 is a diagram showing the relationship between the thickness of the coating layer formed as the support layer 550B and the pitch (crack spacing) of the fine cracks 522 formed in the metal layer 520. FIG. 17 shows the relationship when an acrylic layer is formed as a coating layer.

As shown in FIG. 17, when the thickness of the acrylic layer was 1 μm or less, the pitch of the fine cracks 522 was 50 μm to 100 μm. On the other hand, when the thickness of the acrylic layer was set in the range of 1 μm to 5 μm, the pitch of the fine cracks 522 was 100 μm to 200 μm. As described above, it was found that the pitch of the fine cracks 522 increases as the thickness of the acrylic layer increases. Therefore, by appropriately controlling the thickness of the acrylic layer, it is possible to adjust the pitch of the fine cracks 522. For example, by setting the thickness of the acrylic layer to 0.1 μm or more and 10 μm or less, the thickness of the fine crack 522 can be adjusted within a desired range. Of course, the present invention is not limited to this range, and the optimum numerical range may be set again in the range of 0.1 μm or more and 10 μm or less, for example.

In the configuration described with reference to FIGS. 16 and 17, any configuration may be adopted in order to realize the light-shielding portion and the decorative function portion.

Stretching for forming fine cracks is not limited to biaxial stretching. Uniaxial stretching or stretching of 3 or more axes may be performed. Further, biaxial stretching may be further performed on the base film 19 wound around the second roll 207 shown in FIG. 5 by a roll-to-roll method. Biaxial stretching may be performed after further vacuum deposition and before winding on the second roll 207.

It is also possible to combine at least two feature portions among the feature portions according to the present technology described above. That is, the various characteristic portions described in each embodiment may be arbitrarily combined without distinction between the respective embodiments. Further, the various effects described above are merely exemplary and not limited, and other effects may be exhibited.

In addition, this technology can also adopt the following configurations.
(1)
The first side and
A second surface opposite to the first surface,
A metal layer with fine cracks and
A decorative portion having a gap between the fine cracks or a light-shielding portion formed on at least one of the metal layer and the second surface.
A structure comprising a member having a decorated area to which the decorated portion is adhered so that the first surface faces the surface side.
(2) The structure according to claim 1.
The light-shielding portion is a structure including a gap light-shielding portion formed in the gaps of the fine cracks.
(3) The structure according to (1) or (2).
The light-shielding portion is a structure including a light-shielding layer formed between the metal layer and the second surface.
(4) The structure according to any one of (1) to (3).
The light-shielding portion includes a gap light-shielding portion formed in the gap between the fine cracks and a light-shielding layer located between the metal layer and the second surface and integrally formed with the gap light-shielding portion. Structure containing.
(5) The structure according to (1).
The decorative portion is a structure including a decorative functional portion formed in at least one of the gaps between the fine cracks or the metal layer and the second surface and having a decorative function.
(6) The structure according to (5).
The decoration function unit is a structure having a decoration function utilizing at least one of transmission and reflection of light.
(7) The structure according to (5) or (6).
The decoration function unit is a structure including a gap decoration function unit formed in the gaps of the fine cracks.
(8) The structure according to any one of (5) to (7).
The decorative functional unit is a structure including a decorative functional layer formed between the metal layer and the second surface.
(9) The structure according to any one of (5) to (8).
The decoration function unit is located between the gap decoration function unit formed in the gap between the fine cracks and the metal layer and the second surface, and is integrated with the gap decoration function unit. A structure that includes a decorative functional layer and is composed.
(10) The structure according to any one of (1) to (9).
The metal layer is a structure that is any one of aluminum, titanium, chromium, and an alloy containing at least one of these.
(11) The structure according to any one of (1) to (10).
The metal layer is a structure having a thickness of 30 nm or more and 300 nm or less.
(12) The structure according to any one of (1) to (11).
The fine crack is a structure having a pitch in the range of 1 μm or more and 500 μm or less.
(13) The structure according to any one of (1) to (12).
A structure constructed as a housing component, vehicle, or at least part of a building.
(14) The structure according to any one of (1) to (13).
The decorative portion is a structure having a fixing layer for immobilizing the fine cracks.
(15)
With the base film
Formed on the base film
The first side and
A second surface opposite to the first surface,
A metal layer with fine cracks and
A decorative film comprising a gap between the fine cracks or a decorative portion having a light-shielding portion formed on at least one of the metal layer and the second surface.
(16)
A metal layer is formed on the base film by thin film deposition,
By stretching the base film, fine cracks are formed in the metal layer,
The metal layer on which the fine cracks were formed and
A decorative film including the gaps between the fine cracks or the light-shielding portion formed on at least one of the metal layer and the surface opposite to the design surface is formed.
A transfer film is formed by adhering a carrier film to the decorative film.
A method for manufacturing a structure for forming a molded part so that the decorative film is transferred from the transfer film by an in-mold molding method, a hot stamping method, or a vacuum forming method.
(17)
A metal layer is formed on the base film by thin film deposition,
By stretching the base film, fine cracks are formed in the metal layer,
The metal layer on which the fine cracks were formed and
A transfer film including the gaps between the fine cracks or the light-shielding portion formed on at least one of the metal layer and the surface opposite to the design surface is formed.
A method for manufacturing a structure for forming a molded part so that the metal layer and the light-shielding portion peeled off from the base film by an in-mold molding method, a hot stamping method, or a vacuum forming method are transferred.
(18)
A metal layer is formed on the base film by thin film deposition,
By stretching the base film, fine cracks are formed in the metal layer,
The metal layer on which the fine cracks were formed and
A decorative film including the gaps between the fine cracks or the light-shielding portion formed on at least one of the metal layer and the surface opposite to the design surface is formed.
A method for manufacturing a structure that integrally forms a molded part with the decorative film by an insert molding method.
(19) The manufacturing method according to any one of (16) to (18).
The step of forming fine cracks is a method for producing a structure in which the base film is biaxially stretched at a stretch ratio of 5% or less in each axial direction.
(20)
A metal layer is formed on the base film by thin film deposition,
By stretching the base film, fine cracks are formed in the metal layer,
A method for producing a decorative film, which forms a light-shielding portion in at least one of the gaps between the fine cracks or between the metal layer and the surface opposite to the design surface.
(21) The structure according to any one of (1) to (13).
The fine cracks are irregularly formed structures.
(22) The structure according to any one of (1) to (13) and (21).
The decorative portion is a structure having a support layer having a tensile breaking strength smaller than that of the metal layer and supporting the metal layer.
(23) The structure according to (22).
The support layer portion is a structure that is a base film.
(24) The structure according to (26).
The support layer is a structure that is a coating layer formed on a base film.
(25) The manufacturing method according to any one of (16) to (19).
The metal layer forming step is a method for manufacturing a structure in which vacuum vapor deposition is performed on the base film conveyed along the peripheral surface of a rotating drum from a take-up roll to a take-up roll.

10 ... Metal decoration part 11, 411 ... Decorative area 12 ... Decorative film 12a, 412a ... Design surface 12b ... Adhesive surface 19, 419, 519 ... Base film 20, 420, 520 ... Metal layer 21, 421 ... Sealing Resin 22, 422, 522 ... Fine crack 30 ... Light-shielding part 31 ... Gap light-shielding part 32 ... Light-shielding layer 40 ... Decoration function part 41 ... Gap decoration function part 42 ... Decoration function layer 50, 450 ... Transfer film 100 ... Mobile terminal 101 ... Housing part 200 ... Vacuum vapor deposition device 250 ... Axial stretching device 300, 350 ... Molding device

Claims (20)

The first side and
A second surface opposite to the first surface,
A metal layer with fine cracks and
A decorative portion having a gap between the fine cracks or a light-shielding portion formed on at least one of the metal layer and the second surface.
A structure comprising a member having a decorated area to which the decorated portion is adhered so that the first surface faces the surface side. The structure according to claim 1.
The light-shielding portion is a structure including a gap light-shielding portion formed in the gaps of the fine cracks. The structure according to claim 1.
The light-shielding portion is a structure including a light-shielding layer formed between the metal layer and the second surface. The structure according to claim 1.
The light-shielding portion includes a gap light-shielding portion formed in the gap between the fine cracks, and a light-shielding layer located between the metal layer and the second surface and integrally formed with the gap light-shielding portion. Structure containing. The structure according to claim 1.
The decorative portion is a structure including a decorative functional portion formed in at least one of the gaps between the fine cracks or the metal layer and the second surface and having a decorative function. The structure according to claim 5.
The decoration function unit is a structure having a decoration function utilizing at least one of transmission and reflection of light. The structure according to claim 5.
The decoration function unit is a structure including a gap decoration function unit formed in the gaps of the fine cracks. The structure according to claim 5.
The decorative functional unit is a structure including a decorative functional layer formed between the metal layer and the second surface. The structure according to claim 5.
The decoration function unit is located between the gap decoration function unit formed in the gap between the fine cracks and the metal layer and the second surface, and is integrated with the gap decoration function unit. A structure that includes a decorative functional layer and is composed. The structure according to claim 1.
The metal layer is a structure that is any one of aluminum, titanium, chromium, and an alloy containing at least one of these. The structure according to claim 1.
The metal layer is a structure having a thickness of 30 nm or more and 300 nm or less. The structure according to claim 1.
The fine crack is a structure having a pitch in the range of 1 μm or more and 500 μm or less. The structure according to claim 1.
A structure constructed as a housing component, vehicle, or at least part of a building. The structure according to claim 1.
The decorative portion is a structure having a fixing layer for immobilizing the fine cracks. With the base film
Formed on the base film
The first side and
A second surface opposite to the first surface,
A metal layer with fine cracks and
A decorative film comprising a gap between the fine cracks or a decorative portion having a light-shielding portion formed on at least one of the metal layer and the second surface. A metal layer is formed on the base film by thin film deposition,
By stretching the base film, fine cracks are formed in the metal layer,
The metal layer on which the fine cracks were formed and
A decorative film including the gaps between the fine cracks or the light-shielding portion formed on at least one of the metal layer and the surface opposite to the design surface is formed.
A transfer film is formed by adhering a carrier film to the decorative film.
A method for manufacturing a structure for forming a molded part so that the decorative film is transferred from the transfer film by an in-mold molding method, a hot stamping method, or a vacuum forming method. A metal layer is formed on the base film by thin film deposition,
By stretching the base film, fine cracks are formed in the metal layer,
The metal layer on which the fine cracks were formed and
A transfer film including the gaps between the fine cracks or the light-shielding portion formed on at least one of the metal layer and the surface opposite to the design surface is formed.
A method for manufacturing a structure for forming a molded part so that the metal layer and the light-shielding portion peeled off from the base film by an in-mold molding method, a hot stamping method, or a vacuum forming method are transferred. A metal layer is formed on the base film by thin film deposition,
By stretching the base film, fine cracks are formed in the metal layer,
The metal layer on which the fine cracks were formed and
A decorative film including the gaps between the fine cracks or the light-shielding portion formed on at least one of the metal layer and the surface opposite to the design surface is formed.
A method for manufacturing a structure that integrally forms a molded part with the decorative film by an insert molding method. The manufacturing method according to claim 16.
The step of forming fine cracks is a method for producing a structure in which the base film is biaxially stretched at a stretch ratio of 5% or less in each axial direction. A metal layer is formed on the base film by thin film deposition,
By stretching the base film, fine cracks are formed in the metal layer,
A method for producing a decorative film, which forms a light-shielding portion in at least one of the gaps between the fine cracks or between the metal layer and the surface opposite to the design surface.

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