KR101666799B1 - Method for fabricating a three-dimensional effected film and inmold injection method using the method for fabricating a three-dimensional effected film - Google Patents

Abstract

The present invention provides a method for producing a three-dimensional film and an in-mold injection method using the film. The method for producing a three-dimensional film of the present invention is a step of preparing a substrate film. A step of coating the transferring resin on the base film to a predetermined thickness. A step of forming a three-dimensional pattern layer on which an embossing pattern is transferred to form an intaglio pattern on the transferring resin. And forming a release layer on the three-dimensional pattern layer so as to have a three-dimensional pattern along the depressed pattern of the three-dimensional pattern layer. And a hard coating layer is formed in contact with the upper surface of the release layer. And forming an adhesive layer on the hard coating layer.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a film having a three-dimensional effect and a method of fabricating a three-dimensional effected film using the film,

The present invention relates to a method of producing a film having a three-dimensional effect, and an in-mold injection method using the film having the three-dimensional effect, in which the upper surface of the injection member has a three-dimensional appearance by in-

A transfer film for in-mold injection is a laminate film composed of a plurality of layers each having inherent characteristics, and includes a printed pattern layer containing a metal deposition layer or printing various patterns for expressing a metal feel or pattern . However, the laminated film including the metal deposition layer and the print pattern layer may represent a metallic sense or a planar pattern. However, the hologram effect or the hologram effect may cause the color or pattern to vary depending on the viewing angle of the pattern or the viewing angle. It can not exhibit an optical gradation effect.

In order to give a three-dimensional effect to the product, conventionally, a method of scratching the product with sandpaper was applied. That is, sandpaper is used to sculpt the prints intricately and give a three-dimensional effect to the hairline pattern. However, in this case, the reproducibility of the pattern is poor and the yield is low, which leads to mass production. Further, it is impossible to form other embossed patterns such as other fabric patterns or diamond patterns. In addition, there have been many problems such as occurrence of dust and foreign matter during the scratching operation and the yield is very low.

As a method for forming other patterns such as woven patterns, there has been a method of directly engraving patterns on an in-mold injection mold and transferring them to the surface of the injection molded product when in-mold injection. This is because the manufacturing cost of the mold is increased and maintenance of the mold is very There was a difficult problem.

As a solution to this problem, Korean Patent Laid-Open Publication No. 10-2013-0061848 discloses a method of forming a three-dimensional pattern by gravure printing on a UV cured layer. However, in the above printing method, the transfer accuracy of the pattern is lowered and it is difficult to obtain a thickness exceeding a certain level, which makes it difficult to obtain a pattern of a desired pattern.

Korean Patent Publication No. 10-2013-0061848

The present invention provides a method for producing a film having a three-dimensional effect with a thickness of at least a predetermined thickness, a three-dimensional effect having a high dimensional reproducibility, a high yield, and an in-mold injection method using the three- .

Therefore, in the method for producing a film having a three-dimensional effect of the present invention, a step of preparing a substrate film is performed. A step of forming a three-dimensional pattern layer on the base film, the three-dimensional pattern layer being formed of a transferring resin and transferring a embossed pattern to form an intaglio pattern. And forming a release layer on the three-dimensional pattern layer so as to have a three-dimensional pattern along the depressed pattern of the three-dimensional pattern layer. And a hard coating layer is formed in contact with the upper surface of the release layer. And forming an adhesive layer on the hard coating layer.

Wherein the transferring resin is an ultraviolet ray hardening resin and the step of forming the three-dimensional pattern layer comprises pressing the base film coated with the transferring resin onto a master roll having a relief pattern corresponding to the relief pattern, Transferring the substrate film to the base film, and UV-curing the base film having the engraved pattern.

In this case, the ultraviolet curable resin may be at least one oligomer of acrylate, urethane acrylate, epoxy acrylate, and polyester acrylate.

The step of transferring the three-dimensional pattern onto the transferring resin to form the three-dimensional pattern layer may include: supplying the base film continuously to a master roll having a relief pattern shape; Applying the ultraviolet curable resin onto the base film, pressing the ultraviolet curable resin onto the master roll, transferring the ultraviolet curable resin to the master roll, and curing the ultraviolet curable resin, wherein the viscosity of the ultraviolet curable resin may be 1 to 1000 CPS .

On the other hand, the base film is made of a transparent plastic material and can have an elongation of 50% to 200%.

The release layer is made of at least one resin selected from among fluororesin, silicone resin and acrylic resin, and the thickness of the release layer may be 0.1 탆 to 5 탆.

The method may further include forming a lower primer layer on the upper surface of the hard coat layer between the step of forming the hard coat layer and the step of forming the adhesive layer. And forming a printed pattern layer on the upper surface of the lower primer layer. And forming an upper primer layer for improving the adhesion of the print pattern layer on the print pattern layer.

The upper and lower primer layers may include a main resin, which is at least one of urethane, acrylic, and urethane acrylic resins, and a curing agent composed of one of polyisocyanate and epoxy resin.

An in-mold injection method using a film having a three-dimensional effect in another aspect of the present invention is characterized in that a film having a three-dimensional sensation having the above structure is in-mold injected into an injection member, and the base film is separated from the injection member.

In this case, the hard coating layer may be a hybrid type resin capable of at least one of thermal curing and ultraviolet curing.

According to the present invention, according to the method of producing a film having a three-dimensional effect and the in-mold injection method using the three-dimensional film of the present invention, it is possible to variously realize delicate micro-stereoscopic patterns by an engraved transcription method, In addition, the pattern reproducibility can be ensured and a high yield can be realized in the case of mass production.

1 is a flow chart showing each step of a method of manufacturing a three-dimensional film according to a preferred embodiment of the present invention.
2A to 2I are cross-sectional views illustrating a laminated structure of a film manufactured by the method of manufacturing a film according to a preferred embodiment of the present invention.
FIG. 3 is a schematic view schematically showing a step in the step of forming a three-dimensional pattern layer in FIG.
4A is a schematic view showing a step of in-mold injection of an injection member using the film having the three-dimensional effect shown in Fig. 2 in another aspect of the present invention.
4B is a cross-sectional view illustrating the injection member according to FIG. 4A.

Hereinafter, an apparatus and method for manufacturing a multi-layer patterned film according to an embodiment of the present invention will be described in detail with reference to the accompanying drawings. The terminology used herein is a term used to properly express the preferred embodiment of the present invention, which may vary depending on the intention of the user or operator or the custom of the field to which the present invention belongs. Therefore, the definitions of these terms should be based on the contents throughout this specification.

1 is a block diagram showing each step of a method of manufacturing a three-dimensional film according to a preferred embodiment of the present invention. As shown in FIG. 1, the method for producing a three-dimensional film according to the present invention comprises the steps of preparing a base film (S10), applying a transfer resin to the base film to a predetermined thickness (S20) (S30) of forming a three-dimensional pattern layer on which an embossed pattern is transferred to the transfer resin to form an intaglio pattern; and a step (S30) of forming a three-dimensional pattern on the embossed pattern of the three- (S40) forming a release layer on the upper side of the release layer, forming a hard coat layer on the upper side of the release layer (S50), and forming an adhesive layer on the hard coat layer (S80).

(S55) forming a lower primer layer between the step (S50) of forming the hard coating layer and the step (S80) of forming an adhesive layer, the step of forming a print pattern layer (S60), the step of forming an upper primer layer (S70).

The film having the three-dimensional effect produced by the above-described method can be in-deposited on the injection member later by an in-mold injection process. In this case, the base film and the three-dimensional pattern layer are removed and removed in the injection step, and the hard coating layer having a pattern opposite to that of the three-dimensional pattern layer is exposed to the outside.

FIGS. 2A to 2H are cross-sectional views illustrating a laminated structure of a film manufactured by the method of manufacturing a film according to a preferred embodiment of the present invention. Each step will now be described in more detail with reference to Figures 2A through 2H. As shown in FIG. 2A, first, the base film 110 is prepared.

The base film 110 serves as a base substrate of a film having a three-dimensional feel, and serves to support a plurality of coating layers stacked on the top, which will be described later. The base film 110 may be made of a polymer plastic material. For example, one selected from among PVC, PET, PP, PE, PI, and PEN can be used, and more preferably, PET having excellent stretchability, heat stability, chemical resistance and price competitiveness can be used. In particular, the base film 110 should have a certain elongation or more in order to cope with three-dimensional molding at the time of in-mold injection. The elongation is usually in the range of 50% to 200%, and it is preferable that the elongation is equal in the transverse direction and the longitudinal direction. The base film 110 may be removed after the release of the in-mold film.

Thereafter, as shown in FIG. 2B, a step of coating the transferring resin 121 to a predetermined thickness on the base film 110 is performed. Since the engraved pattern is formed in the transferring resin 121, the transferring resin preferably has a hardness of at least a certain level in order to maintain the engraved pattern 125. In this case, the transferring resin 121 may be an ultraviolet curing resin. Examples of the ultraviolet curable resin include oligomers such as acrylate, urethane acrylate, epoxy acrylate and polyester acrylate, and monomers, photoinitiators and additives may be added thereto. It is preferable to selectively use the hardness in consideration of the adhesion to the base film 110.

Thereafter, as shown in FIG. 2C, a step of forming a three-dimensional pattern layer 120 by transferring a three-dimensional pattern onto the transferring resin 121 is carried out. The three-dimensional pattern layer 120 is formed with an embossed pattern 125 by transferring an emboss pattern. The three-dimensional pattern layer 120 may have various microembossed patterns such as hair lines.

In order to form the three-dimensional pattern layer 120, the three-dimensional pattern may be transferred from a master roll 30 or a master belt on which a relief pattern opposite to the relief pattern 125 is formed.

3 illustrates a step of forming the three-dimensional pattern layer 120, which is a component of the present invention. 3, in order to form the three-dimensional pattern layer 120, a transfer resin supply unit 60, a master roll 30, a press roll 20, an ultraviolet curing member 40, A substrate film unwinding roll 10, and a substrate film rewinding roll 50. [ Therefore, the transferring resin 121 may be an ultraviolet ray hardening resin.

The substrate film unwinding roll 10 is wound with a base film 110 and the base film 110 is fed toward the master roll 30. The transfer resin supply unit 60 is disposed adjacent to the upstream side of the master roll 30 to apply the transfer resin 121 to the base film 110. [ On the outer side of the master roll (30), a relief pattern (35) is formed. The ultraviolet curing member 40 is disposed adjacent to the master roll 30 so that the engraved pattern 125 formed by being transferred by the master roll 30 is cured on the top surface of the base film 110. In this case, it is preferable that the base film 110 is transparent so that the ultraviolet ray passes therethrough. The substrate film rewinding roll 50 recovers the base film 110 on which the ultraviolet cured pattern layer 120 is formed.

The base film 110 is first fed from the base film unwinding roll 10 in the direction of the master roll 30 to form the three-dimensional pattern layer 120 using the base film. The transfer resin 121 is applied from the transfer resin supply unit 60 to a predetermined thickness just before being supplied to the master roll 30. Thereafter, the base film 110 is pressed and adhered to the master roll 30 by the press roll 20, and the relief pattern of the master roll 30 is transferred so that the print pattern layer is engraved. In addition, the print pattern layer is cured by the ultraviolet curing member (40). The substrate film 110 on which the printing pattern layer is formed is separated from the master roll 30 and rewound by the substrate film rewinding roll 50. [

By the process of transferring the relief pattern of the master roll 30 or the master belt by the above method, reproducibility of the pattern is excellent. Further, the three-dimensional pattern layer has a three-dimensional effect.

In this case, the ultraviolet curing member 40 is selectively used depending on the type of resin in the high-pressure mercury lamp and the metal halide lamp, and the integrated light quantity irradiated is suitably 100-1500 mJ / cm2, preferably 300-100 mJ / cm2.

On the other hand, an ultraviolet curable resin for forming a three-dimensional pattern generally has a high viscosity, so that it tends to be impregnated with air bubbles when it is loaded on the press roll 20 and is subjected to pressurized coating. Therefore, at room temperature (below 25 degrees Celsius), it is difficult to increase the working speed, resulting in a decrease in productivity.

Therefore, in the step of forming the three-dimensional pattern layer 120 in the present invention, it is preferable that the temperature of the master roll 30 is kept constant by a method capable of lowering the viscosity of the ultraviolet ray hardening resin. To this end, the master roll 30 has a jacket system, and maintains the temperature by supplying heat oil at a constant temperature during the operation. In operation, the viscosity of 1-1000 CPS is suitable, and the proper temperature range for maintaining the viscosity is 25-80 degrees, preferably 30-50 degrees, depending on the original viscosity of the UV- It is suitable.

In FIG. 3, a printing pattern layer is formed after the transfer resin is applied on the base film first, but the present invention is not limited thereto. That is, in the case of the present invention, an engraved pattern may be formed at the same time as the transfer resin is applied. For example, the resin is applied to a mast roll or a mast belt and pressed onto the base film.

2D, a step of forming a release layer 130 on the upper portion of the three-dimensional pattern layer 120 so as to have a three-dimensional pattern along the depressed pattern 125 of the three-dimensional pattern layer 120 It goes through.

The mold releasing layer 130 can be transferred from the hard coat layer 140, which will be described later, to the injection-molded surface from the adhesive layer 170 during the in-mold injection. The resin used as the release agent for forming the release layer 130 may be at least one resin selected from fluorine resin, silicone resin, and acrylic resin. As a coating method, gravure, microgravure, slot die coating can be used, and the thickness is preferably in the range of 0.1-5 mu m. If the thickness exceeds 5 mu m, the adhesive layer 170 becomes too thick so that the hard coat layer 140 to be coated later can not have sufficient stereoscopic effect. When the thickness is less than 0.1 mu m, (110).

Thereafter, as shown in FIG. 2E, the hard coating layer 140 is formed to contact the upper surface of the release layer 130. Accordingly, the lower surface of the hard coating layer 140 has the same pattern as the engraved pattern 125 of the three-dimensional pattern layer 120.

The hard coating layer 140 is preferably a hybrid type resin capable of thermosetting, UV curing, or both of heat curing and UV curing. The hard coat layer 140 is required to have a hardness higher than a certain level. This is because it is necessary to ensure scratch resistance since the hard coat layer 140 forms the outermost surface of the injection member after in-mold injection and transfer. In addition, the hard coating layer 140 should have a stretch ratio equal to or greater than a predetermined value so as not to cause cracking during injection. Therefore, it is advantageous that the semi-cured state having a certain elongation is advantageous before molding after coating and completely cured after ultraviolet curing after injection molding.

Thereafter, as shown in FIG. 2I, an adhesive layer 170 is formed on the hard coating layer 140. The adhesive layer 170 functions to increase adhesion with the injection member in the in-mold process. The adhesive layer 170 may be selectively used depending on the compatibility with an injection resin in acrylic, urethane, urethane acrylic copolymer, polyester or polyester modified systems.

A lower primer layer 145 and a printed pattern layer 150 and an upper primer layer 160 as shown in FIG. 2F, FIG. 2G and FIG. 2H are formed between the hard coating layer 140 and the adhesive layer 170. [ ) Can be interposed.

2F, the lower primer layer 145 is formed between the hard coating layer 140 and the print pattern layer 150 to be described later. The lower primer layer 145 is formed between the print pattern layer 150 and the lower primer layer 145 It reinforces the adhesive force.

As shown in FIG. 2G, the print pattern layer 150 functions to form a sheath by forming a printed pattern on the outer surface of the injection molded article after injection transfer. The printing may be used alone as a printing ink, or a metal paste may be deposited to give a metal effect, or a silver paste or a silver ink may be used.

The upper primer layer 160 is formed between the print pattern layer 150 and the adhesive layer 170 that is finally laminated to form a gap between the print pattern layer 150 and the adhesive layer 170, To reinforce the adhesive strength. This is because the pigment penetrates into the print pattern layer 150 and is not adhered well to the adhesive layer 170. In order to compensate the adhesion, the upper primer layer 160 is formed. In addition, the upper primer layer 160 may serve as a protective layer for suppressing breakage or deformation of the printed pattern layer 150 during in-mold injection. As the main resin used as the upper primer layer 160, urethane-based, acrylic-based, and urethane-acrylate-based resins are used. As the curing agent, polyisocyanate, epoxy resin or the like may be used selectively or one or more.

The embossed hard coat layer 140, the lower primer layer 1450, the print pattern layer 150, the upper primer layer 160, and the adhesive layer 170 are formed on the injection member, And the base film 110 of the three-dimensional pattern layer 120 is separated from the three-dimensional attachment film 200 by the release layer 130 as a so-called removal film 210 .

Fig. 4A is a view showing an in-mold injection apparatus, and Fig. 4B is a cross-sectional view showing an injection member manufactured thereby. 4A and 4B, in the in-mold injection method using the film 100 having a three-dimensional effect in another aspect of the present invention, a film having a three-dimensional effect between the cavity block 91 and the core block 92 Injecting the injection member 1 while injecting the base film 110 into the injection member 1 while inserting the base film 110 into the injection member 1. Accordingly, the three-dimensional attachment film 200 forms the outer surface of the injection member 1, and the removal film 210 is removed.

In this case, the injection member may be a plastic material that forms an outer shape of a home appliance such as a smart phone, a tablet PC, a refrigerator or a washing machine.

A depressed pattern 125 is formed on the base film 110 and a lower surface of the hard coating layer 140 is formed to correspond to the depressed pattern 125 in order to form the hard coating layer 140 having a three- The hard coating layer 140 has a three-dimensional effect by removing the base film 110 after the three-dimensional pattern is formed.

As a result, the hard coat layer 140 closest to the outside has a three-dimensional effect, so that a clear three-dimensional effect can be obtained, reproducibility can be improved, and a fine pattern can be realized without difficulty.

Hereinafter, in order to facilitate understanding of the present invention, a three-dimensional film (hereinafter, referred to as an "embodiment") produced by a preferred embodiment of the present invention and a three- (Hereinafter referred to as " comparative example ").

<Examples>

A transferring resin 121 containing 50% by weight of a urethane acrylate having 6 functional groups, 30% by weight of a urethane acrylate having 10 functional groups, 15% by weight of an acrylate monomer, 3% by weight of a photoinitiator and 2% Was applied onto the top of a PET film having a thickness of 50 탆 which was the base film 110 and pressed with a master roll 30 on which a micropattern of a hair line was etched and irradiated with UV light (high pressure mercury lamp, 500 mJ / cm 2) Next, 100 parts by weight of a resin mixed with 70% by weight of a fluorine resin and 30% by weight of an acrylic resin was mixed with 5 parts by weight of a melamine curing agent to form a release layer ( 130) was prepared, and a 0.5 μm thick coating layer was formed by a microgravure coating method to form a release layer 130.

The hard coating layer 140 is formed by coating a hard coating composition capable of being thermally cured and UV curable by a micro-gravure coating method on the release layer 130 to form a hard coating layer 140. The urethane- Mu m. Next, the printed pattern layer 150 is formed to a thickness of 2-4 μm, and the same upper side primer layer 160 is coated with 1 μm, and then the adhesive layer 170 is finally coated with 1-2 μm. Thereafter, aging was performed at 40 degrees for 3 days to prepare a final in-mold transfer film.

<Comparative Example>

In Example 1 of the present invention, a method of forming a micro-embossed pattern of a hair line was carried out by pressing with a master roll in which a micropattern of a hairline was formed by etching and peeling off after UV irradiation (high pressure mercury lamp, 500 mJ / Except that a hair line was formed by a method of forming scratches on PET which is a base film 110 using a sandpaper instead of using a method of transferring the base film 110.

Property evaluation

The surface gloss after in-mold injection, the reproducibility (uniformity of surface roughness), and the surface hardness of the hair line were evaluated in Examples and Comparative Examples. In this case, gloss measurement was performed with a glossmeter, surface roughness was measured with an illuminance meter, and surface hardness was measured with a Pencil Hardness Tester.

Table 1 below shows the evaluation results of the transfer films for in-mold use in Examples and Comparative Examples

division Polish
(60 degrees angle) Surface roughness uniformity Surface hardness Example 95 O H Comparative Example 15 X H

Referring to the above Table 1, the gloss of the example was constant, and the gloss of the comparative example was almost the same as that of matte when the sandpaper was sanded. Also, as a result of measuring the surface roughness by taking a sample locally, the examples showed uniformity without locally varying the illuminance, and in the comparative example, the local illuminance variation was large.

The surface hardness showed no significant difference, but the hardness test site showed visible results in the comparative example due to the difference in gloss.

As a result of the above experiment, it is difficult to control the surface gloss during sanding, the reproducibility of appearance is decreased, and when the hair line emboss pattern is formed by the transition, the surface gloss can be easily controlled, Of reproducibility.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the scope of the present invention. Therefore, the true scope of protection of the present invention should be defined only by the appended claims.

30: master roll 100: film having a three-dimensional effect
110: base film 120: three-dimensional pattern layer
121: transfer resin 125: engraved pattern
130: release layer 140: hard coat layer
150: Printed layer 160: Lower primer layer
170: adhesive layer 200: steric adhesive film
210: Removal film

Claims (9)

Preparing a base film;
Forming a three-dimensional pattern layer on the top surface of the base film, the three-dimensional pattern layer being formed of a transferring resin and having an embossed pattern transferred thereto to form an intaglio pattern;
Forming a release layer on top of the three-dimensional pattern layer so as to have a three-dimensional pattern along the depressed pattern of the three-dimensional pattern layer;
Forming a hard coat layer in contact with the upper surface of the release layer; And
And forming an adhesive layer on the hard coating layer,
The step of forming the three-dimensional pattern layer includes:
Continuously supplying the base film to a master roll having an embossed pattern shape;
Applying an ultraviolet curing resin on the base film in front of the master roll;
Curing the base film coated with the ultraviolet curing resin by pressing and transferring the ultraviolet curable resin onto the master roll and ultraviolet curing,
Wherein the ultraviolet curing resin has a viscosity of 1 to 1000 CPS. The method according to claim 1,
The transferring resin is an ultraviolet curable resin,
The step of forming the three-dimensional pattern layer includes:
Pressing the base film coated with the transferring resin onto a master roll on which a relief pattern corresponding to an engraved pattern is formed to transfer the engraved pattern onto the base film; And
And ultraviolet curing the base film having the engraved pattern. 3. The method of claim 2,
Wherein the ultraviolet ray hardening resin is at least one oligomer selected from the group consisting of acrylate, urethane acrylate, epoxy acrylate and polyester acrylate. delete The method according to claim 1,
Wherein the base film is made of a transparent plastic material and has a elongation of 50% to 200%. The method according to claim 1,
Wherein the release layer is made of at least one resin selected from the group consisting of a fluororesin, a silicone resin, and an acrylic resin, and the thickness of the release layer is 0.1 탆 to 5 탆. Preparing a base film;
Forming a three-dimensional pattern layer on the top surface of the base film, the three-dimensional pattern layer being formed of a transferring resin and having an embossed pattern transferred thereto to form an intaglio pattern;
Forming a release layer on top of the three-dimensional pattern layer so as to have a three-dimensional pattern along the depressed pattern of the three-dimensional pattern layer;
Forming a hard coat layer in contact with the upper surface of the release layer; And
And forming an adhesive layer on the hard coating layer,
Between the step of forming the hard coat layer and the step of forming the adhesive layer,
Forming a lower primer layer on the hard coating layer;
Forming a printed pattern layer on the upper surface of the lower primer layer; And
Further comprising the step of forming an upper primer layer for improving the adhesion of the print pattern layer on the print pattern layer,
Wherein the upper and lower primer layers comprise a main resin which is at least one of urethane, acrylic and urethane acrylic resins, and a curing agent composed of one of polyisocyanate and epoxy resin. A film produced by the method for producing a three-dimensional film according to any one of claims 1, 2, 3, 5, 6, and 7 is in-mold injected into an injection member,
And the base film is separated from the injection member. The in-mold injection method using the film having a three-dimensional feel. 9. The method of claim 8,
Wherein the hard coating layer is a hybrid type resin capable of at least one of thermal curing and ultraviolet curing.

Images