WO2016072450A1 - 転写シート及びこれを用いたハードコート体 - Google Patents
転写シート及びこれを用いたハードコート体 Download PDFInfo
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- WO2016072450A1 WO2016072450A1 PCT/JP2015/081164 JP2015081164W WO2016072450A1 WO 2016072450 A1 WO2016072450 A1 WO 2016072450A1 JP 2015081164 W JP2015081164 W JP 2015081164W WO 2016072450 A1 WO2016072450 A1 WO 2016072450A1
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- hard coat
- layer
- resin
- transfer sheet
- mass
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J7/00—Adhesives in the form of films or foils
- C09J7/50—Adhesives in the form of films or foils characterised by a primer layer between the carrier and the adhesive
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
- B32B27/308—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising acrylic (co)polymers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/16—Making multilayered or multicoloured articles
- B29C45/1679—Making multilayered or multicoloured articles applying surface layers onto injection-moulded substrates inside the mould cavity, e.g. in-mould coating [IMC]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/06—Interconnection of layers permitting easy separation
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J201/00—Adhesives based on unspecified macromolecular compounds
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J7/00—Adhesives in the form of films or foils
- C09J7/20—Adhesives in the form of films or foils characterised by their carriers
- C09J7/22—Plastics; Metallised plastics
- C09J7/24—Plastics; Metallised plastics based on macromolecular compounds obtained by reactions involving only carbon-to-carbon unsaturated bonds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/402—Coloured
- B32B2307/4026—Coloured within the layer by addition of a colorant, e.g. pigments, dyes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/536—Hardness
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J157/00—Adhesives based on unspecified polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- C09J157/06—Homopolymers or copolymers containing elements other than carbon and hydrogen
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2301/00—Additional features of adhesives in the form of films or foils
- C09J2301/30—Additional features of adhesives in the form of films or foils characterized by the chemical, physicochemical or physical properties of the adhesive or the carrier
- C09J2301/302—Additional features of adhesives in the form of films or foils characterized by the chemical, physicochemical or physical properties of the adhesive or the carrier the adhesive being pressure-sensitive, i.e. tacky at temperatures inferior to 30°C
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2301/00—Additional features of adhesives in the form of films or foils
- C09J2301/40—Additional features of adhesives in the form of films or foils characterized by the presence of essential components
- C09J2301/414—Additional features of adhesives in the form of films or foils characterized by the presence of essential components presence of a copolymer
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2433/00—Presence of (meth)acrylic polymer
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2433/00—Presence of (meth)acrylic polymer
- C09J2433/003—Presence of (meth)acrylic polymer in the primer coating
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2433/00—Presence of (meth)acrylic polymer
- C09J2433/006—Presence of (meth)acrylic polymer in the substrate
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2467/00—Presence of polyester
- C09J2467/006—Presence of polyester in the substrate
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2475/00—Presence of polyurethane
- C09J2475/003—Presence of polyurethane in the primer coating
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S428/00—Stock material or miscellaneous articles
- Y10S428/914—Transfer or decalcomania
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/28—Web or sheet containing structurally defined element or component and having an adhesive outermost layer
- Y10T428/2843—Web or sheet containing structurally defined element or component and having an adhesive outermost layer including a primer layer
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/28—Web or sheet containing structurally defined element or component and having an adhesive outermost layer
- Y10T428/2848—Three or more layers
Definitions
- the present invention relates to a transfer sheet and a hard coat body using the same. More specifically, the present invention relates to a transfer sheet capable of imparting excellent weather resistance as well as hard coat properties to a resin molded product such as organic glass, and a hard coat body using the same.
- resin molded products such as polycarbonate, polyacrylate, polymethyl methacrylate, polyethylene terephthalate, polyethylene naphthalate, polyolefin, and ABS are excellent in transparency and lighter than inorganic glass. Widely used as a substitute for inorganic glass in the field.
- polycarbonate is excellent in impact resistance, heat resistance, transparency, etc., exterior materials and interior materials for building structures of general residences and public facilities, automotive interior and exterior parts, solar cells Use as a cover, a solar cell substrate, a member of home appliances, or the like has been studied.
- a hard coat layer made of a cured resin is laminated on the surface of the resin molded product. Giving (scratch resistance etc.) is generally performed.
- a transfer sheet provided with a hard coat layer on a base film for release (base film) is used, and a hard coat layer is applied to a resin molded product.
- a technique for transferring is known.
- Patent Document 1 in a hard coat transfer material in which a release layer, a hard coat layer, a primer layer, and a heat seal layer are sequentially formed on one side of a base film, the release layer has a penetration of 10 at 25 ° C.
- the hard coat transfer material which is mainly composed of the following waxes and the hard coat layer is made of UV or electron beam curable resin, provides a hard coat function efficiently and easily to the substrate to be transferred. It is disclosed that equipment contamination can be reduced during coating processing.
- Patent Document 2 discloses an ionizing radiation resin layer made of ionizing radiation curable resin, an intermediate first layer made of butyral resin and isocyanate, and a butyral resin on the base film surface having releasability. It is disclosed that the surface protective transfer material provided with the intermediate second layer and the adhesive layer in this order can impart excellent scratch resistance, transparency, solvent resistance, chemical resistance, and water resistance.
- the conventional transfer sheet can impart a certain hard coat property to the resin molded product, it is not fully satisfactory in terms of imparting weather resistance.
- resin moldings used in exteriors and semi-exteriors such as automobile windows, building windows, roofing parts such as terraces and carports, entrance doors, soundproof walls, windshields, balcony partitions, etc.
- extremely high weather resistance is required because it is exposed to wind and rain, the conventional transfer sheet does not sufficiently satisfy the demand for such a resin molded product.
- JP 2007-253341 A Japanese Patent Laid-Open No. 10-166510
- a laminate method of laminating a laminate sheet itself provided with a hard coat layer on a resin molded product is known.
- the laminate sheet used in such a lamination method has a layer structure in which a primer layer and a hard coat layer are laminated in this order on a base film.
- a hard coat layer is formed by applying a resin composition containing a curable resin on the primer layer and curing the curable resin. Therefore, the primer layer and the hard coat layer are firmly adhered, and excellent weather resistance adhesion is obtained.
- the transfer sheet described above has a layer structure in which a layer structure is different from that of the laminate sheet, and a hard coat layer, a primer layer, and an adhesive layer are laminated in this order on a base film for release. ing. Therefore, the transfer sheet is different from the laminate sheet in terms of the manufacturing process, and a hard coat layer is formed by curing a resin composition containing a curable resin on a base film for release. Later, it is manufactured by forming a primer layer and an adhesive layer in this order.
- the primer layer is formed after the curable resin is cured to form the hard coat layer, the weather resistance adhesion between the hard coat layer and the primer layer becomes insufficient, and this improves the weather resistance. This is thought to be one of the causes of the decline.
- an object of the present invention is to provide a transfer sheet capable of imparting excellent weather resistance as well as hard coat properties to a resin molded product such as organic glass. Furthermore, an object of the present invention is to provide a hard coat body in which a hard coat layer is transferred to a resin molded product using the transfer sheet.
- the present inventor has intensively studied to solve the above problems, and in the transfer sheet having a release base film, a hard coat layer, a primer layer, and an adhesive layer in this order, the hard coat layer is cured.
- a cured product of a resin composition containing a functional resin and further forming a primer layer with a binder resin containing a polyurethane having a mass average molecular weight of 40,000 to 100,000 and an acrylic component of 1 to 30% by mass.
- a binder resin containing a polyurethane having a mass average molecular weight of 40,000 to 100,000 and an acrylic component of 1 to 30% by mass. It has been found that the weather-resistant adhesion between the hard coat layer and the primer layer is improved, and it is possible to impart excellent weather resistance as well as hard coat properties to the resin molded product to be transferred.
- the present invention has been completed by further studies based on such knowledge.
- this invention provides the invention of the aspect hung up below.
- Item 1 At least a release base film, a hard coat layer, a primer layer, and an adhesive layer in this order,
- the hard coat layer is formed of a cured product of a resin composition containing a curable resin
- the transfer sheet, wherein the primer layer is formed of a binder resin containing polyurethane having a mass average molecular weight of 40,000 to 100,000 and an acrylic component of 1 to 30% by mass.
- the primer layer is formed of a binder resin containing polyurethane having a mass average molecular weight of 40,000 to 100,000 and an acrylic component of 1 to 30% by mass.
- Item 2. Item 2.
- the transfer sheet according to Item 1, wherein the polyurethane has a mass average molecular weight of 50,000 to 80,000 and an acrylic component of 5 to 20% by mass.
- Item 3. Item 3.
- Item 4. The transfer sheet according to any one of Items 1 to 3, wherein the polyurethane is a polycarbonate-based urethane acrylic copolymer and / or a polyester-based urethane acrylic copolymer.
- Item 5. The transfer sheet according to any one of Items 1 to 4, wherein the curable resin is an ionizing radiation curable resin.
- Item 7. The transfer sheet according to any one of Items 1 to 6, wherein the adhesive layer contains a heat-sensitive adhesive resin or a pressure-sensitive adhesive resin.
- Item 8. At least one of the substrate film for release and the hard coat layer, between the hard coat layer and the primer layer, between the primer layer and the adhesive layer, and on the surface opposite to the primer layer side of the adhesive layer Item 8.
- the hard coat layer is formed of a cured product of a resin composition containing a curable resin,
- Item 10. The hard coat according to Item 9, wherein the polyurethane has a mass average molecular weight of 50,000 to 80,000 and an acrylic component is contained in an amount of 5 to 20% by mass.
- Item 11 Item 11.
- Item 12. The hard coat according to any one of Items 9 to 11, wherein the polyurethane is a polycarbonate-based urethane acrylic copolymer and / or a polyester-based urethane acrylic copolymer. Item 13. Item 13. The hard coat body according to any one of Items 9 to 12, wherein the curable resin is an ionizing radiation curable resin. Item 14. Item 14. The hard coat body according to any one of Items 9 to 13, wherein the curable resin is a combination of (i) a trifunctional or higher functional ionizing radiation curable resin and (ii) a bifunctional (meth) acrylate monomer. Item 15. Item 15.
- Item 16 There is a partially formed colored layer on at least one of the surface of the hard coat layer, between the hard coat layer and the primer layer, between the primer layer and the adhesive layer, and between the adhesive layer and the resin molded product.
- Item 16. The hard coat body according to any one of Items 9 to 15.
- Item 18. Item 18.
- a hard coat layer formed of a cured product of a resin composition containing a curable resin can be laminated on a resin molded product serving as a transfer target, thereby providing excellent hard coat properties. (Scratch resistance etc.) can be provided in the resin molded product.
- the transfer sheet of the present invention can impart excellent weather resistance to the resin molded product to be transferred.
- the hard coat body of the present invention has both hard coat properties by a hard coat layer formed of a cured product of a resin composition containing a curable resin and excellent weather resistance by a primer layer containing a specific binder resin. Therefore, the required performance (hard coat property and weather resistance) of the exterior member or the semi-exterior member exposed to direct sunlight or wind and rain can be sufficiently provided.
- Transfer Sheet The transfer sheet of the present invention has at least a release base film 1, a hard coat layer 2, a primer layer 3, and an adhesive layer 4 in this order, and the hard coat layer 2 contains a curable resin.
- the primer layer 3 is formed of a binder resin containing polyurethane containing a mass average molecular weight of 40,000 to 100,000 and an acrylic component of 1 to 30% by mass. It is characterized by.
- the transfer sheet of the present invention will be described in detail.
- the transfer sheet of the present invention has a lamination structure having at least a base film 1 for release, a hard coat layer 2, a primer layer 3, and an adhesive layer 4 in this order. Prepare.
- a mold release may be performed between the mold release base film 1 and the hard coat layer 2 as necessary in order to facilitate the release of the mold base film 1.
- a layer may be provided.
- the transfer sheet of the present invention includes at least one of the hard coat layer 2 and the primer layer 3, the primer layer 3 and the adhesive layer 4, and the adhesive layer 4 on the surface opposite to the primer layer 3 side.
- the colored layer 5 partially formed for the purpose of concealing the adhesive application part, information display, imparting design, etc. when fixing the hard coat body produced using the transfer sheet of the present invention. May be provided.
- the transfer sheet of this invention WHEREIN The schematic diagram of the cross section of the aspect which has the colored layer 5 formed between the primer layer 3 and the contact bonding layer 4 is shown.
- the release base film 1 serves as a support base for supporting the hard coat layer 2, the primer layer 3, and the adhesive layer 4, and the hard coat layer 2, the primer layer 3 and the adhesive layer 4 are provided. It is a layer that is peeled off after being transferred to a transfer medium.
- the constituent resin of the base film 1 for releasing is not particularly limited as long as it can be used as a supporting base and the hard coat layer 2 can be peeled off.
- the base film 1 for mold release may be either an unstretched film or a stretched film, it suppresses shrinkage due to heat or ionizing radiation irradiation during production of the transfer film, and has excellent dimensional stability. From this point of view, a stretched film is preferable.
- the stretched film may be uniaxially stretched or biaxially stretched, but from the viewpoint of providing excellent dimensional stability, biaxial stretching is preferred.
- the base film 1 for release may be a single layer formed using a single resin film, or may be a multilayer formed using the same or different resin films.
- the base film 1 for release is subjected to corona discharge, glow discharge, plasma discharge, ozone / UV irradiation, flame treatment, hot air treatment as necessary in order to adjust the peel strength with the hard coat layer 1.
- the surface treatment such as chromium oxidation treatment may be performed.
- the thickness of the release base film 1 is usually 20 to 200 ⁇ m, preferably 30 to 100 ⁇ m, more preferably 38 to 80 ⁇ m.
- the hard coat layer 2 is a layer provided between the release base film 1 and the primer layer 3, and after being transferred to a resin molded product to be transferred, the resin molded product is positioned on the outermost surface. It is a layer that plays a role of imparting hard coat properties (such as scratch resistance) to the surface and contributes to improvement of weather resistance.
- the hard coat layer 2 is formed by a cured product of a resin composition containing a curable resin.
- a curable resin used for formation of the hard-coat layer 2 is resin hardened
- a thermosetting resin, normal temperature curable resin, 1 liquid reaction curable resin Two-component reaction curable resins, ionizing radiation curable resins, and the like can be given.
- thermosetting resin the room temperature curable resin, the one-component reaction curable resin, or the two-component reaction curable resin
- epoxy resin phenol
- thermosetting polyester resins thermosetting polyester resins
- melamine resins alkyd resins
- polyimide resins polyimide resins
- silicone resins thermosetting acrylic resins
- polyurethane resins and the like.
- Epoxy resin is a reaction with amine, acid catalyst, carboxylic acid, acid anhydride, hydroxyl group, dicyandiamide or ketimine; phenol resin is a reaction between base catalyst and excess aldehyde; urea resin is a polycondensation under alkaline or acidic conditions Reaction; Non-thermosetting polyester resin is a co-condensation reaction between maleic anhydride and diol; Melamine resin is a heat polycondensation reaction of methylol melamine; Alkyd resin is an air oxidation of unsaturated groups introduced into side chains, etc.
- thermosetting acrylic resin is a reaction between a hydroxyl group and an amino resin that it has (one-pack type
- carboxyl functional acrylic resin a reaction of a carboxylic acid such as acrylic acid or methacrylic acid with an epoxy compound
- a urethane resin is a resin containing a hydroxyl group-containing polyester resin, polyether resin, acrylic resin, etc.
- an isocyanate compound or a modified product thereof is a reaction of an isocyanate compound or a modified product thereof.
- thermosetting resin a crosslinking agent, a polymerization initiator, a polymerization accelerator, and the like are used as necessary in order to advance the curing reaction as necessary.
- curable resins may be used alone or in a combination of two or more.
- the ionizing radiation curable resin specifically, a prepolymer, oligomer, and / or monomer having a polymerizable unsaturated bond or an epoxy group in the molecule is used. What mixed suitably is mentioned.
- the ionizing radiation refers to an electromagnetic wave or a charged particle beam having an energy quantum capable of polymerizing or cross-linking molecules, and usually an ultraviolet ray or an electron beam is used.
- the ionizing radiation curable resin is preferably one that undergoes radical polymerization (curing) by electron beam irradiation.
- a (meth) acrylate monomer having a radically polymerizable unsaturated group in the molecule is preferable, and a polyfunctional (meth) acrylate monomer is particularly preferable.
- the polyfunctional (meth) acrylate monomer may be a (meth) acrylate monomer having two or more polymerizable unsaturated bonds (bifunctional or more) in the molecule.
- polyfunctional (meth) acrylate examples include ethylene glycol di (meth) acrylate, propylene glycol di (meth) acrylate, 1,4-butanediol di (meth) acrylate, 1,6-hexanediol di ( (Meth) acrylate, neopentyl glycol di (meth) acrylate, polyethylene glycol di (meth) acrylate, hydroxypivalate neopentyl glycol di (meth) acrylate, dicyclopentanyl di (meth) acrylate, caprolactone modified dicyclopentenyl di ( (Meth) acrylate, ethylene oxide-modified phosphoric acid di (meth) acrylate, allylated cyclohexyl di (meth) acrylate, isocyanurate di (meth) acrylate, trimethylolpropane tri (meth) acrylate , Ethylene oxide modified trimethylolpropane tri (me
- the oligomer used as the ionizing radiation curable resin is preferably a (meth) acrylate oligomer having a radical polymerizable unsaturated group in the molecule, and more than two polymerizable unsaturated bonds in the molecule.
- a polyfunctional (meth) acrylate oligomer having (bifunctional or higher) is preferred.
- Examples of the polyfunctional (meth) acrylate oligomer include polycarbonate (meth) acrylate, urethane (meth) acrylate, epoxy (meth) acrylate, polyester (meth) acrylate, polyether (meth) acrylate, polybutadiene (meth) acrylate, and the like. Is mentioned.
- the polycarbonate (meth) acrylate can be obtained, for example, by esterifying a polycarbonate polyol with (meth) acrylic acid.
- Urethane (meth) acrylate can be obtained, for example, by esterifying a polyurethane oligomer obtained by reaction of polyether polyol or polyester polyol and polyisocyanate with (meth) acrylic acid.
- Epoxy (meth) acrylate can be obtained, for example, by reacting (meth) acrylic acid with an oxirane ring of a relatively low molecular weight bisphenol type epoxy resin or novolak type epoxy resin and esterifying it.
- a carboxyl-modified epoxy (meth) acrylate obtained by partially modifying this epoxy (meth) acrylate with a dibasic carboxylic acid anhydride can be used.
- Polyester (meth) acrylate is obtained by esterifying the hydroxyl group of a polyester oligomer having hydroxyl groups at both ends obtained by condensation of a polyvalent carboxylic acid and a polyhydric alcohol with (meth) acrylic acid, for example, or It can be obtained by esterifying the terminal hydroxyl group of an oligomer obtained by adding an alkylene oxide with (meth) acrylic acid.
- the polyether (meth) acrylate can be obtained by esterifying the hydroxyl group of the polyether polyol with (meth) acrylic acid.
- Polybutadiene (meth) acrylate can be obtained by adding (meth) acrylate acid to the side chain of the polybutadiene oligomer.
- These oligomers may be used individually by 1 type, and may be used in combination of 2 or more type.
- curable resins may be used alone or in combination of two or more.
- ionizing radiation curable resins are preferably used from the viewpoint of providing excellent hard coat properties while providing even better weather resistance.
- the ionizing radiation curable resin having three or more functional groups is not particularly limited as long as it is an ionizing radiation curable resin having three or more functional groups introduced therein. Preferably, three or more polymerizable unsaturated bonds are present in the molecule.
- the polyfunctional (meth) acrylate which has (trifunctional or more) is mentioned. Examples of the polyfunctional (meth) acrylate include pentaerythritol (meth) acrylate, polycarbonate (meth) acrylate, urethane (meth) acrylate, epoxy (meth) acrylate, polyester (meth) acrylate, and polyether (meth) acrylate.
- the pentaerythritol-based (meth) acrylate can be obtained, for example, by esterifying some or all of the hydroxyl groups of pentaerythritol or a polymer thereof with (meth) acrylic acid.
- the polycarbonate (meth) acrylate can be obtained, for example, by esterifying part or all of the polycarbonate polyol hydroxyl group with (meth) acrylic acid.
- Urethane (meth) acrylate can be obtained, for example, by esterifying a polyurethane oligomer obtained by the reaction of a polyol such as polyether polyol, polyester polyol, polycarbonate polyol, and polyisocyanate with (meth) acrylic acid.
- Epoxy (meth) acrylate can be obtained, for example, by reacting (meth) acrylic acid with an oxirane ring of a relatively low molecular weight bisphenol type epoxy resin or novolak type epoxy resin and esterifying it.
- a carboxyl-modified epoxy (meth) acrylate obtained by partially modifying this epoxy (meth) acrylate with a dibasic carboxylic acid anhydride can be used.
- Polyester (meth) acrylate is obtained by esterifying the hydroxyl group of a polyester oligomer having hydroxyl groups at both ends obtained by condensation of a polyvalent carboxylic acid and a polyhydric alcohol with (meth) acrylic acid, for example, or It can be obtained by esterifying the terminal hydroxyl group of an oligomer obtained by adding an alkylene oxide with (meth) acrylic acid.
- the polyether (meth) acrylate can be obtained by esterifying the hydroxyl group of the polyether polyol with (meth) acrylic acid.
- Polybutadiene (meth) acrylate can be obtained by adding (meth) acrylate acid to the side chain of the polybutadiene oligomer.
- Silicone (meth) acrylate can be obtained by modifying silicone having a polysiloxane bond in the main chain with (meth) acrylic acid.
- the aminoplast resin (meth) acrylate can be obtained by modifying an aminoplast resin having many reactive groups in a small molecule with (meth) acrylic acid.
- the number of functional groups of the trifunctional or higher ionizing radiation curable resin is not particularly limited as long as it is 3 or more, but from the viewpoint of providing further excellent weather resistance and hard coat properties, for example, 3 to 50, preferably Is 3 to 8, more preferably 4 to 6.
- the average molecular weight of the tri- or higher functional ionizing radiation curable resin varies depending on the type and cannot be defined uniformly, but is, for example, 200 to 100,000, preferably 500 to 50,000, more preferably 1000 to 30,000. Can be mentioned.
- the average molecular weight of the tri- or higher functional ionizing radiation curable resin is a mass average molecular weight measured by GPC analysis and converted to standard polystyrene.
- urethane (meth) acrylate is preferable, and urethane (meth) acrylate having a skeleton such as polyether, polyester, polycarbonate, and the like is more preferable. Can be mentioned.
- These trifunctional or higher functional ionizing radiation curable resins may be used alone or in combination of two or more.
- the bifunctional (meth) acrylate monomer may have a structure in which two (meth) acryloyl groups are bonded via a cyclic or linear aliphatic linker region. Further, the molecular weight of the bifunctional (meth) acrylate monomer is not particularly limited, and may be about 100 to 10,000, for example. From the viewpoint of providing even better weather resistance and hard coat properties, the molecular weight of the bifunctional (meth) acrylate monomer is preferably 190 to 1200, and more preferably 190 to 600.
- the ratio of the trifunctional or higher functional ionizing radiation curable resin (i) and the bifunctional (meth) acrylate monomer (ii) is not particularly limited, but the trifunctional or higher functional ionizing radiation (i) is not limited. It is desirable to use a curable resin as a main agent.
- 100 parts by mass of the trifunctional or higher functional ionizing radiation curable resin (i) has 1 to 2 bifunctional (meth) acrylate monomers. 40 parts by mass, preferably 5 to 35 parts by mass, and more preferably 10 to 30 parts by mass.
- a bifunctional monomer may be appropriately selected from the above-mentioned (meth) acrylate monomers, but more excellent weather resistance and hard coat properties.
- a bifunctional (meth) acrylate monomer of (ii) above (ii-1) two (meth) acryloyl groups are directly bonded to one alicyclic ring or aliphatic heterocyclic ring.
- urethane (meth) acrylate monomer is mentioned.
- these bifunctional (meth) acrylate monomers will be described.
- the bifunctional (meth) acrylate monomer (ii-1) has one alicyclic ring or heterocyclic ring in one molecule, and a linker region having a molecular weight of 200 or less directly or in the alicyclic ring or heterocyclic ring.
- the structure is not particularly limited as long as the structure has two (meth) acryloyl groups (—C ( ⁇ O) —CH (or CH 3 ) ⁇ CH 2 ) bonded via each other.
- the alicyclic or heterocyclic ring contained in the bifunctional (meth) acrylate monomer (ii-1) may be either a monocyclic structure or a condensed ring structure.
- the number of members of the alicyclic or heterocyclic ring (the number of members in the case of a monocyclic structure) is not particularly limited, and examples thereof include 5 to 10, preferably 5 to 8, and more preferably 5 to 6.
- the alicyclic ring or heterocyclic ring may be a condensed ring in which the alicyclic ring or heterocyclic ring (monocyclic) having the above-mentioned number of members is condensed with, for example, 2 to 4, preferably 2 to 3 rings.
- Preferred examples of the bifunctional (meth) acrylate monomer (ii-1) include those having an alicyclic ring.
- alicyclic or heterocyclic ring examples include dicyclopentane, tricyclodecane, cyclohexane, triazine, cyclopentane, and isocyanurate. Of these, dicyclopentane and tricyclodecane are preferable.
- the alicyclic ring or heterocyclic ring may have a substituent other than the (meth) acryloyl group bonded directly or via a linker region having a molecular weight of 200 or less.
- the type of the substituent is not particularly limited, and examples thereof include an alkyl group having 1 to 5 carbon atoms, an alkoxyl group having 1 to 5 carbon atoms, a hydroxyalkyl group having 1 to 5 carbon atoms, a halogen atom, and the like.
- the number of the substituents varies depending on the structure of the alicyclic or heterocyclic ring and cannot be defined uniformly. For example, 0 to 14, preferably 0 to 10, and more preferably 0. Up to 6 can be mentioned.
- a (meth) acryloyl group may be directly linked to the alicyclic or heterocyclic ring, and a (meth) acryloyl group is bonded via a linker. You may do it.
- the molecular weight of the linker moiety may be 200 or less, preferably 14 to 200, more preferably 14 to 150, more preferably 14 to 120. Further, the structure of the linker is not particularly limited as long as the molecular weight range is satisfied.
- an alkylene group having 1 to 8 carbon atoms For example, an alkylene group having 1 to 8 carbon atoms; urethane bond, ester bond, ether bond, thioether bond, amide bond, etc. Bond: those having the above bond in an alkylene group having 1 to 4 carbon atoms.
- linker examples include groups represented by the following general formulas (A) to (J).
- the left end is bonded to the alicyclic or heterocyclic ring, and the right end is bonded to the (meth) acryloyl group.
- n1 represents an integer of 1 to 8, preferably 1 to 6, and more preferably 1 to 4.
- n2 represents an integer of 0 to 6, preferably 0 to 4, and more preferably 0 to 2.
- n3 represents an integer of 1 to 6, preferably 1 to 4, more preferably 1 to 2.
- the total value of n2 and n3 is 12 or less, preferably 6 or less, more preferably 4 or less.
- n4 represents an integer of 0 to 6, preferably 0 to 4, and more preferably 0 to 2.
- n5 represents an integer of 0 to 6, preferably 0 to 4, and more preferably 0 to 2.
- the total value of n4 and n5 is 12 or less, preferably 6 or less, and more preferably 4 or less.
- n6 represents an integer of 0 to 6, preferably 0 to 4, more preferably 0 to 2.
- n7 represents an integer of 1 to 6, preferably 1 to 4, and more preferably 1 to 2.
- the total value of n6 and n7 is 12 or less, preferably 6 or less, and more preferably 4 or less.
- bifunctional (meth) acrylate monomer (ii-1) include compounds represented by the following general formula (1).
- ring A represents a compound having 1 to 3 substituted or unsubstituted alicyclic groups or heterocyclic groups. Specific examples of the alicyclic group or heterocyclic group are as described above. Moreover, in General formula (1), R1 and R2 are the same or different, and show a single bond or a linker whose molecular weight is 200 or less. Specific examples of the linker are as described above. Moreover, in General formula (1), R3 and R4 are the same or different, and show a hydrogen atom or a methyl group.
- the molecular weight of the bifunctional (meth) acrylate monomer (ii-1) is not particularly limited as long as it satisfies the above-mentioned structure, but it is, for example, 200 to 1200, preferably 200 to 800, and more preferably Is 300 to 500.
- the bifunctional (meth) acrylate monomer (ii-1) specifically, one molecule of isophorone diisocyanate has hydroxyalkyl (meth) acrylate (the number of carbon atoms of the hydroxyalkyl group is 1 to 4, preferably 1 to 2).
- (Meth) acrylate monomer tricyclodecane dimethanol diacrylate, dicyclopentanyl di (meth) acrylate, caprolactone-modified dicyclopentenyl di (meth) acrylate, allylated cyclohexyl di (meth) acrylate And isocyanurate di (meth) acrylate.
- (meth) acrylate monomer and tricyclodecane dimethanol diacrylate in which two molecules of hydroxyalkyl (meth) acrylate are urethane-bonded to one molecule of isophorone diisocyanate are exemplified.
- the bifunctional (meth) acrylate monomer (ii-1) may be used alone or in combination of two or more.
- the ratio of the (i) trifunctional or higher functional ionizing radiation curable resin to the (ii-1) bifunctional (meth) acrylate monomer is not particularly limited, but the (i) the trifunctional or higher functional ionization is not limited. It is desirable to use a radiation curable resin as a main agent.
- the bifunctional (meth) acrylate monomer (ii-1) with respect to 100 parts by mass of the trifunctional or higher ionizing radiation curable resin (i). Is 1 to 40 parts by mass, preferably 5 to 35 parts by mass, and more preferably 10 to 30 parts by mass.
- bifunctional urethane (meth) acrylate monomer of (ii-2) As the bifunctional urethane (meth) acrylate monomer (ii-2), two (meth) acryloyl groups (—C ( ⁇ O) —CH (or CH 3 ) ⁇ CH 2 ) contain a urethane bond.
- the structure is not particularly limited as long as the structure is bonded via an aliphatic chain.
- the urethane bond is preferably present in the form incorporated into the aliphatic chain, not at the end of the aliphatic chain.
- the total number of carbon atoms constituting the aliphatic chain is not particularly limited, and examples thereof include 2 to 90, preferably 2 to 70, and more preferably 2 to 50.
- the aliphatic chain may contain a bond other than the urethane bond.
- the bond other than the urethane bond include an ester bond, an amide bond, an ether bond, a carbonate bond, and a thioether bond.
- the aliphatic chain containing a urethane bond specifically includes a group represented by the following general formula (K).
- n8 and n10 are the same or different and each represents an integer of 1 to 35, preferably 2 to 25, more preferably 2 to 8, particularly preferably 2 to 6.
- n9 represents an integer of 1 to 35, preferably 2 to 25, more preferably 2 to 20, and particularly preferably 2 to 8.
- the total value of n8, n9 and n10 is 90 or less, preferably 3 to 70, more preferably 6 to 50, particularly preferably 6 to 24, and most preferably 6 to 20.
- bifunctional urethane (meth) acrylate monomer (ii-2) include compounds represented by the following general formula (2).
- group B represents an aliphatic chain containing a urethane bond. Specific examples of the aliphatic chain are as described above. Moreover, in General formula (2), R3 and R4 are the same or different, and show a hydrogen atom or a methyl group.
- the molecular weight of the bifunctional urethane (meth) acrylate monomer (ii-2) is not particularly limited as long as it satisfies the above-described structure, and examples thereof include 190 to 5000.
- the molecular cross-linking structure of the hard coat layer 3 is made dense so that components such as UV absorbers are not easily detached from the hard coat layer 3, the bifunctional urethane (meth) acrylate monomer of (ii-2) above.
- the molecular weight is preferably 190 to 1200, more preferably 190 to 600.
- the bifunctional urethane (meth) acrylate monomer (ii-2) may be used alone or in combination of two or more.
- the ratio of the trifunctional or higher ionizing radiation curable resin (i) to the bifunctional urethane (meth) acrylate monomer (ii-2) is not particularly limited. It is desirable to use an ionizing radiation curable resin as a main agent.
- an ionizing radiation curable resin as a main agent.
- Acrylate monomer is 1 to 40 parts by mass, preferably 5 to 35 parts by mass, more preferably 10 to 30 parts by mass.
- ionizing radiation curable resins When ionizing radiation curable resin is used in combination with (i) trifunctional or higher functional ionizing radiation curable resin and (ii) bifunctional (meth) acrylate monomer, these ionizing radiation curable resins are used. In addition, a monofunctional (meth) acrylate monomer, a trifunctional or higher functional (meth) acrylate monomer, a bifunctional ionizing radiation curable resin, and the like are included as long as the effects of the present invention are not impaired. May be.
- the amount include 50 to 100 parts by mass, preferably 70 to 100 parts by mass, and more preferably 80 to 100 parts by mass.
- the combination of the above (i) trifunctional or higher functional ionizing radiation curable resin and the above (ii-1) bifunctional (meth) acrylate monomer is used, it is included in the hard coat layer 3.
- a total amount of the trifunctional or higher ionizing radiation curable resin (i) and the bifunctional (meth) acrylate monomer (ii-1) per 100 parts by mass of the total amount of ionizing radiation curable resin to be produced for example, 50 to 100 parts by mass, preferably 60 to 100 parts by mass, and more preferably 60 to 80 parts by mass.
- the ionizing radiation contained in the hard coat layer 3 is used.
- the total amount of the trifunctional or higher ionizing radiation curable resin (i) and the bifunctional urethane (meth) acrylate monomer (ii-2) per 100 parts by mass of the total amount of the curable resin is, for example, 60 to 100 parts by mass, preferably 80 to 100 are mentioned.
- the hard coat layer 2 may contain an ultraviolet absorber as necessary in order to provide weather resistance against ultraviolet exposure.
- an ultraviolet absorber for example, a hydroxyphenyl triazine type compound, a benzotriazole type compound, a benzophenone type compound, an oxalic acid anilide type compound, a salicylic acid phenyl ester type compound, Examples include acrylonitrile compounds. Among these, hydroxyphenyl triazine compounds and benzotriazole compounds are preferable, and hydroxyphenyl triazine compounds are more preferable. These ultraviolet absorbers may be used alone or in combination of two or more.
- the content of the ultraviolet absorber in the hard coat layer 2 is not particularly limited, but for example, 0.1 to 10 parts by mass, preferably 0.2 to 10 parts by mass with respect to 100 parts by mass of the total amount of ionizing radiation curable resin. However, it is more preferably 0.5 to 5 parts by mass, particularly preferably 0.7 to 2 parts by mass.
- the hard coat layer 2 may contain a light stabilizer as necessary in order to further improve the weather resistance.
- the light stabilizer is preferably a hindered amine light stabilizer (HALS).
- HALS hindered amine light stabilizer
- numerator is mentioned.
- the reactive group include functional groups having an ethylenic double bond such as a (meth) acryloyl group, a vinyl group, and an allyl group.
- a light stabilizer for example, 1,2,2,6,6-pentamethyl-4-piperidinyl methacrylate (manufactured by BASF, trade name “SANOR LS-3410”) or (Hitachi Chemical Co., Ltd.) And 2,2,6,6-tetramethyl-4-piperidinyl methacrylate (manufactured by Hitachi Chemical Co., Ltd., trade name “FA-712HM”).
- These light stabilizers may be used individually by 1 type, and may be used in combination of 2 or more type.
- the content of the light stabilizer in the hard coat layer 2 is not particularly limited, but for example, 0.5 to 10 parts by mass, preferably 1 to 8 parts by mass with respect to 100 parts by mass of the total amount of ionizing radiation curable resin, More preferred is 2 to 6 parts by mass.
- the hard coat layer 2 may contain various additives other than those described above as long as the effects of the present invention are not impaired.
- additives include wear resistance improvers, polymerization inhibitors, crosslinking agents, infrared absorbers, antistatic agents, adhesion improvers, leveling agents, thixotropic agents, coupling agents, and lubricants.
- the thickness of the hard coat layer 2 is not particularly limited, and examples thereof include 1 to 100 ⁇ m, preferably 1.5 to 50 ⁇ m, and more preferably 2 to 20 ⁇ m.
- the hard coat layer 2 may be formed by a method corresponding to the type of curable resin to be used. For example, if a thermosetting resin, a room temperature curable resin, a one-component reaction curable resin, or a two-component reaction curable resin is used, a hard coat in which these resins and various additives are mixed as necessary. By applying the resin composition for layer 2 to the substrate film 1 for release by a method such as gravure coating, bar coating, roll coating, reverse roll coating, comma coating, etc., and heating as necessary The resin composition may be cured.
- the resin composition for the hard coat layer 2 only needs to be obtained by dissolving or dispersing a curable resin and, if necessary, an additive in a solvent.
- the solvent used in the resin composition for the hard coat layer 2 may be any solvent as long as it exhibits solubility or compatibility with the curable resin and additives added as necessary.
- the resin composition for the layer 2 may be appropriately selected according to the coating method of the resin composition and the drying method at the time of forming the hard coat layer 2, but from the viewpoint of solubility or compatibility with the curable resin, drying property, etc. Solvents are preferred.
- organic solvent examples include, but are not limited to, alcohols such as methanol, ethanol, and isopropanol; esters such as ethyl acetate, butyl acetate, and propylene glycol monomethyl ether acetate; acetone, methyl ethyl ketone, cyclopentanone, cyclohexanone, and isobutyl ketone. And ketones such as methyl isobutyl ketone. These organic solvents may be used individually by 1 type, and may be used in combination of 2 or more type.
- a resin composition in which ionizing radiation curable resin and various additives are mixed as required is obtained by gravure coating, bar coating, roll coating, reverse roll coating. Then, it may be applied to the substrate film 1 for release by a method such as comma coating, and the resin composition is irradiated with an ionizing radiation such as an electron beam or an ultraviolet ray to be cured.
- an ionizing radiation such as an electron beam or an ultraviolet ray
- the acceleration voltage can be appropriately selected according to the type of ionizing radiation curable resin used, the thickness of the hard coat layer 2, and the like. About 300 kV.
- the irradiation dose is preferably such that the crosslinking density of the resin layer is saturated, and is usually selected in the range of 5 to 300 kGy (0.5 to 30 Mrad), preferably 10 to 100 kGy (1 to 10 Mrad).
- an electron beam source for example, various electron beam accelerators, such as a cock loft Walton type, a van de Graft type, a resonance transformer type, an insulated core transformer type, or a linear type, a dynamitron type, a high frequency type etc. Can be used.
- various electron beam accelerators such as a cock loft Walton type, a van de Graft type, a resonance transformer type, an insulated core transformer type, or a linear type, a dynamitron type, a high frequency type etc. Can be used.
- a hard coat function By adding various additives to the hard coat layer 2 thus formed, a hard coat function, an antifogging coat function, an antiglare coat function, an antireflection coating function, an ultraviolet shielding coating function, an infrared shielding coating function, etc. You may perform the process which provides this function.
- Primer layer 3 The primer layer 3 is disposed between the hard coat layer 2 and the adhesive layer 3, functions as a stress relaxation layer for the hard coat layer 2, and plays a role of improving the adhesion of the hard coat layer 2.
- the primer layer 3 is formed of a binder resin containing polyurethane having a mass average molecular weight of 40,000 to 100,000 and an acrylic component of 1 to 30% by mass.
- a binder resin containing polyurethane having a mass average molecular weight of 40,000 to 100,000 and an acrylic component of 1 to 30% by mass.
- the polyurethane used for the primer layer 3 one having an acrylic skeleton in the polymer chain is used.
- the polyurethane having an acrylic skeleton in the polymer chain is not particularly limited as long as the mass average molecular weight is 40,000 to 100,000 and the acrylic component is 1 to 30% by mass.
- the copolymer may be any of a urethane acrylic copolymer, an acrylic resin having a hydroxyl group or an isocyanate group as a polyol component or a polyisocyanate component constituting a polyurethane, preferably a urethane acrylic copolymer. Can be mentioned.
- Urethane acrylic copolymers can be produced, for example, by a method of reacting a polyol compound and a polyisocyanate compound with an acrylic resin having at least two hydroxyl groups in one molecule (see JP-A-6-1000065, etc.), It can be obtained by a method of reacting an acrylic monomer with a urethane prepolymer having a heavy bond at both ends (see, for example, JP-A-10-1524).
- the polyurethane used as the binder resin for the primer layer 3 preferably has a polycarbonate skeleton or a polyester skeleton in addition to the acrylic skeleton in the polymer chain.
- a polyurethane having a polycarbonate skeleton or a polyester skeleton in a polymer chain as a polyol component or a polyisocyanate component constituting a urethane resin, an acrylic resin having a hydroxyl group or an isocyanate group, and a polycarbonate resin having a hydroxyl group or an isocyanate group, or Polyester resin may be used, but polycarbonate urethane acrylic copolymer that is a copolymer of polycarbonate urethane component and acrylic component, or polyester system that is a copolymer of polyester urethane component and acrylic component A urethane acrylic copolymer is more preferable.
- These polyurethanes may be used individually by 1 type, and may be used in combination of 2 or more type.
- the polycarbonate-based urethane acrylic copolymer can be obtained, for example, by copolymerizing a polycarbonate-based urethane obtained by reacting carbonate diol and diisocyanate with a diol having an acrylic skeleton.
- the polycarbonate urethane acrylic copolymer can also be obtained by reacting a diol having an acrylic skeleton with a carbonate diol and a diisocyanate.
- the diol having an acrylic skeleton specifically, (meth) acrylic acid, (meth) acrylic acid alkyl ester having about 1 to 6 carbon atoms in an alkyl group, or an oligomer obtained by radical polymerization thereof, or Examples of the prepolymer (degree of polymerization of about 2 to 10) include compounds in which two hydroxyl groups are introduced.
- the diisocyanate include aliphatic isocyanates such as hexamethylene diisocyanate; and alicyclic isocyanates such as isophorone diisocyanate and hydrogenated xylylene diisocyanate.
- the carbonate diol specifically, a compound represented by the following general formula (3) (wherein R 5 is an alkylene group having 1 to 12 carbon atoms which may have a substituent, substituted A divalent heterocyclic group having 1 to 12 carbon atoms which may have a group, or a divalent alicyclic group having 1 to 12 carbon atoms which may have a substituent, and m1 is 1 to And an integer of 10).
- the polycarbonate-based urethane acrylic copolymer can be obtained by radical polymerization of a polycarbonate-based polyurethane prepolymer into which a radical polymerizing group is introduced with an acrylic monomer.
- the acrylic monomer include (meth) acrylic acid and (meth) acrylic acid alkyl esters having about 1 to 6 carbon atoms in the alkyl group.
- the polyester-based urethane acrylic copolymer can be obtained, for example, by copolymerizing a polyester-based urethane obtained by reacting an ester diol and diisocyanate with a diol having an acrylic skeleton. Alternatively, it can also be obtained by reacting an ester diol and a diisocyanate with a diol having an acrylic skeleton.
- the diol and diisocyanate having an acrylic skeleton are the same as those used in the production of the polycarbonate-based urethane acrylic copolymer.
- ester diol specifically, a compound represented by the following general formula (4) (wherein R 6 is an alkylene group having 1 to 12 carbon atoms which may have a substituent, a substituent.
- R 6 is an alkylene group having 1 to 12 carbon atoms which may have a substituent, a substituent.
- polyester-based urethane acrylic copolymer can also be obtained by radical polymerization of a polyester-based polyurethane prepolymer having a radical polymerizing group introduced therein with an acrylic monomer.
- the acrylic monomer is the same as that used in the production of the polycarbonate urethane acrylic copolymer.
- the polyurethane used for the primer layer 3 has a mass average molecular weight of 40,000 to 100,000.
- the mass average molecular weight of the polyurethane is preferably 50,000 to 80,000.
- the mass average molecular weight of the polyurethane is a value measured by GPC analysis and converted to standard polystyrene.
- the polyurethane used for the primer layer 3 only needs to satisfy an acrylic component content of 1 to 30% by mass in order to provide excellent weather resistance.
- the content of the acrylic component in the polyurethane is a ratio (mass%) occupied by monomers constituting the acrylic skeleton per the total mass of the polyurethane.
- the content of the acrylic component in the polyurethane is preferably 5 to 20% by mass, more preferably 10 to 20% by mass.
- the content of the acrylic component in the polyurethane can be calculated, for example, by measuring the NMR spectrum of the polyurethane and calculating the ratio of the peak area attributed to the acrylic component to the total peak area.
- the primer layer 3 may contain a binder resin other than the polyurethane as long as the effect of the present invention is not hindered.
- binder resins include urethane resins, (meth) acrylic resins, vinyl chloride / vinyl acetate copolymers, polyester resins, butyral resins, chlorinated polypropylene, and chlorinated polyethylene. These binder resins may be used individually by 1 type, and may be used in combination of 2 or more type. Among these binder resins, a urethane resin is preferable.
- the mixing ratio thereof is not particularly limited, but for example, the polyurethane is 50 parts by mass or more per 100 parts by mass of the binder resin. What is necessary is just to set so that it may become 70 mass parts or more preferably, More preferably, it will be 85 mass parts or more.
- the primer layer 3 may contain an ultraviolet absorber as necessary in order to provide weather resistance against ultraviolet exposure.
- the content of the ultraviolet absorber in the primer layer 3 is not particularly limited. For example, it may be 1 to 50 parts by mass, preferably 2 to 40 parts by mass with respect to 100 parts by mass of the curable resin. More preferred is 3 to 35 parts by mass.
- the primer layer 3 may contain a light stabilizer as necessary in order to further improve the weather resistance.
- the light stabilizer used in the primer layer 3 include a hindered amine light stabilizer (HALS), and more specifically, a hindered amine light stabilizer having no reactive functional group, or the hard coat layer 3.
- HALS hindered amine light stabilizer
- Hindered amine light stabilizers having a reactive functional group preferably used for the formation of.
- a hindered amine light stabilizer having no reactive functional group is preferred as the light stabilizer used in the primer layer 3.
- hindered amine light stabilizer having no reactive functional group examples include 2- (3,5-di-tert-butyl-4-hydroxybenzyl) -2′-n-butylmalonate bis (1 , 2,2,6,6-pentamethyl-4-piperidyl), bis (1,2,2,6,6-pentamethyl-4-piperidyl) sebacate, bis (1-octyloxy-2,2,6,6- Tetramethyl-4-piperidyl) sebacate, tetrakis (2,2,6,6-tetramethyl-4-piperidyl) -1,2,3,4-butanetetracarboxylate and the like.
- These light stabilizers may be used individually by 1 type, and may be used in combination of 2 or more type.
- the content of the light stabilizer in the primer layer 3 is not particularly limited. For example, it may be 0.5 to 20 parts by mass, preferably 1 to 15 parts by mass with respect to 100 parts by mass of the curable resin. However, 2 to 10 parts by mass is more preferable.
- the primer layer 3 may contain a curing agent as necessary in order to promote the curing of the binder resin.
- the curing agent used in the primer layer 3 include isocyanate curing agents such as tolylene diisocyanate, diphenylmethane diisocyanate, hexamethylene diisocyanate, xylylene diisocyanate, cyclohexanephenylene diisocyanate, and naphthalene-1,5-diisocyanate. These curing agents may be used alone or in combination of two or more.
- the content of the curing agent in the primer layer 3 is not particularly limited, and may be, for example, 5 to 40 parts by mass, preferably 8 to 35 parts by mass with respect to 100 parts by mass of the curable resin.
- the amount is preferably 10 to 30 parts by mass.
- the primer layer 3 may contain an antiblocking agent as necessary in order to suppress the blocking phenomenon.
- the anti-blocking agent used in the primer layer 3 include inorganic particles such as silica, alumina, aluminum hydroxide, barium sulfate, talc, and calcium carbonate. These blocking inhibitors may be used alone or in combination of two or more.
- the average particle size of the antiblocking agent is not particularly limited, but is usually about 0.1 to 10 ⁇ m, preferably 0.5 to 8 ⁇ m, more preferably 0, from the viewpoint of transparency and suppression of the occurrence of the blocking phenomenon. 5 to 5 ⁇ m.
- the particle diameter of the antiblocking agent is measured by a laser diffraction particle size distribution measuring device.
- the content of the anti-blocking agent in the primer layer 3 is not particularly limited. For example, it is 1 to 20 parts by mass, preferably (2 to 15 parts by mass, with respect to 100 parts by mass of the curable resin). More preferred is 3 to 10 parts by mass.
- the primer layer 3 may contain various additives other than those described above as long as the effects of the present invention are not impaired.
- additives include wear resistance improvers, infrared absorbers, antistatic agents, adhesion improvers, leveling agents, thixotropic agents, coupling agents, plasticizers, antifoaming agents, and fillers. , Solvent, colorant and the like. These additives can be appropriately selected from those commonly used.
- the thickness of the primer layer 3 is not particularly limited, but may be 0.1 to 10 ⁇ m, preferably 0.1 to 5 ⁇ m, and more preferably 1 to 4 ⁇ m.
- Primer layer 3 includes gravure coat, gravure reverse coat, gravure offset coat, spinner coat, roll coat, reverse roll coat, kiss coat, wheeler coat, dip coat, silk screen solid coat, wire bar coat, flow coat, comma coat, coat It is formed by applying a resin composition for forming the primer layer 3 containing a binder resin on the hard coat layer 2 by a usual coating method such as a flow coating, brush coating, spray coating or the like, or a transfer coating method.
- the transfer coating method is a method in which a coating film of the primer layer 3 is formed on a thin sheet (film substrate) and then the surface of the hard coat layer 2 is coated.
- the resin composition for forming the primer layer 3 only needs to be obtained by dissolving or dispersing a binder resin and, if necessary, an additive in a solvent.
- the solvent used in the resin composition for forming the primer layer 3 may be any solvent as long as it exhibits solubility or compatibility with the binder resin and additives added as necessary. Although it may be appropriately selected according to the application method of the resin composition for formation, the drying method at the time of forming the primer layer 3, etc., an organic solvent is preferable from the viewpoint of solubility or compatibility with the binder resin, drying property, and the like.
- organic solvent examples include, but are not limited to, alcohols such as methanol, ethanol, and isopropanol; esters such as ethyl acetate, butyl acetate, and propylene glycol monomethyl ether acetate; acetone, methyl ethyl ketone, cyclopentanone, cyclohexanone, and isobutyl ketone. And ketones such as methyl isobutyl ketone. These organic solvents may be used individually by 1 type, and may be used in combination of 2 or more type.
- the primer layer 3 in order to improve the adhesion between the hard coat layer 2 and the primer layer 3, the hardening of the hard coat layer 2 is kept semi-cured, and then the primer layer is formed. Adhesion between the hard coat layer 2 and the primer layer 3 can also be improved by completely curing the hard coat layer 2 after applying the resin composition.
- the adhesive layer 4 is a layer disposed on the surface opposite to the base film 1 for release, and plays a role of adhering to a resin molded product serving as a transfer target.
- the adhesive layer 4 may be an adhesive layer made of an adhesive resin such as a heat-sensitive adhesive resin or a pressure-sensitive adhesive resin, and a heat seal layer that exhibits a welding action by heating is preferable.
- Specific examples of the adhesive resin constituting the adhesive layer 4 include acrylic resin, vinyl chloride resin, vinyl acetate resin, vinyl chloride-vinyl acetate copolymer resin, styrene-acrylic copolymer resin, polyester resin, polyamide resin, Examples include polyolefin resins. These adhesive resins may be used individually by 1 type, and may be used in combination of 2 or more type.
- the adhesive layer 4 may contain various additives as required in addition to the adhesive resin.
- additives include ultraviolet absorbers, light stabilizers, and colorants. These additives can be appropriately selected from those commonly used.
- the thickness of the adhesive layer 4 is usually 0.1 to 10 ⁇ m, preferably 0.5 to 6 ⁇ m, and more preferably 1 to 4 ⁇ m.
- the formation of the adhesive layer 4 is performed by applying an adhesive resin onto a predetermined layer by a method such as gravure coating, bar coating, roll coating, reverse roll coating, comma coating, or the like.
- a cover film formed of a resin such as polyethylene resin is attached to the surface of the adhesive layer 4 until it is transferred to the transfer object. It is desirable to keep it.
- a cover film is provided and pasted on the surface of the adhesive layer 4, the cover film may be peeled off during use to expose the adhesive layer.
- the release layer is a layer provided between the release base film 1 and the hard coat layer 2 as necessary in order to facilitate the release of the release base film 1.
- the release layer is formed of a thermoplastic resin that can improve the peelability of the hard coat layer 2.
- a thermoplastic resin that can improve the peelability of the hard coat layer 2.
- specific examples of the thermoplastic resin forming the release layer include silicone resin, fluorine resin, acrylic-melamine resin, polyester resin, polyolefin resin, polystyrene resin, polyurethane resin, vinyl chloride-vinyl acetate resin, and the like. It is done.
- the thickness of the release layer is usually 0.2 to 20 ⁇ m, preferably 0.5 to 15 ⁇ m, and more preferably 1 to 10 ⁇ m.
- the release layer is formed by coating the thermoplastic resin on the base film 1 for release by a method such as gravure coating, bar coating, roll coating, reverse roll coating, comma coating. .
- the colored layer 5 is a base film 1 for mold release for the purpose of concealing an adhesive application portion, fixing information display, and providing design properties when fixing a hard coat body produced using the transfer sheet of the present invention. Between the hard coat layer 2, between the hard coat layer 2 and the primer layer 3, between the primer layer 3 and the adhesive layer 4, and on the surface of the adhesive layer 4 opposite to the primer layer 3 side. One is a layer provided as necessary.
- the fixing method of the hard coat body is selected by fixing with an adhesive, fitting, screwing, etc.
- fixing with an adhesive is preferred because of the ease of work.
- the entire surface of the hard coat body is transparent, the adhesive application portion is easily visible from the surface opposite to the surface on which the adhesive application portion is formed, and the appearance may be impaired.
- the colored layer 5 can be used to display the information or design.
- the colored layer 5 is formed between the release base film 1 and the hard coat layer 2, between the hard coat layer 2 and the primer layer 3, between the primer layer 3 and the adhesive layer 4, and the primer layer 3 of the adhesive layer 4. It is sufficient that it is provided on at least one of the surfaces opposite to the side, but it is provided between the primer layer 3 and the adhesive layer 4 from the viewpoint of adhesion, weather resistance, and wear resistance. Is preferred.
- the colored layer 5 two or more layers having different color tones may be provided at the same or different arrangement locations.
- the black colored layer 5 and the white colored layer 5 may be provided in this order from the hard coat layer 2 side, and the white colored layer 5 and black may be provided from the hard coat layer 2 side.
- the colored layer 5 exhibiting may be provided in this order.
- the shape of the colored layer 5 is not particularly limited as long as it is partially provided when viewed from the direction perpendicular to the surface direction of the transfer sheet of the present invention, depending on the purpose. What is necessary is just to set suitably.
- a frame shape that conceals the outer edge of the hard coat body in the case where the colored layer 5 is provided for the purpose of concealing the adhesive coating portion when fixing the hard coat body produced using the transfer sheet of the present invention, a frame shape that conceals the outer edge of the hard coat body. It is preferable that In the case of a frame shape that conceals the outer edge portion of the hard coat body, the width of the colored layer 5 may be set to about 10 to 200 mm, for example.
- a colored layer 5 having a gradation pattern is, for example, a pattern such as a circle (dot), a rectangle (line), a square, or a triangle, and the pattern becomes smaller as the pattern moves away from the frame-shaped colored layer 5. It may be set so that the color of is lighter.
- the shape of the colored layer 5 is a character, symbol, number, pattern, etc. including a company logo, trademark, and regulatory instructions. Good.
- the color tone exhibited by the colored layer 5 is not particularly limited, and any one of colored transparent, colored translucent, colored opaque and the like may be adopted depending on the purpose.
- the colored layer 5 is used for the purpose of partially concealing the lower part, it is preferably colored and opaque.
- the OD value of the colored layer 5 is a value obtained by the following method.
- the value obtained according to the calculation formula (OD high value ⁇ OD low value) is the OD value of the colored layer 5.
- the OD low value and the OD high value are values measured at a central wavelength of 555 nm using a transmission densitometer.
- the OD value of the colored layer 5 described above can be satisfied by appropriately setting the type and content of the pigment or dye used for forming the colored layer 5.
- the colored layer 5 is formed of a colorant and a binder resin.
- the colorant either a pigment or a dye may be used, or both of them may be used. From the viewpoint of durability and weather resistance, a pigment is preferably used. Further, the color exhibited by the colorant may be appropriately set according to the purpose of the colored layer 5, but a black pigment is preferable when it is provided for the purpose of concealment.
- the type of black pigment is not particularly limited, and examples thereof include carbon black, titanium black, perylene black, and azomethine azo black.
- the binder resin is not particularly limited, but acrylic resin, vinyl chloride resin, vinyl acetate resin, polyester resin, polyamide resin, polyolefin resin, urethane resin, and copolymer resin of these resins (for example, urethane- Acrylic copolymer resin, etc.). These binder resins may be either a one-component curable type or a two-component curable type. Moreover, these binder resins may be used alone or in combination of two or more.
- a polymerization inhibitor such as an acrylic acid, a styrene resin, a polystyrene resin, a polystyrene resin, a polystyrene resin, a polystyrene resin, a polystyrene resin, a polystyrene resin, a polystyrene resin, a polystyrene resin, a polystyrene resin, polystyrenethacrylate, polystyrenethacrylate, polystyrene, acrylate, acrylonitrile-butanediolymer, ethylene glycol dimethacrylate, ethylene glycol dimethacrylate, ethylene glycol dimethacrylate, ethylene glycol dimethacrylate, ethylene glycol dimethacrylate, ethylene glycol dimethacrylate, ethylene glycol dimethacrylate, ethylene glycol dimethacrylate, acrylate, acrylate, acrylate acrylate,
- the thickness of the colored layer 5 may be appropriately set according to the purpose, the OD value to be set, the type and content of the colorant to be used, etc., but usually 0.1 to 20 ⁇ m, preferably 1 to 15 ⁇ m. More preferably, it is 3 to 10 ⁇ m.
- the colored layer 5 is formed by using an ink composition for the colored layer 5 containing a colorant, a binder resin, and an additive that is added as necessary, using gravure coating, screen printing, offset printing, flexographic printing, comma coating, It is carried out by coating on a predetermined layer by a method such as ink jet or dispenser.
- the ink composition for forming the colored layer 5 may be one obtained by dissolving or dispersing a colorant, a binder resin, and an additive added as necessary in a solvent.
- the solvent used in the ink composition for the colored layer 5 may be any solvent as long as it exhibits solubility or compatibility with the colorant, binder resin, and additive added as necessary. What is necessary is just to select suitably according to the coating method of the ink composition for layer 5, the drying method at the time of colored layer 5 formation, etc., but from a viewpoint of solubility or compatibility with a colorant and a binder resin, drying property, etc. Organic solvents are preferred.
- organic solvent examples include, but are not limited to, alcohols such as methanol, ethanol, and isopropanol; esters such as ethyl acetate, butyl acetate, and propylene glycol monomethyl ether acetate; acetone, methyl ethyl ketone, cyclopentanone, cyclohexanone, and isobutyl ketone. And ketones such as methyl isobutyl ketone. These organic solvents may be used individually by 1 type, and may be used in combination of 2 or more type.
- the transfer sheet of the present invention is produced by forming and laminating a hard coat layer 2, a primer layer 3, and an adhesive layer 4 in this order on a substrate film 1 for release.
- a release layer is provided between the release base film 1 and the hard coat layer 2
- the hard coat layer 2 is formed after the release layer is formed on the release base film 1.
- the primer layer 3 and the adhesive layer 4 may be formed and laminated in this order.
- the formation method of the hard coat layer 2, the primer layer 3, the adhesive layer 4, and the release layer is as described above.
- the transfer sheet of the present invention is obtained by transferring the adhesive layer 4, the primer layer 3 and the hard coat layer 2 to a resin molded product to be transferred. In addition, it is used to provide weather resistance.
- the base film 1 for release in the transfer sheet of the present invention is peeled off after being transferred to a resin molded product.
- the resin molded product to be transferred is not particularly limited.
- external interior materials for automobiles and public buildings, parts for automobile interior and exterior, solar battery covers, solar cells examples thereof include battery boards, members of home appliances, covers for lighting, front plates or covers of various display devices, lenses used for traffic lights and optical devices, and the like.
- the resin molded product to be the transfer sheet transferred body of the present invention is preferably an environment exposed to direct sunlight or wind and rain. And exterior members and semi-exterior members used in the above.
- exterior or semi-exterior members include exterior members for vehicles such as automobiles and railways (various windows, sunroofs, roof panels, window reflectors, turn signal lamp lenses, side mirrors, headlamps). Covers, etc .; Building parts such as balcony partition plates, terraces, carports, and other roof materials, entrance doors, building windows; soundproof walls, windbreak walls, etc .; lenses used for traffic lights, etc. It is done.
- the material to be transferred may be a resin molded product that is required to impart hard coat properties (such as scratch resistance), but is preferably transparent and strong and can be used as a substitute for the current glass.
- Organic glass Specific examples of the organic glass include polycarbonate, polymethyl methacrylate, polyacrylate, polyethylene terephthalate, polyethylene naphthalate, polyolefin, and ABS. Among these organic glasses, polycarbonate is excellent in impact resistance and transparency and is preferably used.
- melt volume rate is not particularly limited, 6 ⁇ 25cm 3/10 minutes to, and preferably about 6 ⁇ 12cm 3/10 minutes. Since the lower the melt volume rate, the better the impact resistance, a polycarbonate resin having an appropriate melt volume rate may be selected according to the use of the organic glass.
- the melt volume rate is a value measured under conditions of a temperature of 300 ° C. and a load of 1.2 kgf in accordance with JISK 7210-1999.
- the resin molded product to be transferred may be a laminate of a plurality of the same or different types of resins.
- a resin molded product in which a plurality of the same or different types of resins are laminated can be prepared, for example, by coextrusion.
- the thickness of the resin molded product to be transferred is not particularly limited and may be appropriately set depending on the use of the organic glass, but is usually 0.5 to 50 mm, preferably 1 to 20 mm, and more preferably 1 .5 to 5 mm.
- the substrate film 1 for release is attached.
- a hard coat body can be obtained by peeling. That is, as shown in FIG. 3, the hard coat body manufactured using the transfer sheet of the present invention has at least a resin molded product 6, an adhesive layer 4, a primer layer 3, and a hard coat layer 2 laminated in this order. It becomes a laminated structure. Further, in the transfer sheet of the present invention, if the colored layer 5 is provided, the hard coat body using the transfer sheet of the present invention is colored in the hard coat body manufactured using the transfer sheet of the present invention.
- the layer 5 is on at least one of the surface of the hard coat layer 2, between the hard coat layer 2 and the primer layer 3, between the primer layer 3 and the adhesive layer 4, and between the adhesive layer 4 and the resin molded product 4. Will be placed.
- the hard coat body using the transfer sheet of the present invention has excellent weather resistance as well as hard coat properties (scratch resistance) due to the adhesive layer 4, the primer layer 3, and the hard coat layer 2 laminated on the resin molded product 6. be able to.
- the type of the resin molded product 6 used for the hard coat body is as described above.
- the base film 1 for release is peeled after the transfer sheet of the present invention is applied to a pre-molded resin molded product.
- Method hereinafter referred to as the first method
- a method of peeling the base film 1 for release after the integration with the transfer sheet of the present invention when the resin to be transferred is injection molded hereinafter referred to as the first method. 2 method).
- a resin molded product is molded by extrusion molding or the like, and immediately after or after cooling, the surface of the adhesive layer 4 of the transfer sheet of the present invention using a roll or the like, A method of pressing and laminating the resin molded product is exemplified.
- the adhesive layer 4 may be heated to such an extent that at least a part of the adhesive layer 4 is melted as necessary.
- the transfer sheet can be heated by preheating the transfer sheet before pressure bonding, heating at the same time as pressure bonding with a hot-pressing roll, or the like.
- the resin molded product may be preheated before transfer. After sticking the transfer sheet of the present invention to the resin molded product, the substrate film 1 for release may be peeled off and removed. Further, after the transfer sheet of the present invention is attached to a resin molded product, it may be further subjected to a molding process such as bending. Such a molding process may be performed either before or after the release of the base film 1 for release.
- the production of the hard coat body by the second method can be performed by a known injection molding method using a transfer sheet.
- Step I Insert the transfer sheet of the present invention into an injection mold (arranged on the resin side where the adhesive layer 4 is injected), close the injection mold, and inject the fluidized resin into the mold, The transfer sheet of the invention is integrated.
- Step II The release base film 1 is peeled from the transfer sheet of the present invention integrated with a resin molded product.
- the transfer sheet of the present invention in order to facilitate integration of the transfer sheet of the present invention with the injected resin, before the transfer sheet of the present invention is inserted into an injection mold, the transfer sheet of the present invention is It may be heated. Moreover, the resin injected by the residual heat of the injected resin and the transfer sheet of the present invention can be integrated without preheating the transfer sheet of the present invention.
- the transfer sheet of the present invention inserted into the injection mold may be attached to the injection mold by vacuum suction or the like before injecting the resin.
- the peeling of the peeling base film 1 may be performed simultaneously with the separation of the injection mold or after the separation of the injection mold. Moreover, after peeling the base film 1 for peeling in a II process, you may install a protective film in the surface of the hard-coat layer 2. FIG. Moreover, the state which the base film 1 for mold release attached
- First step The transfer sheet of the present invention is supplied and fixed between a pair of male and female molds in the mold open state so that the surface of the adhesive layer 4 faces the cavity. Further, the adhesive layer 4 of the transfer sheet of the present invention is heated and softened, and vacuum suction is performed from the mold side facing the base film 1 for release, and the transfer sheet of the present invention is moved to the movable mold. The transfer sheet of the present invention is preformed by bringing it into close contact with each other.
- Second step After clamping both molds, the resin molded product and the transfer sheet of the present invention are laminated by injecting, filling and solidifying the resin in a fluid state in the cavity formed by both molds. Integrate.
- Third step The movable mold is separated from the fixed mold, the resin molded product in which the transfer sheet of the present invention is integrated is taken out, and the release base film 1 is peeled from the transfer sheet of the present invention.
- the peeling of the peeling base film 1 may be performed simultaneously with the separation of the mold or may be performed after the separation of the mold. Moreover, after peeling the base film 1 for peeling in a 3rd process, you may install a protective film in the surface of the hard-coat layer 2. FIG. Moreover, the state which the base film 1 for mold release attached
- Test Example 1 Performance evaluation of transfer sheet and hard coat body using the same 1.
- Production of transfer sheets (Examples 1 to 16 and Comparative Examples 1 to 8)
- a resin film A for forming a hard coat layer described below was formed on a base film for release (thickness 75 ⁇ m) made of biaxially stretched polyethylene terephthalate.
- a hard coat layer (3 ⁇ m) was laminated on the support film layer by coating any of D and curing it with electron beam irradiation of 10 Mrad.
- any of the following primer layer forming resin compositions 1 to 6 was applied by a gravure reverse method to form a primer layer having a thickness of 3 ⁇ m.
- a heat fusion resin (acrylic resin) was applied by a gravure reverse method to form an adhesive layer having a thickness of 4 ⁇ m.
- a transfer sheet was obtained in which a hard coat layer, a primer layer, and an adhesive layer were laminated in this order on a release base film.
- Table 1 shows the types of the resin composition for forming the hard coat layer and the resin composition for forming the primer layer used in the production of the transfer sheet of each example and comparative example.
- ⁇ Resin Composition A for Hard Coat Layer Formation (Used in Examples 1 to 3, 6 to 9, and Comparative Examples 1 to 8)> -Hexafunctional ionizing radiation curable resin (mixture of 60 parts by mass of hexafunctional urethane acrylate (molecular weight about 1,000) and 40 parts by mass of bifunctional caprolactone-modified urethane acrylate (molecular weight of about several thousand)): 100 parts by mass Triazine-based UV absorber (“Tinuvin479” manufactured by BASF Japan Ltd.): 0.7 parts by mass.
- ⁇ Resin composition B for forming hard coat layer (used in Examples 4, 5, 11, 14 to 16)> -Polyfunctional acrylate having an isocyanurate ring (mass average molecular weight of about 27,000: mainly composed of 4 to 8 functional acrylate polymer): 80 parts by mass-An aliphatic chain in which two (meth) acryloyl groups contain urethane bonds Bifunctional urethane acrylate monomer # 1 (molecular weight of about 400): 20 parts by mass / hydroxyphenyltriazine-based ultraviolet absorber (“Tinuvin479” manufactured by BASF Japan Ltd.): 0.7 parts by mass / reactive functionality -Containing light stabilizer (1,2,2,6,6-pentamethyl-4-piperidinyl methacrylate, “Sanol LS-3410” manufactured by Nippon Emulsifier Co., Ltd.): 4.2 parts by mass / non-reactive silicone compound (Polyether-modified silicone oil):
- ⁇ Resin Composition C for Hard Coat Layer Formation (Used in Example 10)> -Hexafunctional ionizing radiation curable resin (mixture of 60 parts by mass of hexafunctional urethane acrylate (molecular weight about 1,000) and 40 parts by mass of bifunctional caprolactone-modified urethane acrylate (molecular weight of about several thousand)): 100 parts by mass Cycloaliphatic urethane diacrylate in which two hydroxyethyl acrylates are bonded to isophorone diisocyanate by urethane: 16 parts by mass-Hydroxyphenyltriazine-based ultraviolet absorber ("Tinuvin479" manufactured by BASF Japan Ltd.): 2.3 parts by mass-reactive functional group (1,2,2,6,6-pentamethyl-4-piperidinyl methacrylate, “Sanol LS-3410” manufactured by Nippon Emulsifier Co., Ltd.): 4.2 parts by mass / non-re
- ⁇ Resin composition D for forming hard coat layer (used in Examples 12 and 13)> -Polyfunctional acrylate having an isocyanurate ring (mass average molecular weight of about 27,000: mainly composed of 4 to 8 functional acrylate polymer): 80 parts by mass-An aliphatic chain in which two (meth) acryloyl groups contain urethane bonds Bifunctional urethane acrylate monomer # 2 (molecular weight of about 400): 20 parts by mass / hydroxyphenyltriazine-based UV absorber (BASF Japan “Tinuvin479”): 2 parts by mass # 2 bifunctional urethane acrylate The monomer is the same as that used in the resin composition B for forming the hard coat layer.
- Light stabilizer having a reactive functional group (1,2,2,6,6-pentamethyl-4-piperidinyl methacrylate, “Sanol LS-3410” manufactured by Nippon Emulsifier Co., Ltd.): 4.2 parts by mass Reactive silicone compound (polyether-modified silicone oil): 0.3 part by mass / Scratch resistant filler (silica particles, average particle size: 2 ⁇ m): 2 parts by weight
- ⁇ Resin composition 1 for forming primer layer (used in Examples 1 to 7, 10 to 13, 14 and Comparative Examples 1 to 4)> ⁇ Polycarbonate urethane acrylic copolymer (mass average molecular weight and acrylic component content are as shown in Table 1): 100 parts by mass ⁇ Hydroxyphenyl triazine UV absorber * 1 : 17 parts by mass ⁇ Hydroxyphenyl triazine UV Absorber * 2 : 13 parts by mass, hindered amine light stabilizer * 3 : 8 parts by mass, antiblocking agent * 4 : 9 parts by mass, curing agent (hexamethylene diisocyanate): 25 parts by mass * 1 Tinuvin 400 (trade name) 2- [4-[(2-hydroxy-3-dodecyloxypropyl) oxy] -2-hydroxyphenyl] -4,6-bis (2,4-dimethylphenyl) -1,3,5-triazine, BASF * 2 Tinuvin 479 (trade name), 2- (2-hydroxy-4- [
- ⁇ Resin composition 2 for forming primer layer (used in Examples 8 and 9)> ⁇ Polycarbonate urethane acrylic copolymer (mass average molecular weight and acrylic component content are as shown in Table 1): 100 parts by mass ⁇ Hydroxyphenyl triazine UV absorber * 1 : 17 parts by mass ⁇ Hydroxyphenyl triazine UV Absorber * 2 : 13 parts by mass, hindered amine light stabilizer * 3 : 8 parts by mass, curing agent (hexamethylene diisocyanate): 25 parts by mass * 1 Tinuvin 400 (trade name), 2- [4-[(2- Hydroxy-3-dodecyloxypropyl) oxy] -2-hydroxyphenyl] -4,6-bis (2,4-dimethylphenyl) -1,3,5-triazine, manufactured by BASF Japan Ltd.
- Tinuvin 479 product) Name
- 2- (2-hydroxy-4- [1-octyloxycarbonylethoxy] phenyl) -4,6-bi (4-phenylphenyl) -1,3,5-triazine manufactured by BASF Japan Ltd.
- 3 Tinuvin 123 (trade name), bis (1-octyloxy-2,2,6,6-tetramethyl-4-piperidyl ) Sebacate), manufactured by BASF Japan Ltd.
- ⁇ Resin composition 3 for forming primer layer (used in Comparative Example 5)> ⁇ Polycarbonate urethane resin (mass average molecular weight 1 to 20,000): 100 parts by mass ⁇ Hydroxyphenyl triazine UV absorber * 1 : 17 parts ⁇ Hydroxyphenyl triazine UV absorber * 2 : 13 parts ⁇ Hindered amine light Stabilizer * 3 : 8 parts by mass Antiblocking agent * 4 : 9 parts by mass Curing agent (hexamethylene diisocyanate): 25 parts by mass * 1 Tinuvin 400 (trade name), 2- [4-[(2-hydroxy- 3-dodecyloxypropyl) oxy] -2-hydroxyphenyl] -4,6-bis (2,4-dimethylphenyl) -1,3,5-triazine, manufactured by BASF Japan Ltd.
- Tinuvin 479 (trade name) 2- (2-hydroxy-4- [1-octyloxycarbonylethoxy] phenyl) -4,6-bis (4-phen Ruphenyl) -1,3,5-triazine, manufactured by BASF Japan Ltd.
- 3 Tinuvin 123 (trade name), bis (1-octyloxy-2,2,6,6-tetramethyl-4-piperidyl) sebacate), BASF * 4 Silica particles, average particle size: 3 ⁇ m
- ⁇ Resin Composition 4 for Primer Layer Formation (Used in Comparative Example 6)> ⁇ Polycarbonate urethane resin (mass average molecular weight: 10,000 to 20,000): 20 parts by mass • Acrylic polyol (mass average molecular weight: 30,000 to 40,000): 80 parts by mass • Hydroxyphenyltriazine-based UV absorber * 1 : 17 parts by mass Phenyltriazine-based UV absorber * 2 : 13 parts by mass, hindered amine light stabilizer * 3 : 8 parts by mass, antiblocking agent * 4 : 9 parts by mass, curing agent (hexamethylene diisocyanate): 25 parts by mass * 1 Tinuvin 400 (Trade name), 2- [4-[(2-hydroxy-3-dodecyloxypropyl) oxy] -2-hydroxyphenyl] -4,6-bis (2,4-dimethylphenyl) -1,3,5 -Triazine, manufactured by BASF Japan Ltd.
- Tinuvin 479 (trade name), 2- (2-hydroxy-4- [1-octyloxy) Carbonylethoxy] phenyl) -4,6-bis (4-phenylphenyl) -1,3,5-triazine, manufactured by BASF Japan Ltd.
- 3 Tinuvin 123 (trade name), bis (1-octyloxy-2,2, 6,6-tetramethyl-4-piperidyl) sebacate), manufactured by BASF Japan Ltd.
- ⁇ Resin composition 5 for forming primer layer (used in Comparative Example 7)> ⁇ Acrylic polyol (mass average molecular weight 30 to 40,000): 100 parts by mass ⁇ Hydroxyphenyl triazine UV absorber * 1 : 17 parts ⁇ Hydroxyphenyl triazine UV absorber * 2 : 13 parts ⁇ Hindered amine light stabilizer * 3 : 8 parts by mass Antiblocking agent * 4 : 9 parts by mass Curing agent (hexamethylene diisocyanate): 25 parts by mass * 1 Tinuvin 400 (trade name), 2- [4-[(2-hydroxy-3- Dodecyloxypropyl) oxy] -2-hydroxyphenyl] -4,6-bis (2,4-dimethylphenyl) -1,3,5-triazine, manufactured by BASF Japan Ltd.
- Tinuvin 479 (trade name), 2 -(2-Hydroxy-4- [1-octyloxycarbonylethoxy] phenyl) -4,6-bis (4-phenylphenyl) 1,3,5-triazine, manufactured by BASF Japan * 3 Tinuvin 123 (trade name), bis (1-octyloxy-2,2,6,6-tetramethyl-4-piperidyl) sebacate), BASF Japan stock * 4 Silica particles, average particle size: 3 ⁇ m
- ⁇ Resin composition 6 for forming primer layer (used in Comparative Example 8)> ⁇ Polyurethane urethane resin (mass average molecular weight 1 to 20,000): 70 parts by mass • Acrylic polyol (mass average molecular weight 30,000 to 40,000): 30 parts by mass • Hydroxyphenyltriazine-based UV absorber * 1 : 17 parts by mass Phenyltriazine-based UV absorber * 2 : 13 parts by mass, hindered amine light stabilizer * 3 : 8 parts by mass, antiblocking agent * 4 : 9 parts by mass, curing agent (hexamethylene diisocyanate): 25 parts by mass * 1 Tinuvin 400 (Trade name), 2- [4-[(2-hydroxy-3-dodecyloxypropyl) oxy] -2-hydroxyphenyl] -4,6-bis (2,4-dimethylphenyl) -1,3,5 -Triazine, manufactured by BASF Japan Ltd.
- Tinuvin 479 (trade name), 2- (2-hydroxy-4- [1-octyloxy) Carbonylethoxy] phenyl) -4,6-bis (4-phenylphenyl) -1,3,5-triazine, manufactured by BASF Japan Ltd.
- 3 Tinuvin 123 (trade name), bis (1-octyloxy-2,2, 6,6-tetramethyl-4-piperidyl) sebacate), manufactured by BASF Japan Ltd.
- ⁇ Resin composition 7 for forming primer layer (used in Examples 15 and 16)> ⁇ Polyester urethane-acrylic copolymer (mass average molecular weight and acrylic component content are as shown in Table 1): 100 parts by mass ⁇ Hydroxyphenyltriazine-based UV absorber * 1 : 17 parts by mass ⁇ Hydroxyphenyltriazine Ultraviolet absorber * 2 : 13 parts by mass, hindered amine light stabilizer * 3 : 8 parts by mass, antiblocking agent * 4 : 9 parts by mass, curing agent (hexamethylene diisocyanate): 25 parts by mass * 1 Tinuvin 400 (trade name) ), 2- [4-[(2-hydroxy-3-dodecyloxypropyl) oxy] -2-hydroxyphenyl] -4,6-bis (2,4-dimethylphenyl) -1,3,5-triazine, * 2 Tinuvin 479 (trade name), 2- (2-hydroxy-4- [1-octyl
- the mass average molecular weight of the binder resin used for the primer layer is polystyrene equivalent (measured at 9 levels between molecular weights 1110000 to 1050 and a calibration curve is created) by GPC under the following conditions. It calculated
- the transfer sheet was supplied and fixed between a pair of male and female molds (movable mold and fixed mold) in an open state so that the adhesive layer surface was directed toward the cavity. Thereafter, the adhesive layer of the transfer sheet is heated to 100 ° C. to be softened, and vacuum suction is performed from the mold side facing the base film side for release, and the softened transfer sheet is transferred to the movable mold.
- a transfer sheet was preformed by closely adhering along the shape. Subsequently, after clamping the molds, into a cavity formed by the molds, a polycarbonate resin in a fluid state (Teijin Ltd. Panlite L-1250Z, MVR8cm 3 / 10min ) molding temperature 315 ° C.
- the pressure 170MPa The polycarbonate molded product and the transfer sheet were laminated and integrated by injection, filling, and solidifying. Then, after separating the movable mold from the fixed mold, the polycarbonate, adhesive layer, primer layer, and hard coat layer are laminated in this order by peeling the base film for release. The body was manufactured.
- the hard coat layer is formed of a cured product of a resin composition containing an ionizing radiation curable resin
- the primer layer has a mass average molecular weight of 40,000 to 100,000 and an acrylic component content of 1 to 30% by mass.
- the residual ratio of the hard coat layer after the weather resistance test is high, and the primer layer and the hard coat layer are firmly adhered, It was confirmed to have excellent weather resistance.
- the primer layer is formed using a urethane-acrylic copolymer having a mass average molecular weight of 50,000 to 80,000 and an acrylic component content of 5 to 20% by mass (Examples 4 to 16), Remarkably excellent weather resistance was observed.
- the primer layer is formed using a urethane acrylic copolymer having a mass average molecular weight of less than 40,000 even if the acrylic component content is 1 to 30% by mass (Comparative Example 1), the weather resistance was inferior. Further, even when the content of the acrylic component in the urethane acrylic copolymer is 1 to 30% by mass, the primer layer is formed using the urethane acrylic copolymer having a mass average molecular weight exceeding 100,000 (Comparative Example 2). ), Whitening of the hard coat body was recognized by the weather resistance test, and weather resistance could not be provided.
- a primer layer is formed using a urethane acrylic copolymer having an acrylic component content outside the range of 1 to 30% by mass even if the mass average molecular weight satisfies 40,000 to 100,000 (Comparative Example 3). And 4), the weather resistance was inferior. Furthermore, even when the primer layer was formed using acrylic polyol alone, urethane acrylate alone, or a mixture of acrylic polyol and urethane acrylate as the binder resin (Comparative Examples 5 to 8), excellent weather resistance was not recognized.
- Test Example 2 Colored layer-transfer sheet having a hiding function, and performance evaluation of the hard coat material using the same 1.
- Production of transfer sheet (Example 17) A resin composition A for forming a hard coat layer used in Test Example 1 was applied to a release base film (thickness 75 ⁇ m) made of biaxially stretched polyethylene terephthalate. Then, a hard coat layer (thickness 3 ⁇ m) was laminated on the support film layer by curing with electron beam irradiation 10 Mrad. Next, the hard coat layer surface was subjected to corona discharge treatment, and the primer layer-forming resin composition 1 used in Test Example 1 was applied by a gravure reverse method to form a primer layer having a thickness of 3 ⁇ m.
- an ink composition for forming a colored layer black pigment: carbon black (average particle size: 24 nm) 210 parts by weight, binder resin: vinyl acetate resin 100 parts by weight, acrylic resin 100 parts by weight
- a colored layer thickness: 3 ⁇ m
- a frame shape a shape having an opening
- a heat-sealing resin (acrylic resin) was applied on the colored layer by a gravure reverse method to form an adhesive layer having a thickness of 4 ⁇ m.
- a transfer sheet was obtained in which a hard coat layer, a primer layer, a partially formed colored layer, and an adhesive layer were sequentially laminated on a release base film.
- the OD value of the colored layer in the obtained transfer sheet was measured by the above method using a transmission densitometer (D200-II, manufactured by GretagMacbeth), and was 5.8.
- the hard coat layer is formed of a cured product of a resin composition containing an ionizing radiation curable resin, and the primer layer has a mass average molecular weight of 40,000 to 100,000, and When formed using a urethane acrylic copolymer having an acrylic component content of 1 to 30% by mass (Example 17), the residual ratio of the hard coat layer after the weather resistance test is high, and the primer layer and the hard coat It was confirmed that the layers were firmly adhered and had excellent weather resistance.
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Abstract
Description
即ち、本発明は、下記に掲げる態様の発明を提供する。
項1. 少なくとも、離型用の基材フィルム、ハードコート層、プライマー層、及び接着層をこの順に有し、
前記ハードコート層が、硬化性樹脂を含む樹脂組成物の硬化物によって形成されており、
前記プライマー層が、質量平均分子量が4万~10万、且つアクリル成分が1~30質量%含まれるポリウレタンを含むバインダー樹脂で形成されている、転写シート。
項2. 前記ポリウレタンが、質量平均分子量が5万~8万であり、且つアクリル成分が5~20質量%含まれている、項1に記載の転写シート。
項3. 前記ポリウレタンがウレタンアクリル共重合体である、項1又は2に記載の転写シート。
項4. 前記ポリウレタンが、ポリカーボネート系ウレタンアクリル共重合体及び/又はポリエステル系ウレタンアクリル共重合体である、項1~3のいずれかに記載の転写シート。
項5. 前記硬化性樹脂が、電離放射線硬化性樹脂である、項1~4のいずれかに記載の転写シート。
項6. 前記硬化性樹脂が、(i)3官能以上の電離放射線硬化性樹脂と、(ii)2官能の(メタ)アクリレートモノマーの組み合わせである、項1~5のいずれかに記載の転写シート。
項7. 前記接着層が、感熱接着性樹脂又は加圧接着性樹脂を含む、項1~6のいずれかに記載の転写シート。
項8. 離型用の基材フィルムとハードコート層の間、ハードコート層とプライマー層の間、プライマー層と接着層の間、及び接着層のプライマー層側とは反対側の面上のいずれか少なくとも1つに、部分的に形成された着色層を有する、項1~7のいずれかに記載の転写シート。
項9. 少なくとも、ハードコート層、プライマー層、接着層、及び樹脂成型品をこの順に有し、
前記ハードコート層が、硬化性樹脂を含む樹脂組成物の硬化物によって形成されており、
前記プライマー層が、質量平均分子量が4万~10万、且つアクリル成分が1~30質量%含まれるポリウレタンを含むバインダー樹脂で形成されている、ハードコート体。
項10. 前記ポリウレタンが、質量平均分子量が5万~8万であり、且つアクリル成分が5~20質量%含まれている、項9に記載のハードコート体。
項11. 前記ポリウレタンがウレタンアクリル共重合体である、項9又は10に記載のハードコート体。
項12. 前記ポリウレタンが、ポリカーボネート系ウレタンアクリル共重合体及び/又はポリエステル系ウレタンアクリル共重合体である、項9~11のいずれかに記載のハードコート体。
項13. 前記硬化性樹脂が、電離放射線硬化性樹脂である、項9~12のいずれかに記載のハードコート体。
項14. 前記硬化性樹脂が、(i)3官能以上の電離放射線硬化性樹脂と、(ii)2官能の(メタ)アクリレートモノマーの組み合わせである、項9~13のいずれかに記載のハードコート体。
項15. 前記接着層が、感熱接着性樹脂又は加圧接着性樹脂を含む、項9~14のいずれかに記載のハードコート体。
項16. ハードコート層の表面、ハードコート層とプライマー層の間、プライマー層と接着層の間、及び接着層と樹脂成型品の間のいずれか少なくとも1つに、部分的に形成された着色層を有する、項9~15のいずれかに記載のハードコート体。
項17. 項1~8のいずれかに記載の転写シートを、接着層が樹脂成型品に接するように貼り合わせた後に、離型用の基材フィルムを剥離する、ハードコート体の製造方法。
項18. 項1~8のいずれかに記載の転写シートを予め成形された樹脂成型品に貼り合わせた後に、離型用の基材フィルムを剥離する、項17に記載のハードコート体の製造方法。
項19. 項1~8のいずれかに記載の転写シートに対して樹脂を射出させて一体化させた後に、離型用の基材フィルムを剥離する、項17に記載のハードコート体の製造方法。
本発明の転写シートは、少なくとも、離型用の基材フィルム1、ハードコート層2、プライマー層3、及び接着層4をこの順に有し、当該ハードコート層2が、硬化性樹脂を含む樹脂組成物の硬化物によって形成されており、当該プライマー層3が、質量平均分子量4万~10万、且つアクリル成分が1~30質量%含まれるポリウレタンを含むバインダー樹脂で形成されていることを特徴とする。以下、本発明の転写シートについて詳述する。
本発明の転写シートは、図1に示すように、少なくとも、離型用の基材フィルム1、ハードコート層2、プライマー層3、及び接着層4をこの順に有する積層構造を備える。
[離型用の基材フィルム1]
離型用の基材フィルム1は、ハードコート層2、プライマー層3、及び接着層4を支持する支持基材としての役割を果し、ハードコート層2、プライマー層3、及び接着層4を被転写体に転写した後に剥離される層である。
ハードコート層2は、離型用の基材フィルム1とプライマー層3の間に設けられる層であり、被転写体となる樹脂成型品に転写された後に、最表面に位置して樹脂成型品にハードコート性(耐傷性等)を付与する役割を果たし、耐候性の向上にも寄与する層である。
ハードコート層2は、硬化性樹脂を含む樹脂組成物の硬化物によって形成される。ハードコート層2の形成に使用される硬化性樹脂としては、架橋により硬化する樹脂であることを限度として特に制限されないが、例えば、熱硬化性樹脂、常温硬化性樹脂、1液反応硬化性樹脂、2液反応硬化性樹脂、電離放射線硬化性樹脂等が挙げられる。
3官能以上の電離放射線硬化性樹脂としては、3つ以上の官能基が導入されている電離放射線硬化性樹脂である限り特に制限されないが、好ましくは分子内に重合性不飽和結合を3個以上(3官能以上)有する多官能性(メタ)アクリレートが挙げられる。多官能性(メタ)アクリレートとしては、例えば、ペンタエリスリトール系(メタ)アクリレート、ポリカーボネート(メタ)アクリレート、ウレタン(メタ)アクリレート、エポキシ(メタ)アクリレート、ポリエステル(メタ)アクリレート、ポリエーテル(メタ)アクリレート、ポリブタジエン(メタ)アクリレート、シリコーン(メタ)アクリレート、アミノプラスト樹脂(メタ)アクリレート等が挙げられる。ここで、ペンタエリスリトール系(メタ)アクリレートは、例えば、ペンタエリスリトール又はその重合物の水酸基の一部又は全てを(メタ)アクリル酸でエステル化することにより得ることができる。ポリカーボネート(メタ)アクリレートは、例えば、ポリカーボネートポリオール水酸基の一部又は全てを(メタ)アクリル酸でエステル化することにより得ることができる。ウレタン(メタ)アクリレートは、例えば、ポリエーテルポリオール、ポリエステルポリオール、ポリカーボネートポリオール等のポリオールとポリイソシアネートの反応によって得られるポリウレタンオリゴマーを、(メタ)アクリル酸でエステル化することにより得ることができる。エポキシ(メタ)アクリレートは、例えば、比較的低分子量のビスフェノール型エポキシ樹脂やノボラック型エポキシ樹脂のオキシラン環に、(メタ)アクリル酸を反応しエステル化することにより得ることができる。また、このエポキシ(メタ)アクリレートを部分的に二塩基性カルボン酸無水物で変性したカルボキシル変性型のエポキシ(メタ)アクリレートも用いることができる。ポリエステル(メタ)アクリレートは、例えば多価カルボン酸と多価アルコールの縮合によって得られる両末端に水酸基を有するポリエステルオリゴマーの水酸基を(メタ)アクリル酸でエステル化することにより、或いは多価カルボン酸にアルキレンオキシドを付加して得られるオリゴマーの末端の水酸基を(メタ)アクリル酸でエステル化することにより得ることができる。ポリエーテル(メタ)アクリレートは、ポリエーテルポリオールの水酸基を(メタ)アクリル酸でエステル化することにより得ることができる。ポリブタジエン(メタ)アクリレートは、ポリブタジエンオリゴマーの側鎖に(メタ)アクリレート酸を付加することにより得ることができる。シリコーン(メタ)アクリレートは、主鎖にポリシロキサン結合をもつシリコーンを(メタ)アクリル酸で変性させることにより得ることができる。アミノプラスト樹脂(メタ)アクリレートは、小さな分子内に多くの反応性基をもつアミノプラスト樹脂を(メタ)アクリル酸で変性させることにより得ることができる。これらの3官能以上の電離放射線硬化性樹脂は、1種単独で使用してもよく、また2種以上を組み合わせて使用してもよい。
2官能の(メタ)アクリレートモノマーは、2つの(メタ)アクリロイル基が環状又は直鎖状の脂肪族のリンカー領域を介して結合している構造であればよい。また、2官能の(メタ)アクリレートモノマーの分子量については、特に制限されず、例えば、100~10000程度であればよい。より一層優れた耐候性及びハードコート性を備えさせるという観点から、2官能の(メタ)アクリレートモノマーの分子量として、好ましくは190~1200、更に好ましくは190~600が挙げられる。
前記(ii-1)の2官能の(メタ)アクリレートモノマーとしては、1分子中に脂環又は複素環を1つ有し、且つ当該脂環又は複素環に直接又は分子量200以下のリンカー領域を介して結合した(メタ)アクリロイル基(-C(=O)-CH(又はCH3)=CH2)を2つ有する構造であることを限度として特に制限されない。
前記(ii-2)の2官能のウレタン(メタ)アクリレートモノマーとしては、2つの(メタ)アクリロイル基(-C(=O)-CH(又はCH3)=CH2)が、ウレタン結合を含む脂肪族鎖を介して結合している構造であることを限度として特に制限されない。
電離放射線硬化性樹脂として、前記(i)の3官能以上の電離放射線硬化性樹脂と、前記(ii)の2官能の(メタ)アクリレートモノマーを組み合わせて使用する場合、これらの電離放射線硬化性樹脂以外に、本発明の効果を損なわない範囲で、必要に応じて、単官能の(メタ)アクリレートモノマー、3官能以上の(メタ)アクリレートモノマー、2官能の電離放射線硬化性樹脂等が含まれていてもよい。ハードコート層3に含まれる電離放射線硬化性樹脂の総量100質量部当たり、前記(i)の3官能以上の電離放射線硬化性樹脂と、前記(ii)の2官能の(メタ)アクリレートモノマーの合計量としては、例えば50~100質量部、好ましくは70~100質量部、更に好ましくは80~100質量部が挙げられる。
ハードコート層2には、紫外線曝露に対する耐候性を備えさせるために、必要に応じて、紫外線吸収剤が含まれていてもよい。ハードコート層2に使用される紫外線吸収剤の種類については、特に制限されないが、例えば、ヒドロキシフェニルトリアジン系化合物、ベンゾトリアゾール系化合物、ベンゾフェノン系化合物、シュウ酸アニリド系化合物、サリチル酸フェニルエステル系化合物、アクリルニトリル系化合物等が挙げられる。これらの中でも、好ましくはヒドロキシフェニルトリアジン系化合物、ベンゾトリアゾール系化合物、更に好ましくはヒドロキシフェニルトリアジン系化合物が挙げられる。これらの紫外線吸収剤は、1種を単独で使用してもよく、また2種以上を組み合わせて使用してもよい。
ハードコート層2の厚さについては、特に制限されないが、例えば、1~100μm、好ましくは1.5~50μm、更に好ましくは2~20μmが挙げられる。
ハードコート層2の形成は、使用する硬化性樹脂の種類に応じた方法を採用すればよい。例えば、熱硬化性樹脂、常温硬化性樹脂、1液反応硬化性樹脂、又は2液反応硬化性樹脂を使用する場合であれば、これらの樹脂と必要に応じて各種添加剤を混合したハードコート層2用の樹脂組成物を、グラビアコート、バーコート、ロールコート、リバースロールコート、コンマコート等の方法で離型用の基材フィルム1に塗工し、必要に応じて加熱を行うことにより、当該樹脂組成物を硬化させればよい。
プライマー層3は、ハードコート層2と接着層3の間に配され、ハードコート層2に対する応力緩和層として機能すると共に、ハードコート層2の密着性を向上させる役割を果たす層である。
接着層4は、離型用の基材フィルム1とは反対側の表面に配される層であり、被転写体となる樹脂成型品に接着する役割を果たす。
離型層は、離型用の基材フィルム1を剥離し易くするために、離型用の基材フィルム1とハードコート層2の間に必要に応じて設けられる層である。
着色層5は、本発明の転写シートを用いて製造したハードコート体を固定する際の接着剤塗布部の隠蔽、情報表示、意匠性の付与等の目的で、離型用の基材フィルム1とハードコート層2の間、ハードコート層2とプライマー層3の間、プライマー層3と接着層4の間、及び接着層4のプライマー層3側とは反対側の面上のいずれか少なくとも1つに、必要に応じて設けられる層である。
(着色層5のOD値の測定方法)
本発明の転写シートから離形用の基材フィルム1を剥離した状態のシート、又は本発明の転写シートを用いて製造したハードコート体において、着色層5が設けられていない部位のOD値(ODlow値)と、着色層5が設けられている部位のOD値(ODhigh値)を測定する。算出式(ODhigh値-ODlow値)に従って求められる値が着色層5のOD値となる。ここで、ODlow値とODhigh値は、透過濃度計を用い、中心波長555nmにて測定される値である。
本発明の転写シートは、離型用の基材フィルム1の上に、ハードコート層2、プライマー層3、及び接着層4をこの順に形成して積層させることにより製造される。また、離型用の基材フィルム1とハードコート層2の間に離型層を設ける場合には、離型用の基材フィルム1の上に離型層を形成した後に、ハードコート層2、プライマー層3、及び接着層4をこの順に形成して積層させればよい。
本発明の転写シートは、被転写体となる樹脂成型品に対して、接着層4、プライマー層3、及びハードコート層2を転写することにより、ハードコート性(耐傷性等)と共に耐候性を付与するために使用される。本発明の転写シートにおける離型用の基材フィルム1は、樹脂成型品に転写された後に剥離される。
本発明の転写シートを前記接着層4が被転写体となる樹脂成型品6に接するように貼り合わせた後に、離型用の基材フィルム1を剥離することによって、ハードコート体を得ることができる。即ち、本発明の転写シートを用いて製造したハードコート体は、図3に示すように、少なくとも、樹脂成型品6、接着層4、プライマー層3、及びハードコート層2がこの順に積層された積層構造になる。また、本発明の転写シートにおいて、着色層5が設けられている場合であれば、本発明の転写シートを用いたハードコート体は、発明の転写シートを用いて製造したハードコート体において、着色層5は、ハードコート層2の表面、ハードコート層2とプライマー層3の間、プライマー層3と接着層4の間、及び接着層4と樹脂成型品4の間のいずれか少なくとも1つに配置されることになる。本発明の転写シートを用いたハードコート体は、樹脂成型品6上に積層された接着層4、プライマー層3及びハードコート層2によって、ハードコート性(耐傷性)と共に優れた耐候性を備えることができる。
第I工程:本発明の転写シートを射出成形型に挿入(接着層4が射出される樹脂側に配置)し、射出成形型を閉じ、流動状態の樹脂を型内に射出して樹脂と本発明の転写シートを一体化する。
第II工程:樹脂成型品と一体化された本発明の転写シートから離型用の基材フィルム1を剥離する。
第1工程:型開き状態の雌雄一対の金型の間に、本発明の転写シートを、接着層4面がキャビティ側に向くように供給して、固定する。更に、本発明の転写シートの接着層4を加熱、軟化させると共に、離型用の基材フィルム1と対面している金型側から真空吸引して、本発明の転写シートを当該可動金型の形状に沿って密着させることにより、本発明の転写シートを予備成形する。
第2工程:両金型を型締めした後、両金型で形成されるキャビティ内に、流動状態の樹脂を射出、充填して固化させることにより、樹脂成型品と本発明の転写シートを積層一体化させる。
第3工程:可動金型を固定金型から離間させて、本発明の転写シートが一体化された樹脂成型品を取り出し、本発明の転写シートから離型用の基材フィルム1を剥離する。
1.転写シート(実施例1~16及び比較例1~8)の製造
2軸延伸ポリエチレンテレフタレートからなる離形用の基材フィルム(厚さ75μm)に、下記ハードコート層形成用の樹脂組成物A~Dのいずれかを塗工し、電子線照射10Mradにて硬化させることにより、支持フィルム層上にハードコート層(3μm)を積層させた。次いで、当該ハードコート層面にコロナ放電処理をした上に、下記プライマー層形成用の樹脂組成物1~6のいずれかをグラビアリバース法によって塗工して厚さ3μmのプライマー層を形成し、更に当該プライマー層上に、熱融着樹脂(アクリル樹脂)をグラビアリバース法によって塗工して厚さ4μmの接着層を形成した。斯して、離形用の基材フィルム上に、ハードコート層、プライマー層、及び接着層が順に積層された転写シートを得た。なお、各実施例及び比較例の転写シートの製造に使用したハードコート層形成用の樹脂組成物及びプライマー層形成用の樹脂組成物の種類は、表1に示す通りである。
・6官能の電離放射線硬化性樹脂(6官能のウレタンアクリレート(分子量約1,000)60質量部と2官能のカプロラクトン変性ウレタンアクリレート(分子量数千程度)40質量部の混合物):100質量部
・ヒドロキシフェニルトリアジン系紫外線吸収剤(BASFジャパン株式会社製「Tinuvin479」):0.7質量部
・反応性官能基を有する光安定剤(1,2,2,6,6-ペンタメチル-4-ピペリジニルメタクリレート、日本乳化剤株式会社製「サノールLS-3410」):4.2質量部・非反応性シリコーン化合物(ポリエーテル変性シリコーンオイル):0.3質量部
・耐傷フィラー(シリカ粒子、平均粒子径:2μm):2重量部
・イソシアヌレート環を有する多官能アクリレート(質量平均分子量約27,000:4~8官能のアクリレートポリマーを主成分とする):80質量部
・2つの(メタ)アクリロイル基がウレタン結合を含む脂肪族鎖を介して結合している2官能ウレタンアクリレートモノマー#1(分子量約400):20質量部
・ヒドロキシフェニルトリアジン系紫外線吸収剤(BASFジャパン株式会社製「Tinuvin479」):0.7質量部
・反応性官能基を有する光安定剤(1,2,2,6,6-ペンタメチル-4-ピペリジニルメタクリレート、日本乳化剤株式会社製「サノールLS-3410」):4.2質量部・非反応性シリコーン化合物(ポリエーテル変性シリコーンオイル):0.3質量部
・耐傷フィラー(シリカ粒子、平均粒子径:2μm):2重量部
#1 2官能ウレタンアクリレートモノマーは、下記式(X)で示される化合物1分子と下記式(Y)で示される化合物2分子が結合したものであり、下記式(X)で示される化合物のイソシアネート基と下記式(Y)で示される化合物の水酸基とが反応してウレタン結合を形成している。
・6官能の電離放射線硬化性樹脂(6官能のウレタンアクリレート(分子量約1,000)60質量部と2官能のカプロラクトン変性ウレタンアクリレート(分子量数千程度)40質量部の混合物):100質量部
・イソホロンジイソシアネートにヒドロキシエチルアクリレート2つがウレタン結合した脂環式ウレタンジアクリレート:16質量部
・ヒドロキシフェニルトリアジン系紫外線吸収剤(BASFジャパン株式会社製「Tinuvin479」):2.3質量部
・反応性官能基を有する光安定剤(1,2,2,6,6-ペンタメチル-4-ピペリジニルメタクリレート、日本乳化剤株式会社製「サノールLS-3410」):4.2質量部・非反応性シリコーン化合物(ポリエーテル変性シリコーンオイル):0.3質量部
・耐傷フィラー(シリカ粒子、平均粒子径:2μm):2重量部
・イソシアヌレート環を有する多官能アクリレート(質量平均分子量約27,000:4~8官能のアクリレートポリマーを主成分とする):80質量部
・2つの(メタ)アクリロイル基がウレタン結合を含む脂肪族鎖を介して結合している2官能ウレタンアクリレートモノマー#2(分子量約400):20質量部
・ヒドロキシフェニルトリアジン系紫外線吸収剤(BASFジャパン株式会社製「Tinuvin479」):2質量部
#2 2官能ウレタンアクリレートモノマーは、前記ハードコート層形成用の樹脂組成物Bで使用したものと同じ。
・反応性官能基を有する光安定剤(1,2,2,6,6-ペンタメチル-4-ピペリジニルメタクリレート、日本乳化剤株式会社製「サノールLS-3410」):4.2質量部・非反応性シリコーン化合物(ポリエーテル変性シリコーンオイル):0.3質量部
・耐傷フィラー(シリカ粒子、平均粒子径:2μm):2重量部
・ ポリカーボネート系ウレタンアクリル共重合体(質量平均分子量及びアクリル成分の含有量は、表1に示す通り):100質量部
・ ヒドロキシフェニルトリアジン系紫外線吸収剤*1:17質量部
・ ヒドロキシフェニルトリアジン系紫外線吸収剤*2:13質量部
・ ヒンダードアミン系光安定剤*3:8質量部
・ ブロッキング防止剤*4:9質量部
・ 硬化剤(ヘキサメチレンジイソシアネート):25質量部
*1 チヌビン400(商品名)、2-[4-[(2-ヒドロキシ-3-ドデシルオキシプロピル)オキシ]-2-ヒドロキシフェニル]-4,6-ビス(2,4-ジメチルフェニル)-1,3,5-トリアジン、BASFジャパン株式会社製
*2 チヌビン479(商品名)、2-(2-ヒドロキシ-4-[1-オクチルオキシカルボニルエトキシ]フェニル)-4,6-ビス(4-フェニルフェニル)-1,3,5-トリアジン、BASFジャパン株式会社製
*3 チヌビン123(商品名)、ビス(1-オクチロキシ-2,2,6,6-テトラメチル-4-ピペリジル)セバケート)、BASFジャパン株式会社製
*4 シリカ粒子、平均粒径:3μm
・ ポリカーボネート系ウレタンアクリル共重合体(質量平均分子量及びアクリル成分の含有量は、表1に示す通り):100質量部
・ ヒドロキシフェニルトリアジン系紫外線吸収剤*1:17質量部
・ ヒドロキシフェニルトリアジン系紫外線吸収剤*2:13質量部
・ ヒンダードアミン系光安定剤*3:8質量部
・ 硬化剤(ヘキサメチレンジイソシアネート):25質量部
*1 チヌビン400(商品名)、2-[4-[(2-ヒドロキシ-3-ドデシルオキシプロピル)オキシ]-2-ヒドロキシフェニル]-4,6-ビス(2,4-ジメチルフェニル)-1,3,5-トリアジン、BASFジャパン株式会社製
*2 チヌビン479(商品名)、2-(2-ヒドロキシ-4-[1-オクチルオキシカルボニルエトキシ]フェニル)-4,6-ビス(4-フェニルフェニル)-1,3,5-トリアジン、BASFジャパン株式会社製
*3 チヌビン123(商品名)、ビス(1-オクチロキシ-2,2,6,6-テトラメチル-4-ピペリジル)セバケート)、BASFジャパン株式会社製
・ ポリカーボネート系ウレタン樹脂(質量平均分子量1~2万):100質量部
・ ヒドロキシフェニルトリアジン系紫外線吸収剤*1:17質量部
・ ヒドロキシフェニルトリアジン系紫外線吸収剤*2:13質量部
・ ヒンダードアミン系光安定剤*3:8質量部
・ ブロッキング防止剤*4:9質量部
・ 硬化剤(ヘキサメチレンジイソシアネート):25質量部
*1 チヌビン400(商品名)、2-[4-[(2-ヒドロキシ-3-ドデシルオキシプロピル)オキシ]-2-ヒドロキシフェニル]-4,6-ビス(2,4-ジメチルフェニル)-1,3,5-トリアジン、BASFジャパン株式会社製
*2 チヌビン479(商品名)、2-(2-ヒドロキシ-4-[1-オクチルオキシカルボニルエトキシ]フェニル)-4,6-ビス(4-フェニルフェニル)-1,3,5-トリアジン、BASFジャパン株式会社製
*3 チヌビン123(商品名)、ビス(1-オクチロキシ-2,2,6,6-テトラメチル-4-ピペリジル)セバケート)、BASFジャパン株式会社製
*4 シリカ粒子、平均粒径:3μm
・ ポリカーボネート系ウレタン樹脂(質量平均分子量1~2万):20質量部
・アクリルポリオール(質量平均分子量3~4万):80質量部
・ ヒドロキシフェニルトリアジン系紫外線吸収剤*1:17質量部
・ ヒドロキシフェニルトリアジン系紫外線吸収剤*2:13質量部
・ ヒンダードアミン系光安定剤*3:8質量部
・ ブロッキング防止剤*4:9質量部
・ 硬化剤(ヘキサメチレンジイソシアネート):25質量部
*1 チヌビン400(商品名)、2-[4-[(2-ヒドロキシ-3-ドデシルオキシプロピル)オキシ]-2-ヒドロキシフェニル]-4,6-ビス(2,4-ジメチルフェニル)-1,3,5-トリアジン、BASFジャパン株式会社製
*2 チヌビン479(商品名)、2-(2-ヒドロキシ-4-[1-オクチルオキシカルボニルエトキシ]フェニル)-4,6-ビス(4-フェニルフェニル)-1,3,5-トリアジン、BASFジャパン株式会社製
*3 チヌビン123(商品名)、ビス(1-オクチロキシ-2,2,6,6-テトラメチル-4-ピペリジル)セバケート)、BASFジャパン株式会社製
*4 シリカ粒子、平均粒径:3μm
・アクリルポリオール(質量平均分子量3~4万):100質量部
・ ヒドロキシフェニルトリアジン系紫外線吸収剤*1:17質量部
・ ヒドロキシフェニルトリアジン系紫外線吸収剤*2:13質量部
・ ヒンダードアミン系光安定剤*3:8質量部
・ ブロッキング防止剤*4:9質量部
・ 硬化剤(ヘキサメチレンジイソシアネート):25質量部
*1 チヌビン400(商品名)、2-[4-[(2-ヒドロキシ-3-ドデシルオキシプロピル)オキシ]-2-ヒドロキシフェニル]-4,6-ビス(2,4-ジメチルフェニル)-1,3,5-トリアジン、BASFジャパン株式会社製
*2 チヌビン479(商品名)、2-(2-ヒドロキシ-4-[1-オクチルオキシカルボニルエトキシ]フェニル)-4,6-ビス(4-フェニルフェニル)-1,3,5-トリアジン、BASFジャパン株式会社製
*3 チヌビン123(商品名)、ビス(1-オクチロキシ-2,2,6,6-テトラメチル-4-ピペリジル)セバケート)、BASFジャパン株式会社製
*4 シリカ粒子、平均粒径:3μm
・ ポリカーボネート系ウレタン樹脂(質量平均分子量1~2万):70質量部
・アクリルポリオール(質量平均分子量3~4万):30質量部
・ ヒドロキシフェニルトリアジン系紫外線吸収剤*1:17質量部
・ ヒドロキシフェニルトリアジン系紫外線吸収剤*2:13質量部
・ ヒンダードアミン系光安定剤*3:8質量部
・ ブロッキング防止剤*4:9質量部
・ 硬化剤(ヘキサメチレンジイソシアネート):25質量部
*1 チヌビン400(商品名)、2-[4-[(2-ヒドロキシ-3-ドデシルオキシプロピル)オキシ]-2-ヒドロキシフェニル]-4,6-ビス(2,4-ジメチルフェニル)-1,3,5-トリアジン、BASFジャパン株式会社製
*2 チヌビン479(商品名)、2-(2-ヒドロキシ-4-[1-オクチルオキシカルボニルエトキシ]フェニル)-4,6-ビス(4-フェニルフェニル)-1,3,5-トリアジン、BASFジャパン株式会社製
*3 チヌビン123(商品名)、ビス(1-オクチロキシ-2,2,6,6-テトラメチル-4-ピペリジル)セバケート)、BASFジャパン株式会社製
*4 シリカ粒子、平均粒径:3μm
・ ポリエステル系ウレタン-アクリル共重合体(質量平均分子量及びアクリル成分の含有量は、表1に示す通り):100質量部
・ ヒドロキシフェニルトリアジン系紫外線吸収剤*1:17質量部
・ ヒドロキシフェニルトリアジン系紫外線吸収剤*2:13質量部
・ ヒンダードアミン系光安定剤*3:8質量部
・ ブロッキング防止剤*4:9質量部
・ 硬化剤(ヘキサメチレンジイソシアネート):25質量部
*1 チヌビン400(商品名)、2-[4-[(2-ヒドロキシ-3-ドデシルオキシプロピル)オキシ]-2-ヒドロキシフェニル]-4,6-ビス(2,4-ジメチルフェニル)-1,3,5-トリアジン、BASFジャパン株式会社製
*2 チヌビン479(商品名)、2-(2-ヒドロキシ-4-[1-オクチルオキシカルボニルエトキシ]フェニル)-4,6-ビス(4-フェニルフェニル)-1,3,5-トリアジン、BASFジャパン株式会社製
*3 チヌビン123(商品名)、ビス(1-オクチロキシ-2,2,6,6-テトラメチル-4-ピペリジル)セバケート)、BASFジャパン株式会社製
*4 シリカ粒子、平均粒径:3μm
装置名:Waters 2695(Waters社製)
カラム:GPC LF-804(Shodex社) 3本直列接続
溶媒:テトラヒドロフラン
前記で得られた各転写シートを用いて、ハードコート層、プライマー層及び接着層をポリカーボネート板に転写し、ポリカーボネート板、接着層、プライマー層、及びハードコート層がこの順で積層されているハードコート体を得た。なお、実施例1~9、11、及び比較例1~8の転写シートについては下記第1法によって転写を行い、実施例10、及び12~16の転写シートについては下記第2法によって転写を行った。
厚み2mmのポリカーボネート板を、150℃のホットプレートを用いて加熱した。加熱したポリカーボネート板の片面に転写シートを接着層がポリカーボネート板側になるように配置した上で、190℃の熱ラミロールにて3回加熱ラミネート加工した。その後、離形用の基材フィルムを剥離することにより、ポリカーボネート板、接着層、プライマー層、及びハードコート層がこの順で積層されているハードコート体を製造した。
型開き状態の雌雄一対の金型(可動金型と固定金型)の間に、転写シートを、接着層面がキャビティ側に向くように供給して、固定した。その後、転写シートの接着層を100℃に加熱して軟化させると共に、離形用の基材フィルム側と対面している金型側から真空吸引して、軟化した転写シートを当該可動金型の形状に沿って密着させることにより、転写シートを予備成形した。次いで、両金型を型締めした後、両金型で形成されるキャビティ内に、流動状態のポリカーボネート樹脂(帝人社製 パンライトL-1250Z、MVR8cm3/10min)を成形温度315℃、圧力170MPaにて射出、充填して固化させることにより、ポリカーボネート成型品と転写シートを積層一体化させた。その後、可動金型を固定金型から離間させた後、離形用の基材フィルムを剥離することにより、ポリカーボネート、接着層、プライマー層、及びハードコート層がこの順で積層されているハードコート体を製造した。
製造直後の各ハードコート体について、促進耐候性試験機(SUV-W23、(岩崎電気)社製)を用いて、(1)紫外線を60mW/cm2、63℃、50RH%で20時間、(2)暗黒、30℃、98RH%で4時間、及び(3)前記(2)の条件の前後に水噴射30秒間の条件を1サイクルとして、5~15サイクルの耐候性試験を行った。
1.転写シート(実施例17)の製造
2軸延伸ポリエチレンテレフタレートからなる離形用の基材フィルム(厚さ75μm)に、前記試験例1で使用したハードコート層形成用の樹脂組成物Aを塗工し、電子線 照射10Mradにて硬化させることにより、支持フィルム層上にハードコート層(厚さ3μm)を積層させた。次いで、当該ハードコート層面にコロナ放電処理をした上に、前記試験例1で使用したプライマー層形成用の樹脂組成物1をグラビアリバース法によって塗工して厚さ3μmのプライマー層を形成した。更に当該プライマー層上に、着色層形成用のインキ組成物(黒色顔料:カーボンブラック(平均粒径24nm)210重量部、バインダー樹脂:塩酢ビ樹脂100重量部、アクリル樹脂100重量部の混合物を含有)をグラビアダイレクト法にて、3度重ね塗り塗工することにより、縦170mm、横100mm、幅20mmの枠状(開口部を有する形状)の着色層(厚さ3μm)を形成した。更に当該着色層上に、熱融着樹脂(アクリル樹脂)をグラビアリバース法によって塗工して厚さ4μmの接着層を形成した。斯して、離形用の基材フィルム上に、ハードコート層、プライマー層、部分的に形成された着色層、及び接着層が順に積層された転写シートを得た。なお、得られた転写シートにおける着色層のOD値を、透過濃度計(D200-II、GretagMacbeth社製)を用いて前記方法で測定したところ、5.8であった。
前記で得られた転写シートを用いて、前記試験例1と同様の方法で、ハードコート体を製造して耐候性の評価を行った。得られた結果を表2に示す。この結果から、着色層を設けた場合であっても、ハードコート層を電離放射線硬化樹脂を含む樹脂組成物の硬化物で形成し、且つプライマー層を質量平均分子量が4万~10万、且つアクリル成分の含有量が1~30質量%を満たすウレタンアクリル共重合体を用いて形成した場合(実施例17)では、耐候性試験後のハードコート層の残存割合が高く、プライマー層とハードコート層が強固に密着しており、優れた耐候性を備えていることが確認された。
2 ハードコート層
3 プライマー層
4 接着層
5 着色層
6 樹脂成型品
Claims (19)
- 少なくとも、離型用の基材フィルム、ハードコート層、プライマー層、及び接着層をこの順に有し、
前記ハードコート層が、硬化性樹脂を含む樹脂組成物の硬化物によって形成されており、
前記プライマー層が、質量平均分子量が4万~10万、且つアクリル成分が1~30質量%含まれるポリウレタンを含むバインダー樹脂で形成されている、転写シート。 - 前記ポリウレタンが、質量平均分子量が5万~8万であり、且つアクリル成分が5~20質量%含まれている、請求項1に記載の転写シート。
- 前記ポリウレタンがウレタンアクリル共重合体である、請求項1又は2に記載の転写シート。
- 前記ポリウレタンが、ポリカーボネート系ウレタンアクリル共重合体及び/又はポリエステル系ウレタンアクリル共重合体である、請求項1~3のいずれかに記載の転写シート。
- 前記硬化性樹脂が、電離放射線硬化性樹脂である、請求項1~4のいずれかに記載の転写シート。
- 前記硬化性樹脂が、(i)3官能以上の電離放射線硬化性樹脂と、(ii)2官能の(メタ)アクリレートモノマーの組み合わせである、請求項1~5のいずれかに記載の転写シート。
- 前記接着層が、感熱接着性樹脂又は加圧接着性樹脂を含む、請求項1~6のいずれかに記載の転写シート。
- 離型用の基材フィルムとハードコート層の間、ハードコート層とプライマー層の間、プライマー層と接着層の間、及び接着層のプライマー層側とは反対側の面上のいずれか少なくとも1つに、部分的に形成された着色層を有する、請求項1~7のいずれかに記載の転写シート。
- 少なくとも、ハードコート層、プライマー層、接着層、及び樹脂成型品をこの順に有し、
前記ハードコート層が、硬化性樹脂を含む樹脂組成物の硬化物によって形成されており、
前記プライマー層が、質量平均分子量が4万~10万、且つアクリル成分が1~30質量%含まれるポリウレタンを含むバインダー樹脂で形成されている、ハードコート体。 - 前記ポリウレタンが、質量平均分子量が5万~8万であり、且つアクリル成分が5~20質量%含まれている、請求項9に記載のハードコート体。
- 前記ポリウレタンがウレタンアクリル共重合体である、請求項9又は10に記載のハードコート体。
- 前記ポリウレタンが、ポリカーボネート系ウレタンアクリル共重合体及び/又はポリエステル系ウレタンアクリル共重合体である、請求項9~11のいずれかに記載のハードコート体。
- 前記硬化性樹脂が、電離放射線硬化性樹脂である、請求項9~12のいずれかに記載のハードコート体。
- 前記硬化性樹脂が、(i)3官能以上の電離放射線硬化性樹脂と、(ii)2官能の(メタ)アクリレートモノマーの組み合わせである、請求項9~13のいずれかに記載のハードコート体。
- 前記接着層が、感熱接着性樹脂又は加圧接着性樹脂を含む、請求項9~14のいずれかに記載のハードコート体。
- ハードコート層の表面、ハードコート層とプライマー層の間、プライマー層と接着層の間、及び接着層と樹脂成型品の間のいずれか少なくとも1つに、部分的に形成された着色層を有する、請求項9~15のいずれかに記載のハードコート体。
- 請求項1~8のいずれかに記載の転写シートを、接着層が樹脂成型品に接するように貼り合わせた後に、離型用の基材フィルムを剥離する、ハードコート体の製造方法。
- 請求項1~8のいずれかに記載の転写シートを予め成形された樹脂成型品に貼り合わせた後に、離型用の基材フィルムを剥離する、請求項17に記載のハードコート体の製造方法。
- 請求項1~8のいずれかに記載の転写シートに対して樹脂を射出させて一体化させた後に、離型用の基材フィルムを剥離する、請求項17に記載のハードコート体の製造方法。
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EP3216602B1 (en) | 2022-01-12 |
JPWO2016072450A1 (ja) | 2017-08-31 |
JP6631532B2 (ja) | 2020-01-15 |
EP3216602A1 (en) | 2017-09-13 |
US11529798B2 (en) | 2022-12-20 |
CN107000419A (zh) | 2017-08-01 |
EP3216602A4 (en) | 2018-06-20 |
CN107000419B (zh) | 2020-03-10 |
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