Classifications

• • 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
  • C09J7/30—Adhesives in the form of films or foils characterised by the adhesive composition
  • C09J7/38—Pressure-sensitive adhesives [PSA]
  • C09J7/381—Pressure-sensitive adhesives [PSA] based on macromolecular compounds obtained by reactions involving only carbon-to-carbon unsaturated bonds
  • C09J7/385—Acrylic polymers
• • 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
  • C09J11/00—Features of adhesives not provided for in group C09J9/00, e.g. additives
  • C09J11/02—Non-macromolecular additives
  • C09J11/04—Non-macromolecular additives inorganic
• • 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
  • C09J11/00—Features of adhesives not provided for in group C09J9/00, e.g. additives
  • C09J11/08—Macromolecular additives
• • 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
  • C09J7/29—Laminated material

Definitions

• the present disclosure relates to a heat-stretchable decorative film for light projection and an article to which the same is bonded.
• Patent Document 1 JP 2005-014374 A describes a decorative film that is used as, for example, an interior material of an automobile, in which a glittering texture (unevenness) is formed on an upper surface of a transparent or opaque first synthetic resin film, and a transparent second synthetic resin film including one layer or multiple layers is laminated on the texture.
• a glittering texture unevenness
• Patent Document 2 JP 2015-167314 A describes a transport vehicle on which an image display device is mounted, the image display device including: an image projection unit that projects an image in an enlarged manner; a screen unit on which the image is projected; and an image processing substrate to which an image signal is input and that performs distortion correction of the image signal based on a dynamic relative position between the image projection unit and the screen unit and outputs the corrected image signal to the image projection unit, in which the image projection unit outputs a result of detecting a vibration or an acceleration of the image projection unit to the image processing substrate as an image projection unit sensor signal, the screen unit outputs a result of detecting a vibration or an acceleration of the screen unit to the image processing substrate as a screen unit sensor signal, the image processing substrate includes a distortion correction circuit, and the distortion correction circuit calculates the dynamic relative position based on the screen unit sensor signal and the image projection unit sensor signal to correct distortion of the image signal.
• Patent Document 3 JP 2017-074869 A describes a display device for a vehicle including: a passenger seat-side instrument panel that is provided on the front side of a passenger seat in a vehicle front-rear direction and does not include a glove compartment; a screen that is stored in the passenger seat-side instrument panel and is disposed on the rear side of the passenger seat-side instrument panel in the vehicle front-rear direction when pulled out; and a projector that is provided at a front end portion of a vehicle interior ceiling or a front pillar on the passenger seat side and projects an image on the screen.
• Patent document 1 JP 2005-014374 A
• Patent document 2 JP 2015-167314 A
• Patent document 3 JP 2017-074869 A
• a screen used in a light projection display system exhibits decorativeness and conformability to a three-dimensional shape. Therefore, for example, in a case where this screen is applied to an instrument panel portion of an automobile, the design of a vehicle interior space may deteriorate.
• a portion called a hot spot where the brightness is extremely high may be generated. This hot spot may interfere with image uniformity, vehicle driving, and the like.
• the present disclosure provides a heat-stretchable decorative film for light projection that exhibits decorativeness when light is not projected, functions as a screen when light is projected, and can reduce the generation of hot spots, and an article to which the decorative film is bonded.
• a heat-stretchable decorative film for light projection including a decorative layer and an adhesive layer, in which at least one of the decorative layer and the adhesive layer includes light-diffusing particles, and a total amount of the light-diffusing particles per unit area in the decorative layer and the adhesive layer is about 2.0 g/m2 or greater.
• an article including: a base component; and the above-described decorative film that is bonded to the base component.
• a method of manufacturing an article including: a step of preparing the above-described decorative film and a base component; and a step of applying the decorative film to a surface of the base component using a three-dimensional overlay method to form an article in which the decorative film is bonded to the surface of the base component.
• a heat-stretchable decorative film for light projection that exhibits decorativeness when light is not projected, functions as a screen when light is projected, and can reduce the generation of hot spots; and an article to which the decorative film is bonded.
• the heat-stretchable decorative film for light projection according to the present disclosure can be applied to, for example, a curved surface portion of an instrument panel or the like that requires decorativeness and cannot be used as a screen in the related art.
• FIG. 1 is a cross-sectional view illustrating a heat-stretchable decorative film for light projection according to one embodiment of the present disclosure.
• FIG. 2 is a cross-sectional view illustrating a heat-stretchable decorative film for light projection according to another embodiment of the present disclosure.
• FIG. 3 is a graph illustrating a 7/10 value angle of brightness with respect to the total amount of light-diffusing particles in a decorative layer and an adhesive layer of the decorative film according to the embodiment of the present disclosure.
• FIG. 4 is a graph illustrating a 9/10 value angle of brightness with respect to the total amount of light-diffusing particles in the decorative layer and the adhesive layer of the decorative film according to the embodiment of the present disclosure.
• FIG. 5 is a graph illustrating a brightness value with respect to a viewing angle in a comparative decorative film.
• FIG. 6 is a graph illustrating a brightness value with respect to a viewing angle in the decorative film according to the embodiment of the present disclosure.
• FIG. 7 is a graph illustrating a brightness value with respect to a viewing angle in a decorative film according to another embodiment of the present disclosure.
• FIG. 8 is a graph illustrating a brightness value with respect to a viewing angle in a decorative film according to still another embodiment of the present disclosure.
• FIG. 9 is a graph illustrating a brightness value with respect to a viewing angle in a decorative film according to still another embodiment of the present disclosure.
• FIG. 10 is a graph illustrating a brightness value with respect to a viewing angle in a decorative film according to still another embodiment of the present disclosure. DESCRIPTION OF THE PREFERRED EMBODIMENTS
• a heat-stretchable decorative film for light projection (hereinafter, also simply abbreviated as “decorative film”) according to a first embodiment of the present disclosure includes a decorative layer and an adhesive layer, in which at least one of the decorative layer and the adhesive layer includes light-diffusing particles, and a total amount of the light-diffusing particles per unit area in the decorative layer and the adhesive layer is about 2.0 g/m2 or greater. Since at least one of the decorative layer and the adhesive layer in the decorative film includes a predetermined amount of light-diffusing particles, the decorative film exhibits decorativeness when light is not projected, functions as a screen when light is projected, and can reduce the generation of hot spots caused by light emitted from a light projection portion.
• a 7/10 value angle of brightness may be about 20 degrees or greater.
• a 9/10 value angle of brightness may be about 30 degrees or greater.
• a difference in refractive index between the light-diffusing particles to be used and the decorative layer or the adhesive layer that does not include the particles may be about 0.05 or higher.
• the light- diffusing particles having the above-described refractive index are likely to diffuse light emitted from a light projection portion. Therefore, the generation of hot spots can be further reduced.
• the light-diffusing particles to be used has an average particle size from about 0.1 to about 5.0 ⁇ m.
• the light-diffusing particles having the above-described average particle size can be prevented from falling off without adversely affecting the flatness of the adhesive layer and the decorative layer.
• the light-diffusing particles having the above-described refractive index are likely to diffuse light emitted from a light projection portion without adversely affecting decorativeness. Therefore, the generation of hot spots can be further reduced.
• the light-diffusing particles may include at least one kind of styrene particles or titanium oxide particles.
• the above-described particles are likely to diffuse light emitted from a light projection portion without adversely affecting decorativeness. Therefore, the generation of hot spots can be further reduced.
• the heat-stretchable decorative film for light projection according to the first embodiment may further include: a protective layer that is provided on or over the decorative layer; and/or a glittering layer or a support layer including a glittering layer that is provided between the decorative layer and the adhesive layer.
• a protective layer that is provided on or over the decorative layer
• a glittering layer or a support layer including a glittering layer that is provided between the decorative layer and the adhesive layer.
• the heat-stretchable decorative film for light projection according to the first embodiment may be used for rear projection because it can reduce the generation of hot spots.
• the heat-stretchable decorative film for light projection according to the first embodiment may be used for a vehicle because it can reduce the generation of hot spots and is less likely to interfere with driving.
• An article according to a second embodiment includes: a base component that is an adherend; and the heat-stretchable decorative film for light projection according to the first embodiment that is bonded to the base component.
• the article to which the decorative film according to the present disclosure is applied exhibits decorativeness when light is not projected, and can function as a screen in which the generation of hot spots is reduced when light is projected.
• a method of manufacturing an article according to a third embodiment includes: a step of preparing the heat-stretchable decorative film for light projection according to the first embodiment and a base component that is an adherend; and a step of applying the decorative film to a surface of the base component using a three-dimensional overlay method to form an article in which the decorative film is bonded to the surface of the base component. According to this method, it is possible to obtain an article that exhibits decorativeness when light is not projected and can function as a screen in which the generation of hot spots is reduced when light is projected.
• the definition of“film” also includes an article called“sheet”.
• “storage modulus” refers to a shear storage modulus G’ obtained by performing a viscoelasticity measurement in a tension mode at a frequency of 10 Hz using a dynamic viscoelasticity measuring device.
• “transparent” represents that an average transmittance in a visible range is about 80% or higher and preferably about 90% or higher.
• “semi-transparent” represents that an average transmittance in a visible range is lower than about 80% and preferably about 75% or lower and an underlayer is not completely shielded.
• “(meth)acryl” represents acryl or methacryl
• “(meth)acrylate” represents acrylate or methacrylate
• “substantially” represents that a variation generated by measurement or manufacturing error is included and a variation of about 20% is allowed.
• “three-dimensional overlay method” refers to a molding method including: a step of preparing a film and a base component having a three-dimensional shape; a step of disposing the film and the base component in a vacuum chamber including a heating device, in which the film separates an internal space of the vacuum chamber into two spaces and the base component is disposed in one of the separated internal spaces; a step of heating the film using the heating device; a step of causing both of the internal space where the base component is disposed and the opposite internal space to be in a reduced pressure atmosphere; and a step of covering an article with the film by bringing the base component and the film into contact with each other while causing the internal space where the base component is disposed to be in a reduced pressure atmosphere and causing the opposite internal space to be in a pressurized atmosphere or a normal pressure atmosphere.
• a heat-stretchable decorative film for light projection includes a decorative layer and an adhesive layer, in which at least one of the decorative layer and the adhesive layer includes light-diffusing particles, and a total amount of the light-diffusing particles per unit area in the decorative layer and the adhesive layer is about 2.0 g/m2 or greater.
• FIGS. 1 and 2 A cross-sectional view of the heat-stretchable decorative film for light projection according to the embodiment of the present disclosure is illustrated in FIGS. 1 and 2.
• the total amount of the light-diffusing particles per unit area in the decorative layer and the adhesive layer in the decorative film according to the present disclosure is preferably about 2.0 g/m2 or greater, about 2.5 g/m2 or greater, or about 3.0 g/m2 or greater.
• the total amount is preferably about 20 g/m2 or less, about 15 g/m2 or less, about 10 g/m2 or less, or about 8 g/m2 or less.
• the amount (g/m2) of light-diffusing particles per unit area in each of the decorative layer and the adhesive layer can be calculated from a value obtained by multiplying the density (g/m3) of the light- diffusing particles in each of the layers by the thickness (m) of each of the layers.
• At least one of the decorative layer and the adhesive layer includes a predetermined amount of light- diffusing particles. Therefore, the generation of hot spots caused by light from a light projection portion can be reduced.
• the degree to which the generation of hot spots is reduced can be quantified by a position (viewing angle from the starting point) where the brightness value is 7/10 of the maximum brightness value of light in the vicinity of the center of the light projection portion that has passed through the decorative film, that is, can be quantified by the 7/10 value angle of brightness (hereinafter, also simply referred to as“7/10 value angle”).
• the 7/10 value angle of brightness may be about 20 degrees or greater, about 25 degrees or greater, or about 30 degrees or greater.
• the upper limit value of the 7/10 value angle of brightness is not particularly limited and, for example, may be about 85 degrees or less, about 80 degrees or less, or about 75 degrees or less.
• the degree to which the generation of hot spots is reduced can be quantified by adopting a position where the brightness value is 9/10 of the maximum brightness value of light in the vicinity of the center of the light projection portion that has passed through the decorative film, that is, can be quantified by the 9/10 value angle of brightness (hereinafter, also simply referred to as“9/10 value angle”).
• the 9/10 value angle of brightness may be about 30 degrees or greater, about 32 degrees or greater, or about 35 degrees or greater.
• the upper limit value of the 9/10 value angle of brightness is not particularly limited and, for example, may be about 60 degrees or less, about 57 degrees or less, or about 55 degrees or less.
• the thickness of the decorative film may be about 25 ⁇ m or greater, about 50 ⁇ m or greater, or about 100 ⁇ m or greater and may be about 2 mm or less, about 1 mm or less, or about 500 ⁇ m or less.
• the decorative film is sufficiently conformable to an article having a complex shape such that a structure having a good external appearance can be provided.
• the decorative layer in the decorative film according to the present disclosure may be: a color layer that exhibits a paint color, for example, a light color such as white or yellow or a deep color such as red, brown, green, blue, gray, or black; a pattern layer that gives a pattern such as a wood pattern, a pebble pattern, a geometrical pattern, or a leather pattern, a logo, or a design to an article; a relief (relief pattern) layer having a surface on which an uneven shape is provided; or a combination of the layers.
• the decorative layer may be applied to a part or the entire area of a layer constituting the decorative film, for example, the protective layer, the glittering layer, the support layer, or the adhesive layer directly or through a joining layer.
• a material of the color layer is not limited to the following example, for example, a material obtained by dispersing a pigment in a binder resin such as a (meth)acrylic resin or a polyurethane resin can be used.
• the pigment include: an inorganic pigment such as carbon black, chrome yellow, yellow iron oxide, red oxide, or red iron oxide; and an organic pigment, for example, a phthalocyanine pigment such as phthalocyanine blue or phthalocyanine green, an azo lake pigment, an indigo pigment, a perinone pigment, a perylene pigment, a quinophthalone pigment, a dioxazine pigment, or a quinacridone pigment such as quinacridone red.
• the color layer can be formed using the above-described material with a coating method such as a gravure coating method, a roll coating method, a die coating method, a bar coating method, or a knife coating method.
• the patern layer is not limited to the following example, for example, a layer in which a patern such as a figure, a logo, or a design is directly applied to the protective layer, the glitering layer, the support layer, the adhesive layer, or the like using a printing method such as a gravure direct printing method, a gravure offset printing method, an ink jet printing method, a laser printing method, or a screen printing method may be adopted, or a film, a sheet, or the like having a figure, a logo, or a design that is formed using, for example, a coating method such as a gravure coating method, a roll coating method, a die coating method, a bar coating method, or a knife coating method, a punching method, or an etching method can be used.
• a material of the patern layer for example, the same materials as the materials used for the color layer can be used.
• thermoplastic resin film having a surface on which an uneven shape is formed using a method of the related art such as embossing, scratch processing, laser processing, dry etching, hot pressing can be used.
• the relief layer can also be formed by applying a thermoseting or radiation-curable resin such as a curable (meth)acrylic resin to a release liner having an uneven shape, curing the resin by heating or radiation exposure, and removing the release liner.
• the thermoplastic resin, the thermoseting resin, and the radiation-curable resin used for the relief layer are not particularly limited.
• a fluororesin a polyester resin such as PET or PEN, a (meth)acrylic resin, a polyolefin resin such as polyethylene or polypropylene, a thermoplastic elastomer, polycarbonate, polyamide, an ABS resin, an acrylonitrile -styrene resin, polystyrene, vinyl chloride, or polyurethane
• the relief layer may include at least one pigment used for the color layer.
• the decorative layer according to the present disclosure may include an optional component such as an antioxidant, an ultraviolet absorber, a light stabilizer, a heat stabilizer, a dispersant, a plasticizer, a flow improver, a surfactant, a leveling agent, a silane coupling agent, or a catalyst.
• an optional component such as an antioxidant, an ultraviolet absorber, a light stabilizer, a heat stabilizer, a dispersant, a plasticizer, a flow improver, a surfactant, a leveling agent, a silane coupling agent, or a catalyst.
• the thickness of the decorative layer may vary and may be about 0.1 ⁇ m or greater, about 1 ⁇ m or greater, or about 2 ⁇ m or graeter and may be about 30 ⁇ m or less, about 25 ⁇ m or less, or about 20 ⁇ m or less.
• the decorative film may further include an adhesive layer for bonding the decorative film to the base component.
• an adhesive layer for example, a solvent type, an emulsion type, a pressure- sensitive type, a heat-sensitive type, a thermosetting type, or an ultraviolet curable type adhesive that is generally used and is formed of a (meth)acryl, a polyolefin, a polyurethane, a polyester, a rubber can be used.
• the adhesive layer can be applied using a well-known coating method.
• the adhesive layer according to the present disclosure may include an optional component such as an antioxidant, an ultraviolet absorber, a light stabilizer, a heat stabilizer, a tackifier, a dispersant, a plasticizer, a flow improver, a surfactant, a leveling agent, a silane coupling agent, a catalyst, a pigment, or a dye.
• an optional component such as an antioxidant, an ultraviolet absorber, a light stabilizer, a heat stabilizer, a tackifier, a dispersant, a plasticizer, a flow improver, a surfactant, a leveling agent, a silane coupling agent, a catalyst, a pigment, or a dye.
• the thickness of the adhesive layer may be about 5 m or greater, about 10 ⁇ m or greater, or about 20 ⁇ m or greater and may be about 200 ⁇ m or less, about 100 ⁇ m or less, or about 80 ⁇ m or less.
• the decorative layer and the adhesive layer includes light-diffusing particles.
• the adhesive layer is generally thicker than the decorative layer and is close to the light projection portion side. Therefore, from the viewpoint of light diffusion efficiency or the like, it is preferable that the adhesive layer includes the light-diffusing particles.
• the light-diffusing particles may be any particles having light diffusing properties, and organic or inorganic particles in which a difference in refractive index from the decorative layer or the adhesive layer that does not include the particles is about 0.05 or higher, about 0.06 or higher, or 0.07 or higher can be used.
• the difference in refractive index may be about 1.5 or lower, about 1.4 or lower, or about 1.3 or lower.
• the light-diffusing particles may be solid or hollow and may have a spherical shape or a non-spherical shape such as a plate shape or an elliptical shape.
• a material of the light-diffusing particles is not limited to the following example, for example, an inorganic material such as silica, mica, barium sulfate, titanium oxide, or glass or a resin material such as styrene can be used alone or in combination of two or more kinds thereof.
• a transparent material such as styrene or glass that is less likely to interfere with decoration of the color layer or the like and has high transparency is desirable as a single substance.
• particles having a small particle size for example, titanium oxide having a small particle size is desirable.
• the light-diffusing particles may have, for example, an average particle size of about 0.1 ⁇ m or greater, about 0.2 ⁇ m or greater, or about 0.3 ⁇ m or greater and about 5.0 ⁇ m or less, about 4 ⁇ m or less, or about 3 ⁇ m or less.
• particles having an average particle size of 1 ⁇ m or less are called particles having a small particle size.
• the decorative film according to the present disclosure may further include at least one selected from the group consisting of the protective layer, the glittering layer, the support layer, the joining layer, and the release liner.
• a material of the protective layer that is applicable to the decorative film according to the present disclosure is not limited to the following example, for example, a (meth)acrylic resin such as polymethyl methacrylate (PMMA) or a (meth)acrylic copolymer, polyurethane, a fluororesin such as an ethylene-tetrafluoroethylene copolymer (ETFE), polyvinylidene fluoride (PVDF), or a methyl methacrylate-vinylidene fluoride copolymer (PMMA/PVDF), a silicone resin, polyvinyl chloride (PVC), polycarbonate (PC), a polyolefin such as polyethylene (PE) or polypropylene (PP), a polyester such as polyethylene terephthalate (PET) or polyethylene naphthalate (PEN), or a copolymer such as an ethylene/acrylic acid copolymer (EAA) and an ionomer thereof, an ethylene- ethyl
• the use of a (meth)acrylic resin, polyurethane, a fluororesin, or polyvinyl chloride is preferable from the viewpoint of chemical resistance and/or weather resistance, and the use of a (meth)acrylic resin or polyurethane is more preferable from the viewpoint of abrasion resistance and/or environmental load when the material is burned or buried as waste.
• the protective layer may have a multi-layer structure.
• the protective layer may be a laminate including films formed of the above-described resins or may be a multi-layer coating including the above- described resins.
• the protective layer may include a three-dimensional uneven shape such as an embossed pattern that is provided on a part or the entire area of the surface thereof.
• the protective layer may include the uneven shape.
• an image suitable for the uneven shape for example, an image conforming to the uneven shape
• the design can be further improved.
• the uneven shape is preferable, and the advantageous effect of projecting an image to a film having decorative performance as in the present disclosure is further improved.
• the protective layer can be formed by coating a resin composition to a region on or over the decorative layer directly or through the joining layer or the like.
• the coating of the protective layer can be performed before or after applying the decorative film to the base component that is an adherend.
• the resin composition may be coated to the release liner to form a protective layer film, and this film may be laminated on the decorative layer through the joining layer.
• the protective layer film can also be directly laminated on the decorative layer without going through the joining layer.
• the protective layer film can be formed, for example, by coating a resin material such as a curable (meth)acrylic resin composition or a reactive polyurethane composition to the release liner or the like using an knife coating method, a bar coating method, a blade coating method, a doctor blade coating method, a roll coating method, a cast coating method, or the like and optionally photocuring or thermally curing the composition.
• a resin material such as a curable (meth)acrylic resin composition or a reactive polyurethane composition
• the protective layer a layer that is formed in a film shape in advance by extrusion, drawing, or the like may also be used.
• This film can be laminated on the decorative layer through the joining layer.
• the decorative layer has adhesiveness to the film
• the film can also be directly laminated on the decorative layer without going through the joining layer.
• the protective layer can also be formed by multilayer extrusion together with another layer.
• a (meth)acrylic film can be used as the other layer.
• Examples of the (meth)acrylic film include polymethyl methacrylate (PMMA), polybutyl acrylate, a (meth)acrylic copolymer, an ethylene/acrylic copolymer, and an ethylene vinyl acetate/acrylic copolymer.
• the resin can be used in the form of a film.
• the (meth)acrylic film has superior transparency and/or abrasion resistance, is resistant to heat and/or light, and is not likely undergo color fading and/or a change in gloss even when used outdoors. Further, the (meth)acrylic film has superior formability without using a plasticizer, has a characteristic in that deep drawing can be performed thereon, and also has superior contamination resistance because the plasticizer is not used.
• the (meth)acrylic film is mainly formed of PMMA.
• the (meth)acrylic resin having superior abrasion resistance and the like is used as the other layer and the fluororesin such as ETFE, PVDF, or PMMA/PVDF having superior chemical resistance is used as the protective layer, the formed protective layer can obtain the performances of the two layers.
• the protective layer according to the present disclosure may include an optional component such as a filler, an antioxidant, an ultraviolet absorber, a light stabilizer, a heat stabilizer, a bar coating material, a gloss imparting agent, a dispersant, a plasticizer, a flow improver, a surfactant, a leveling agent, a silane coupling agent, a catalyst, a pigment, or a dye.
• an optional component such as a filler, an antioxidant, an ultraviolet absorber, a light stabilizer, a heat stabilizer, a bar coating material, a gloss imparting agent, a dispersant, a plasticizer, a flow improver, a surfactant, a leveling agent, a silane coupling agent, a catalyst, a pigment, or a dye.
• an ultraviolet absorber such as benzotriazole or Tinuvin (trade name) 400 (available from BASF SE) and a hindered amine light stabilizer (HALS) such as Tinuvin (trade name) 292 (available from BASF SE)
• HALS hindered amine light stabilizer
• Tinuvin trade name 292
• the bar coating material may be included in the protective layer or may be separately coated and applied as a bar coating layer.
• the protective layer may be partially semi-transparent or opaque. From the viewpoint of display performance of an image or a video, it is preferable that the protective layer is transparent. From the viewpoint of the transparency and protective performance such as chemical resistance of the protective layer, it is preferable that a pigment, a filler, or the above-described light-diffusing particles having a particle size that can contribute to light scattering properties are included in the protective layer.
• the light-diffusing particles are included in the decorative layer and/or the adhesive layer that is closer to the light projection portion side of the light projection device than the protective layer and is protected by the protective layer, deterioration in the protective performance and decorativeness of the decorative film can be prevented, and the generation of hot spots can be further reduced as compared to the light-diffusing particles are included in the protective layer.
• the thickness of the protective layer may vary and may be, for example, about 1 ⁇ m or greater, about 5 ⁇ m or greaster, or about 10 ⁇ m or greater and may be about 200 ⁇ m or less, about 100 ⁇ m or less, or about 80 ⁇ m or less.
• the protective layer is thin from the viewpoint of shape conformability.
• the thickness of the protective layer is preferably about 100 ⁇ m or less or about 80 ⁇ m or less.
• the protective layer is thick.
• the thickness of the protective layer is preferably about 5 ⁇ m or greater or about 10 ⁇ m or greater.
• the storage modulus of the protective layer may be about 1.0 x 106 Pa or higher, about 1.5 x 106 Pa or higher, or about 2.0 x 106 Pa or higher, and may be about 1.5 x 108 Pa or lower, or about 1.3 x 108 Pa or lower when measured in a tension mode at a frequency of 10 Hz in a temperature range of 110°C to 150°C.
• the storage modulus of the protective layer refers to one value obtained by measuring the storage modulus of the multi-layer structure as a whole in which the storage modulus values of the respective layers are combined.
• the scratch resistance of the decorative film including the protective layer can be evaluated based on the pencil hardness defined by JISK 5600-5-4.
• the pencil hardness may be 6 B or higher, 5 B or higher, 4 B or higher, or 3 B or higher.
• the glittering layer may be a layer that includes a metal selected from the group consisting of aluminum, nickel, gold, silver, copper, platinum, chromium, iron, tin, indium, titanium, lead, zinc, and germanium or an alloy or a compound including the above-described metal, the layer being formed on a part or the entire surface of the layer constituting the decorative film, for example, the decorative layer of the protective layer including the decorative layer or the support layer described below using a method such as vacuum deposition, sputtering, ion plating, plating, or the like.
• the thickness of the glittering layer can be appropriately selected according to required decorativeness, brightness, and the like.
• the decorative film according to the present disclosure can also function as a screen when light is projected. Therefore, in a case where the glittering layer is applied, it is preferable that the glittering layer is a layer that can allow transmission of light emitted from the light projection portion.
• the decorative film according to the present disclosure may include the support layer to which the decorative layer and/or the glittering layer can be applied.
• various resins for example, a (meth)acrylic resin such as polymethyl methacrylate (PMMA), polyurethane (PU), polyvinyl chloride (PVC), polycarbonate (PC), an acrylonitrile-butadiene-styrene copolymer (ABS), a polyolefin such as polyethylene (PE) or polypropylene (PP), a polyester such as polyethylene terephthalate (PET) or polyethylene naphthalate (PEN), a copolymer such as an ethylene-acrylic acid copolymer, an ethylene -ethyl acrylate copolymer, or an ethylene-vinyl acetate copolymer, and a mixture thereof can be used.
• PMMA polymethyl methacrylate
• PU polyurethane
• PVC polyvinyl chloride
• PC polycarbonate
• ABS
• polyurethane, polyvinyl chloride, polyethylene terephthalate, an acrylonitrile-butadiene- styrene copolymer, or polycarbonate can be preferably used as the support layer.
• the support layer may also have a function of providing uniform elongation during molding and/or a function of effectively protecting an article (structure) from puncture, impact, or the like applied from the outside.
• the support layer may undergo a surface treatment such as priming, a corona treatment, a plasma treatment, or a flame treatment.
• the support layer according to the present disclosure may include an optional component such as an antioxidant, an ultraviolet absorber, a filler, a light stabilizer, a heat stabilizer, a dispersant, a plasticizer, a flow improver, a surfactant, a leveling agent, a silane coupling agent, a catalyst, a pigment, or a dye.
• the support layer may be partially semi-transparent or opaque. From the viewpoint of display performance of an image or a video, it is preferable that the support layer is transparent. In consideration of the influence on decorativeness or glittering properties of the decorative layer or the glittering layer, it is preferable that the surface of the support layer is substantially flat.
• a pigment, a filler, or the above-described light-diffusing particles having a particle size that can contribute to light scattering properties and surface unevenness are included in the support layer.
• the thickness of the support layer may vary and, from the viewpoints of the formability, strength, impact resistance, and the like of the decorative film, may be generally about 10 ⁇ m or greater, about 20 ⁇ m or greater, or about 50 ⁇ m or greater and may be about 500 ⁇ m or less, about 200 ⁇ m or less, or about 100 ⁇ m or less.
• the storage modulus of the support layer may be about 1.0 x 106 Pa or higher, about 1.5 x 106 Pa or higher, or about 2.0 x 106 Pa or higher, and may be about 1.5 * 108 Pa or lower, or about 1.3 x 108 Pa or lower when measured in a tension mode at a frequency of 10 Hz in a temperature range of 1 l0°C to l50°C.
• the support layer may have a single-layer or multi-layer structure.
• the storage modulus of the support layer refers to one value obtained by measuring the storage modulus of the multi-layer structure as a whole in which the storage modulus values of the respective layers are combined.
• the joining layer (also referred to as“primer layer” or the like) may be used.
• the joining layer for example, a solvent type, an emulsion type, a pressure-sensitive type, a heat-sensitive type, a thermosetting type, or an ultraviolet curable type adhesive that is generally used and is formed of a (meth)acryl, a polyolefin, a polyurethane, a polyester, a rubber can be used.
• the joining layer can be applied using a well-known coating method.
• the joining layer according to the present disclosure may include an optional component such as an antioxidant, an ultraviolet absorber, a light stabilizer, a heat stabilizer, a tackifier, a dispersant, a plasticizer, a flow improver, a surfactant, a leveling agent, a silane coupling agent, a catalyst, a pigment, or a dye.
• an optional component such as an antioxidant, an ultraviolet absorber, a light stabilizer, a heat stabilizer, a tackifier, a dispersant, a plasticizer, a flow improver, a surfactant, a leveling agent, a silane coupling agent, a catalyst, a pigment, or a dye.
• the thickness of the joining layer may be about 0.05 ⁇ m or greater, about 0.5 ⁇ m or greater, or about 5 ⁇ m or greater and may be about 100 ⁇ m or less, about 50 ⁇ m or less, or about 20 ⁇ m or less.
• any preferable release liner can be used.
• the release liner include a release liner prepared from paper (for example, kraft paper) or a polymer material (for example, a polyolefin resin such as polyethylene or polypropylene, ethylene vinyl acetate, polyurethane, or a polyester such as polyethylene terephthalate).
• a layer of a release agent such as a silicone-containing material or a fluorocarbon-containing material may be optionally applied.
• the thickness of the release liner may be, for example, about 5 ⁇ m or greater, about 15 ⁇ m or greater, or about 25 ⁇ m or greater and may be about 300 ⁇ m or less, about 200 ⁇ m or less, or about 150 ⁇ m or less.
• the heat-stretchable decorative film for light projection according to the present disclosure exhibits decorativeness when light is not projected, and has performance of functioning as a screen when light is projected. Therefore, the heat-stretchable decorative film for light projection can be used for an interior or exterior member of a vehicle such as an automobile or a train, a ship, an airplane, or the like, a home electronic appliance, a building material, a show window, or a showcase.
• the heat- stretchable decorative film for light projection according to the present disclosure exhibits performance capable of reducing the generation of hot spots, and thus is particularly suitable for the use in an interior member such as an instrument panel of an automobile.
• the decorative film is applied to an instrument panel portion of an automobile having a curved surface shape
• information of an image or a video can be projected from a rear projection display system or the like to the instrument panel portion as necessary while maintaining the external appearance of the related as it is or preventing deterioration in the design of a vehicle interior space.
• the decorative film can be manufactured, for example, by forming the respective layers such as the decorative layer or the adhesive layer on the release liner such as a PET film with a surface having undergone a release treatment or on the layer such as the protective layer or the support layer constituting the decorative film using a coating method or the like and optionally laminating the respective layers through the joining layer.
• the respective layers can also be sequentially laminated by repeatedly performing a coating step and optionally a drying and/or curing step on one release liner.
• the decorative film can also be formed by multilayer extrusion of the materials of the respective layers.
• the decorative layer (120, 220) is applied to the release liner (not illustrated) using gravure ink and a gravure coating method, and a drying and/or curing step is optionally further performed to form a laminate A.
• a (meth)acrylic resin such as PMMA or a fluororesin such as PMMA/PVDF is applied to another release liner (not illustrated) using a coating method, a single layer or multilayer extrusion method, or the like, and a drying and/or curing step is optionally further performed to form a laminate B including the protective layer (110, 210).
• the decorative layer of the laminate A and the protective layer of the laminate B are bonded to each other directly or through the joining layer by optionally applying heat and/or pressure.
• the release liner on the decorative layer side of the laminate C may be removed, and subsequently the glittering layer (230) may be applied to the decorative layer directly through the joining layer using a vapor deposition method or the like.
• the glittering layer (230) may be applied to the support layer (240) using a vapor deposition method or the like directly or through the joining layer to form a laminate D, and the decorative layer of the laminate C and the glittering layer of the laminate D may be bonded to each other directly or through the joining layer by optionally applying heat and/or pressure.
• the adhesive layer (150, 250) is applied to another release liner (not illustrated) using a coating method or the like, and a drying and/or curing step is optionally further performed to form a laminate F.
• the adhesive layer of the laminate F is bonded to the decorative layer of the laminate C or, if present, to the glittering layer or the support layer by optionally applying heat and/or pressure.
• the heat-stretchable decorative film for light projection (100, 200) is formed.
• an article in which a base component is covered with the decorative film can be formed by applying the decorative film to the base component using insert molding (IM) or a three-dimensional overlay method (TOM).
• IM insert molding
• TOM three-dimensional overlay method
• a thermoplastic material for forming the base component to the decorative film
• an article in which the decorative film and the extruded thermoplastic material are integrated can be formed.
• IM, TOM, and the extrusion method can be performed using a well-known method of the related art.
• the decorative film according to the present disclosure can be used in various forming techniques such as TOM, IM, or the extrusion method but can be preferably used particularly in TOM.
• the base component is not particularly limited to the following example, for example, polypropylene, polycarbonate, an acrylonitrile-butadiene-styrene copolymer or, a mixture thereof can be used.
• the base component may have various planes and/or three-dimensional shapes.
• the maximum area stretch rate of the decorative film after molding is about 50% or higher, about 100% or higher, or about 150% or higher and is about 500% or lower, about 400% or lower, or about 300% or lower.
• A the area of a portion of the decorative film before molding
• B the area of a portion of the decorative film corresponding to A after molding.
• the maximum area stretch rate refers to a value of a portion where the area stretch rate is the highest in the decorative film on the entire surface of the molded article.
• a flat film is bonded to an article having a three- dimensional shape using TOM
• a portion where the film is initially bonded to the base component is not substantially stretched, and the area stretch rate is about 0%.
• the area stretch rate may be 200% or higher. This way, the area stretch rate may largely vary depending on positions.
• the success or failure of molding is determined based on whether a defect such as non conformation to the base component or the breakage of the film occurs in the portion where the film is most largely stretched.
• the maximum area stretch rate is a substantial index indicating the success or failure of the molded article.
• the maximum area stretch rate can be verified, for example, by printing 1 mm2 squares on the entire surface of the decorative film before molding and measuring a change in area after molding or by measuring the thickness of the decorative film before or after molding.
• part(s) and percent represent part(s) by mass and mass percent.
• Table 1 Materials shown in Table 1 were mixed with each other at a mixing ratio shown in Table 2 to prepare each of coating solutions for preparing a decorative layer and an adhesive layer.
• a pressure-sensitive acrylic adhesive in a coating solution for an adhesive layer a pressure-sensitive adhesive that was adjusted to have an acrylic resin theoretical refractive index of about 1.49 was used.
• Table 2 all the numerical values are represented by mass%.
• a coating solution G-3 for a decorative layer was coated to a release liner formed of a polyester resin and subsequently was heated and dried at 110°C for 5 minutes. As a result, a laminate A including a decorative layer having a thickness of about 6 ⁇ m was formed. Next, the decorative layer of the laminate A and a multilayer-extruded film (hereinafter, also simply referred to as “protective layer”) as a protective layer formed of PMMA and PVDF and having a thickness of about 105 ⁇ m were laminated at 120°C to form a laminate B.
• a multilayer-extruded film hereinafter, also simply referred to as “protective layer” as a protective layer formed of PMMA and PVDF and having a thickness of about 105 ⁇ m were laminated at 120°C to form a laminate B.
• the decorative layer of the laminate B and a polyurethane film (hereinafter also simply referred to as“support layer”) as a support layer having a thickness of 20 ⁇ m were laminated at 120°C to form a laminate C.
• a coating solution T-4 for an adhesive layer was coated to another release liner formed of a polyester resin using a knife coater and was heated and dried at 120°C for 10 minutes to form a laminate D including an adhesive layer having a thickness of about 40 ⁇ m.
• the support layer of the laminate C and the adhesive layer of the laminate D were laminated at 50°C to form a decorative film.
• a decorative film according to Example 2 was prepared under the same conditions as those of Example 1, except that the coating solution for the decorative layer was changed to G-1, the thickness of the decorative layer was changed to about 8 ⁇ m, and the coating solution for the adhesive layer was changed to T-3.
• a decorative film according to Example 3 was prepared under the same conditions as those of Example 1, except that the coating solution for the decorative layer was changed to G-2, and the thickness of the decorative layer was changed to about 8 ⁇ m.
• Example 4
• a decorative film according to Example 4 was prepared under the same conditions as those of Example 1, except that the thickness of the decorative layer was changed to about 8 ⁇ m, and the coating solution for the adhesive layer was changed to T-2.
• a decorative film according to Example 5 was prepared under the same conditions as those of Example 1, except that the coating solution for the decorative layer was changed to G-1, and the thickness of the decorative layer was changed to about 10 ⁇ m.
• a decorative film according to Example 6 was prepared under the same conditions as those of Example 1, except that the coating solution for the decorative layer was changed to G-2, the thickness of the decorative layer was changed to about 10 ⁇ m, and the coating solution for the adhesive layer was changed to T-2.
• a decorative film according to Example 7 was prepared under the same conditions as those of Example 1, except that the thickness of the decorative layer was changed to about 10 ⁇ m, and the coating solution for the adhesive layer was changed to T-3.
• a decorative film according to Example 8 was prepared under the same conditions as those of Example 1, except that the thickness of the decorative layer was changed to about 10 ⁇ m.
• a decorative film according to Example 9 was prepared under the same conditions as those of Example 1, except that the coating solution for the decorative layer was changed to G-0, the thickness of the decorative layer was changed to about 8 ⁇ m, and the coating solution for the adhesive layer was changed to T-5.
• a decorative film according to Example 10 was prepared under the same conditions as those of Example 1, except that the coating solution for the decorative layer was changed to G-0, the thickness of the decorative layer was changed to about 8 ⁇ m, and the coating solution for the adhesive layer was changed to T-6.
• a decorative film according to Example 11 was prepared under the same conditions as those of Example 1, except that the coating solution for the decorative layer was changed to G-0, the thickness of the decorative layer was changed to about 8 ⁇ m, a support layer including a tin-deposited layer having a thickness of 300 to 700 nm corresponding to a glittering layer was adopted, and the coating solution for the adhesive layer was changed to T-6.
• the coating solution for the decorative layer was changed to G-0
• the thickness of the decorative layer was changed to about 8 ⁇ m
• a support layer including a tin-deposited layer having a thickness of 300 to 700 nm corresponding to a glittering layer was adopted, and the coating solution for the adhesive layer was changed to T-6.
• a decorative film according to Example 12 was prepared under the same conditions as those of Example 1, except that the coating solution for the decorative layer was changed to G-0, the thickness of the decorative layer was changed to about 8 ⁇ m, and the coating solution for the adhesive layer was changed to T-7.
• a decorative film according to Example 13 was prepared under the same conditions as those of Example 1, except that the coating solution for the decorative layer was changed to G-0, the thickness of the decorative layer was changed to about 8 m, the coating solution for the adhesive layer was changed to T-7, and the thickness of the adhesive layer was changed to about 60 ⁇ m.
• a decorative film according to Comparative Example 1 was prepared under the same conditions as those of Example 1, except that the coating solution for the decorative layer was changed to G-0, the thickness of the decorative layer was changed to about 8 ⁇ m, and the coating solution for the adhesive layer was changed to T-l .
• a sample of the decorative film was disposed between“EZ Contrast” (available from ELDIM) as a camera for measuring brightness and a light projection portion of“Camcorder Projector CP45R” (available from 3M) as a small projector such that a main surface of the decorative film was perpendicular to the light projection portion and the distance between the light projection portion and the decorative film was about 32 cm.
• the results relating to the 7/10 value angle, the 9/10 value angle, and the brightness value at each viewing angle are shown in Table 3 and FIGS. 3 to 10.
• FIG. 5 corresponds to the configuration of Comparative Example 1
• FIGS. 6 to 10 correspond to Examples 8 to 10, 12, and 13.
• the 7/10 value angle tended to be about 20 degrees or greater.
• the 7/10 value angle was less than 20 degrees, as can be seen from FIG. 5
• the generation of hot spots was poor.
• the decorative films according to Examples 1 to 13 in which the 7/10 value angle was about 20 degrees or greater as can be seen from FIGS. 6 to 10, the generation of hot spots was able to be significantly reduced.
• the 9/10 value angle tended to be about 30 degrees or greater.
• the generation of hot spots was able to be further reduced as compared to the decorative film (FIG. 7) according to Example 9 in which the 7/10 value angle was about 20 degrees or greater and the 9/10 value angle was less than about 30 degrees.

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• Chemical & Material Sciences (AREA)
• Organic Chemistry (AREA)
• Inorganic Chemistry (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Laminated Bodies (AREA)
• Overhead Projectors And Projection Screens (AREA)
• Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)

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• 2018
  • 2018-02-07 JP JP2018020295A patent/JP7071141B2/ja active Active
• 2019
  • 2019-02-06 WO PCT/IB2019/050923 patent/WO2019155361A1/en unknown
  • 2019-02-06 CN CN201980011595.1A patent/CN111684034B/zh not_active Expired - Fee Related
  • 2019-02-06 EP EP19709782.7A patent/EP3749728A1/en not_active Withdrawn

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