JPH04314523A - Shaping film - Google Patents

Abstract

PURPOSE:To obtain a molded body possessing a delicate, quiet, slimy and mat surface, by a method wherein a fine uneven layer where an uneven mean space, uneven mean surface roughness and a 60 deg.C gloss value of the surface are made respectively 20-50mum, 0.7-2.0mum and 2.0 or lower is formed on the whole of the surface. CONSTITUTION:An uneven mean space of an uneven pattern 2 formed on the surface of a shaping film is made 20-50mum. Furthermore, uneven mean surface roughness Ra and 60 deg. gloss value of its surface are made respectively 0.7-2.0mum and 2.0 or lower, through which a shaping film for manufacturing of a molded body having a delicate, quiet and slimy surface and suede tone is obtained.

Description

[Detailed description of the invention]

0001

[Industrial Application Field] The present invention is applicable to transfer, melamine molding,
The present invention relates to a molding film that is used in press molding and the like and can impart fine irregularities to the surface of the molded product.

0002

2. Description of the Related Art Conventionally, there have been the following techniques for forming fine irregularities on the surface of a molded article, that is, a matte surface called a matte. First, a technique for forming fine irregularities on the surface of an object to be transferred using a transfer sheet will be explained. The transfer sheet is placed on a releasable base sheet,
This transfer sheet is formed by forming a transfer layer consisting of a release layer, a pattern layer, and an adhesive layer.This transfer sheet is brought into contact with another object to be transferred, and the adhesive layer, pattern layer, and release layer are applied to the surface of the object to be transferred. This is a technology that transfers images in sequence and transfers them. Therefore, the outermost surface of the object to be transferred becomes a peeling layer. Conventionally, in order to form such an uneven pattern on the surface of an object to be transferred, a releasable base sheet with an uneven pattern formed on the surface in advance is used, a transfer layer is formed on this, and the transfer layer is applied. The transfer material was brought into contact with the transfer material and the transfer was performed. As a result of this transfer, a transfer layer having an uneven pattern was transferred to the surface of the object to be transferred, resulting in a matte surface.

Next, a conventional technique for forming fine irregularities on the surface of a molded article will be explained. Examples of molded products include decorative laminates, which are made by impregnating decorative base paper with a thermosetting resin, drying it, and then laminating it together with core paper, overlay paper, and a base material, which are then placed between upper and lower heating plates. It is sandwiched between metal mirror plates and heat-pressed. Such a decorative board is made by, for example, laminating melamine resin-impregnated paper on about four sheets of phenolic resin-impregnated core paper, and then layering an overlay paper impregnated with melamine resin on top of that and heat-pressing the paper. There is a melamine decorative board. Another example is a DAP decorative board in which diallyl phthalate (DAP) resin-impregnated papers are sequentially stacked on a plate-like base material and pressed under heat. When providing unevenness to the surface of these decorative laminates, a molding film with an uneven surface is inserted between the mirror-finished plates, the plate-like base material is sandwiched, and the film is formed by heating and pressing. After the mold was released, a decorative board having an uneven surface was obtained.

Furthermore, as another example of a molded article, an ionizing radiation-curable resin is applied to the surface of the object to be coated, a molded film with an uneven surface is covered thereon, and ionizing radiation is irradiated. The coating film was cured, and the molded film with the uneven surface was peeled off to obtain a coated object having the uneven surface. Furthermore, as another example of a molded product, a molded product having an uneven surface is obtained by covering a molded film impregnated with an unsaturated polyester resin, curing the resin, and peeling off the molded film. I was getting .

[0005]

[Problems to be Solved by the Invention] However, although the molded products manufactured using the above-mentioned conventional molded film with an uneven pattern have a matte surface,
It felt smooth or rough to the touch, and didn't feel slimy. SUMMARY OF THE INVENTION Therefore, an object of the present invention is to provide a molded film that can produce a suede-like molded product with a moist and slimy surface.

[0006]

[Means for Solving the Problems] In order to solve the above-mentioned problems, the present invention provides a structure in which a grain-like fine uneven surface is formed on the surface of the imprinting film, and the uneven surface is , the average interval of the unevenness is 20 to 50 μm, the average surface roughness Ra of the unevenness is 0.7 to 2.0 μm, and the surface is 60 μm.
°Gloss value is 2.0 or less. By forming the grain shape within such a specific numerical range, it is possible to obtain a matte surface that feels moist and slimy to the touch. The feel is not smooth or shiny, but unlike the rough feel, it is soft and suede-like, giving off a certain sense of luxury. Here, the average inclination angle refers to the heights of the uneven peaks h1 and h2, as shown in Figure 2.
, h3 to hn, it refers to θa expressed by the following formula [Equation 1].

[0007]

[Math 1]

The shaped film of the present invention is formed from a base film 1 and an uneven layer 2 laminated on the base film 1. The present invention uses PET film as the material of the base film 1, and in order to prevent the laminated uneven layer 2 from peeling off from the base film 1,
The base film 1 is treated to facilitate adhesion. Such adhesion-facilitating treatments include corona discharge treatment, coating with various known primers, and forming a heat-sensitive adhesive layer on the film surface.

[0009] The uneven layer 2 formed on the base film 1 is formed using a resin composition consisting of an inorganic filler and a binder resin. The binder resin is mainly an acrylic polyol crosslinked with polyisocyanate, and the fillers are calcium carbonate CaCO3 and silica gel SiO2. The weight ratio of calcium carbonate and silica gel added is 20:10 to 29:1, and the particle size of calcium carbonate, which is the main filler, is 2 to 5 μm, preferably 3 μm.
Let it be m. Moreover, the average particle size of silica gel is about three times the particle size of calcium carbonate. The silica gel works to adjust the surface roughness of the imprinted film, and if only calcium carbonate is used without adding silica gel, the resulting surface will be close to flat, achieving the above purpose. Surface cannot be obtained. Silica gel also works to prevent calcium carbonate from settling.

[0010] As the material of the base film 1 of the shaped film of the present invention, for example, polyethylene terephthalate (
PET), polyester resins such as polybutylene terephthalate, polyethylene terephthalate-isophthalate copolymer, polyolefin resins such as polyethylene, polypropylene, polymethylpentene, polyvinyl fluoride, polyvinylidene fluoride, polytetrafluoroethylene, ethylene- Polyfluorinated ethylene resins such as tetrafluoroethylene copolymers, polyamides such as nylon 6 and nylon 66, polyvinyl chloride, vinyl chloride-acetic acid copolymers, ethylene-vinyl acetate copolymers, ethylene vinyl alcohol copolymers vinyl copolymers such as polyvinyl alcohol and vinylon, cellulose resins such as cellulose triacetate and cellophane, acrylic resins such as polyethyl methacrylate and butyl polyacrylate, polystyrene, polycarbonate, polyarylate, and polyimide. , etc., or high-quality paper, tissue paper, glassine paper, parchment paper,
etc. paper is used.

The uneven layer 2 is applied to the base film 1 by slit reverse coating. The reason for adopting this coating method is that when using a normal coating method such as gravure coating, the filler particles in the resin composition that forms the uneven layer 2 flow in a circular pattern and form streaks on the imprinted film. This is because it will be put away. Therefore, in the present invention, in order to prevent the formation of such streaks, the coating is performed using the slit reverse coating method shown in FIG. 3, which allows the coating film to be formed to a certain degree of thickness. FIG. 3 shows an outline of the slit reverse coat. The resin composition discharged from the nozzle coating device 4 is applied onto the base film 1 running on a backup roll 6, and then applied with the squeeze roll 5 controlling the coating thickness.

Furthermore, in the present invention, a release agent is contained in the uneven layer 2 of the mold-forming film of the present invention. As the mold release agent, silicone, fluororesin, various waxes, etc. are used. The present invention uses a molding film as the base film 1 of the transfer sheet, and contains a release agent in the release layer consisting of the uneven layer 2 on the base film 1.
The transfer layer formed on the release layer on the base film 1 is easily transferred to the object to be transferred. The mold release agent must be compatible with the binder and must not bleed to the surface too much. If there is a large amount of bleeding on the surface, unevenness will occur in the uneven layer 2 of the molded film. In order to eliminate such unevenness, it is important to have a combination with good compatibility with the binder resin for forming the uneven layer 2. For example, when an acrylic polyol is used as a binder, an amino-modified silicone oil having good compatibility with the acrylic polyol is used. In addition, if the amount of the release agent added is too small, peeling becomes difficult, and if it is too large, the adhesion between the uneven layer molding resin and the base film 1 decreases, so 0 to 8% by weight, preferably 0.1 to 8% by weight. 5% by weight is good.

[0013] Then, by forming a transfer layer on the imprinting film of the present invention, bringing the film into contact with an object to be transferred, and transferring the transfer layer to the object, the surface has fine irregularities. It is possible to obtain a molded article with a transferred transfer layer that has a moist and slimy surface and is soft and smooth like suede. As a method for forming a transfer layer on a pattern-forming film and transferring it to an object to be transferred, a known method can be applied, for example, the method shown in the section of the prior art section above.

[0014] Furthermore, by inserting the molded film of the present invention between a press plate and a molded product to be molded by pressing between hot press plates, a press molded article having fine irregularities on the surface can be obtained. be able to. As such a molded body,
For example, there are melamine decorative boards, DAP decorative boards, etc. To produce a melamine decorative board with an uneven surface, a melamine resin-impregnated sheet is layered on top of about four sheets of phenolic resin-impregnated core paper, and then an overlay paper impregnated with melamine resin is laminated on top of the melamine resin-impregnated sheet, and then two mirror-finished sheets are laminated. For example, by inserting the molded film of the present invention between metal plates,
m2, by heating and pressing at 135℃ for 20 minutes, it has a moist and slimy feel to the touch.
Moreover, a melamine decorative board that is soft and smooth like suede and has fine irregularities on the surface is obtained.

[0015] In addition, in order to manufacture a DAP decorative board with an uneven surface, papers impregnated with diallyl phthalate resin are stacked one after another on a plate-like base material, and in the same manner as in the manufacturing method of a melamine decorative board, the paper sheets impregnated with diallyl phthalate resin are piled up between the mirror-finished metal plates. Then, using the forming film of the present invention, the temperature was 140 to 150°C, 15 kg/cm2, 1
By heating and compressing for about 0 minutes, it feels like
D has a moist, slimy feel, is soft and smooth like suede, and has minute irregularities on its surface.
AP decorative board can be obtained.

Furthermore, according to the shaped film of the present invention,
An ionizing radiation-curable resin is applied to the surface of the object to be coated, a molding film is placed on top of it, and ionizing radiation such as ultraviolet rays or electron beams is irradiated to cure the coating, and then the molding film is peeled off. By doing so, it is possible to obtain a coated object that feels moist and slimy to the touch, is soft and smooth like suede, and has fine irregularities on its surface.

The ionizing radiation curable resins include electron beam curable resins and ultraviolet ray curable resins, and the components of both are almost the same except that the ultraviolet ray curable resin contains a photopolymerization initiator and a sensitizer. . Ionizing radiation-curable resins generally have a polymer, oligomer, monomer, etc. as a film-forming component that has a radically polymerizable double bond in the solution, and other non-reactive polymers as necessary. , organic solvents, wax and other additives.

The film-forming component used in the ionizing radiation-curable resin is preferably one having an acrylate functional group, such as a relatively low molecular weight polyester resin, polyether resin, acrylic resin, epoxy resin, Urethane resin, alkyd resin, spiroacetal resin, polybutadiene resin, polythiol polyene resin,
Oligomers or prepolymers such as (meth)acrylates of polyfunctional compounds such as polyhydric alcohols and reactive diluents such as ethyl (meth)acrylate, ethylhexyl (meth)acrylate, styrene, methylstyrene, N
- Monofunctional monomers such as vinylpyrrolidone as well as polyfunctional monomers, e.g. trimethylolpropane tri(meth)
Acrylate, hexanediol (meth)acrylate, tripropylene glycol di(meth)acrylate,
Relatively large amounts of diethylene glycol di(meth)acrylate, pentaerythritol tri(meth)acrylate, dipentaerythritol hexa(meth)acrylate, 1,6-hexanediol di(meth)acrylate, neopentyl glycol di(meth)acrylate, etc. It contains.

Furthermore, in order to make the above-mentioned ionizing radiation-curable resin into an ultraviolet-curable resin, acetophenones, benzophenones, Michler benzoyl benzoate, α-amyloxime ester, and tetramethyl are added as photopolymerization initiators. Thiuram monosulfide, thioxanthone, and photosensitizers such as n-butylamine, triethylamine, and tri-n-butylphosphine can be used in combination. Particularly in the present invention, polyester acrylate with diallyl phthalate added is preferred.

These ionizing radiation-curable resins can be cured by conventional curing methods, ie, by irradiation with electron beams or ultraviolet rays. For example, in the case of electron beam curing, 50~
An electron beam or the like having an energy of 1000 KeV, preferably 100 to 300 KeV is used, and in the case of ultraviolet curing, ultraviolet rays emitted from light beams of an ultra-high pressure mercury lamp, a high pressure mercury lamp, a low pressure mercury lamp, a carbon arc, a xenon arc, a metal halide lamp, etc. are used. Available.

Furthermore, according to the shaped film of the present invention, a sheet pasted on a base material is impregnated with an unsaturated polyester resin liquid, and the shaped film of the present invention is coated thereon and cured. Thereafter, by peeling off the imprinting film, it is possible to obtain a molded product that feels moist and slimy to the touch, is soft and smooth like suede, and has fine irregularities on the surface. .

[0022]

Example 1 A filler was prepared by mixing calcium carbonate CaCO3 with a particle size of 3 μm and silica gel SiO2 with a particle size of 10 μm in a weight ratio of 28:2. Next, 100 parts by weight of acrylic polyol and 8.5 parts by weight of polyisocyanate
A binder was composed of parts by weight.

A resin composition for forming an uneven layer was prepared using 52 parts by weight of the filler, 48 parts by weight of the binder, and 4 parts by weight of amino-modified silicone oil as a mold release agent. PET film treated with this resin composition for easy adhesion (manufactured by Diafoil Co., Ltd.: TE, product name, thickness 38
15 μm (dry coating thickness) on top of 15 μm (dry coating thickness), and
After drying for 0 seconds, it was aged at 60° C. for 3 days.

The average surface roughness Ra of the surface of the molded film thus obtained was 1.2μ. In addition, the height difference between the convex and concave portions is 8.0 μm on average, and the average interval between concave and convex portions is 30 μm.
The average inclination angle of the unevenness was 14°. In this example, P treated with easy-to-adhesion treatment was used as the base film for the shaped film.
The reason for using the ET film is that it has good adhesion to the uneven layer coated on the film.

[0025]

[Example 2] On the imprinting film produced in Example 1,
An ultraviolet curable resin (manufactured by Dainichiseika Kagyo Co., Ltd.: Seika Beam, trade name) is applied to a thickness of 10 μm (dry coating thickness), and an acrylic adhesive is applied as an adhesive layer on top of this. A transfer sheet was obtained by irradiating with one UV light of 80 W/cm at 20 m/min.

Next, using this transfer sheet, ABS
The image was transferred onto a sheet using a hot roll transfer machine to obtain a transfer body having fine irregularities formed on its surface. The surface of the transfer body thus obtained has exactly the same surface shape as the transfer film used, with an Ra of 1.2 μm, an average difference in height between convex and concave portions of 8.0 μm, and an average spacing between concave and convex portions of 30 μm.
m, and the average inclination angle of the unevenness was 14°.

[0027]

[Example 3] A melamine resin-impregnated sheet is placed on top of about four sheets of phenolic resin-impregnated core paper, and then a 35g/m2
A layer of overlay paper impregnated with melamine resin was laminated, sandwiched between two mirror-finished metal plates, and the imprinting film manufactured in Example 1 with an uneven surface was inserted, and the weight was 100 kg/cm2. By heating and pressing at ℃ for 20 minutes, a melamine decorative board with fine irregularities formed on the surface was obtained.

The surface of the melamine decorative board thus obtained has exactly the same surface shape as the molded film used, and has an R
a is 1.2 μm, the average height difference between the convex part and the concave part is 8.0 μm,
The average spacing of the unevenness is 30 μm, and the average slope angle of the unevenness is 14°.
I got something like this.

[0029]

[Example 4] Papers impregnated with diallyl phthalate resin were stacked one after another on a board base material, and the imprinting film produced in Example 1 was used between the mirror-finished metal plates in the same manner as in the production of melamine decorative boards. 140-150℃, 15kg/cm
2. Heat-pressing was performed for about 10 minutes.

The surface of the DAP decorative board thus obtained has the same surface shape as the transfer film used, and has an Ra
The average height difference between the convex and concave portions was 8.0 μm, the average interval between the concave and convex portions was 30 μm, and the average inclination angle of the concave and convex portions was 14°.

[0031]

[Example 5] A pattern was printed on a polyvinyl chloride sheet with a thickness of 0.25 m/m, and an ultraviolet curable resin (manufactured by Dainichiseika Kagyo Co., Ltd.: Seikabeam, trade name) was applied to 50 μm (dry coating thickness). ), and then a shaped film prepared as follows was laminated thereon. That is, this shaped film was made by mixing the resin of Example 1 with 30μ easy-adhesive PP.
(Tocero; OP-Z) with a film thickness of 15μ, dry coating, drying at 100°C for 30 seconds, and then drying at 60°C.
A shaped film was obtained by aging for 3 days. One UV light of 80W/cm is applied to this laminate body for 20m.
After irradiating at a rate of /min, the imprinting film was peeled off to obtain a sheet-like product with fine irregularities formed on the surface.

The surface of the sheet-like product thus obtained had exactly the same surface shape as the molded film used, with an Ra of 1.2 μm, an average difference in height between convex and concave portions of 8.0 μm, and no unevenness. The average spacing was 30 μm, and the average inclination angle of the unevenness was 14°. In this example, a polypropylene film was particularly used as the base film for the shaped film for the following reasons. P used in the above example
Since the ET film absorbs irradiation with wavelengths of 365 nm or less, it has the disadvantage of insufficient curing when curing the ultraviolet curable resin coating. On the other hand, compared to PET film, polypropylene film has a
It has excellent transmittance in the wavelength range of nm or more, and since a mercury lamp with a wavelength of around 254 nm is usually used for UV irradiation, it is better to use a polypropylene film with excellent transmittance at 365 nm for curing the UV curable resin. is preferred.

FIG. 4 is a graph showing the transmittance of PET film and polypropylene film for various wavelengths. It can be seen from FIG. 4 that the polypropylene film exhibits superior transmittance in the range of 200 to 365 nm compared to the PET film.

[0034]

Effects of the Invention As described in detail above, according to the present invention, the surface shape of the imprinting film can be adjusted so that the average spacing of the concave and convex portions is 20 to 20.
50 μm, average surface roughness Ra of unevenness is 0.7 to 2.0 μm
m and the 60° gloss value of the surface were set to 2.0 or less, so that a matte surface with a moist and slimy feel could be obtained. The feel was not smooth or shiny, but rather than rough, it had a soft, suede-like feel, giving it a certain sense of luxury.

[0035] The transferred body or molded article transferred or molded using the imprinting film of the present invention has the same surface shape as that of the imprinting film of the present invention, and the surface feel is also the same as that of the imprinting film. It had the same feel as the previous one.

[Brief explanation of drawings]

FIG. 1 shows a shaped film of the present invention.

FIG. 2 is a diagram for explaining the average inclination angle of unevenness.

FIG. 3 shows a slit reverse coating used in the present invention.

FIG. 4 shows a graph of transmittance of PET film and polypropylene film for various wavelengths.

[Explanation of symbols]

1 Base film 2　　　　　　Uneven layer 4 Nozzle coating equipment 5 Squeeze roll 6 Backup role

Claims (7)

[Claims] Claim 1: A finely textured layer having an average interval of 20 to 50 μm, an average surface roughness Ra of 0.7 to 2.0 μm, and a 60° gross value of the surface of 2.0 or less. An imprinting film characterized in that the film has the following properties on its entire surface. 2. The shaped film according to claim 1, wherein the shaped film is formed of a base film and an uneven layer laminated on the base film. 3. The mold-forming film according to claim 1, wherein the uneven layer contains a mold release agent. 4. The shaped film according to claim 1, wherein the uneven layer is formed by slit reverse coating. 5. The molded film according to claim 1, wherein the uneven layer is formed using an inorganic filler and a binder. 6. The molded film according to claim 5, wherein the inorganic filler is calcium carbonate and silica gel, and the main binder is an acrylic polyol crosslinked with polyisocyanate. [Claim 7] The base film is made of P that has been treated to facilitate adhesion.
The forming film according to claim 2, which is an ET film.