Decorative film, method for producing a decorative film and method for producing a foiled molded part

Abstract

Decorative film for covering a molded part, comprising the following layers, wherein the layers are arranged in the specified order in the direction of the material thickness of the decorative film: a top layer; a base material layer; an adhesive layer; a protective layer to protect the adhesive layer; and a shape-stabilizing layer comprising a cut line, wherein the cut line has a cut section, the cut section extending from the side of the shape-stabilizing layer facing away from the protective layer only over a part of the layer thickness of the shape-stabilizing layer, wherein the cut depth of the cut section is 150 µm to 300 µm.

Description

BACKGROUND Technical area

[0001] The present invention relates to a decorative film, a method for producing a decorative film and a method for producing a filmed molded part. Related state of the art

[0002] It is well known that decorative films are used to give vehicles, such as cars, a different appearance or to deliberately alter their design. One advantage of decorative films is that they can be applied to the exterior of vehicles, such as the roof and side panels, to change the vehicle's look or design. This allows the appearance of vehicles to be changed without the need for repainting, for example.

[0003] Various decorative films for modifying the exterior appearance of vehicles are known from the prior art, and some of them are commercially available. However, most of these films are flexible and must be applied to the vehicle's surface and simultaneously conformed to its shape. Applying such films to a vehicle's surface without altering its appearance requires professional expertise.

[0004] Decorative films are known that each comprise a release liner, an adhesive layer, and a top layer, wherein the release liner contains a dimensionally stable layer to improve the processability of the films for application to exterior vehicle parts (see Japanese patent applications JP 2016-198900 A and JP 2016-203434 A). The dimensionally stable layer contained in the release liner allows the decorative films to be pre-formed to the shape of the surface to be covered. The subsequent positioning of a pre-formed decorative film on the surface to be covered is easier compared to using a flat decorative film.

[0005] Examples of decorative foils are also known from US 2012 / 0 316 519 A1, JP 2005 - 309 021 A, DE 31 50 779 A1, JP H04 - 29 132 A, JP 3 199 207 U, US 4 091 135 A, JP 2019 - 189 413 A and JP 2016 - 198 900 A. SUMMARY OF THE INVENTION

[0006] In cases where a pre-formable decorative film is applied to a surface, such as a vehicle exterior panel, the film is first pre-formed and then cut to size. A release liner is then removed from the pre-formed film to expose the entire surface of the adhesive layer of a multi-layered decorative film body. The adhesive layer is then pressed onto the surface and bonded to it. Because the entire surface of the adhesive layer is exposed at this stage, precise positioning of the film at its intended location is difficult.If a multi-layered decorative film body has been applied to the surface to be covered and the application position is subsequently corrected, small wrinkles are created by the tensions exerted on the multi-layered decorative film body, resulting in an uneven gloss on the surface, which is caused by this micro-wrinkle formation of the multi-layered decorative film body and results in an unfavorable appearance.

[0007] Therefore, it is conceivable that after the pre-forming process a cutting line is provided on the release layer in order to remove parts of the release layer in a direction parallel to the cutting line in order to expose the corresponding parts of the adhesive layer and then to gradually attach these parts of the adhesive layer to the surface to be bonded.

[0008] However, it proves difficult to precisely incorporate a desired cutting line into the pre-formed decorative film, as the pre-formed decorative film has a three-dimensional shape.

[0009] The present invention relates to the provision of a decorative film with improved processability with regard to the application of the decorative film to a molded part, a method for producing a decorative film, a filmed molded part produced using said decorative film, and a method for producing a filmed molded part.

[0010] The invention comprises the following embodiments: <1> Decorative film for covering a molded part, comprising the following layers, wherein the layers are arranged in the specified order in the direction of the material thickness of the decorative film: a top layer; a base material layer; an adhesive layer; a protective layer to protect the adhesive layer; and a shape-stabilizing layer comprising a cutting line, wherein the cutting line has at least one cut section, wherein the cutting line has a cut section, wherein the cut section extends from the side of the shape-stabilizing layer facing away from the protective layer only over a part of the layer thickness of the shape-stabilizing layer, and wherein the cutting depth of the cut section is 150 µm to 300 µm. <2> Decorative film according to <1> , where the cut section alternates with an uncut section along the cutting line, with the length of the uncut section being 1.5 mm or less. <3> Decorative film according to <1> or <2> , where The cut section alternates with an uncut section along the cutting line, with the length of the cut section being from 0.5 mm to 2.5 mm. <4> Decorative film according to <1> , <2> or <3> , where the base material layer contains at least one resin from the group consisting of vinyl chloride resin, acrylic resin and ABS resin, the top layer contains at least one resin from the group of fluoro resin, acrylic resin and vinyl chloride resin and the dimensionally stable layer contains at least one resin from the group of ABS resin and vinyl chloride resin. <5> Method for producing a decorative film for covering a molded part, comprising the following steps: Applying a top layer to one surface side of a base material layer; Applying an adhesive layer to another surface side of the base material layer; Covering the adhesive layer with a protective layer to protect the adhesive layer; Applying a dimensionally stable layer using an adhesive to a surface of the protective layer facing away from the adhesive layer; and Forming a cut line having an incised section in the shape-stabilizing layer, wherein the incised section extends from the side of the shape-stabilizing layer facing away from the protective layer only over a part of the layer thickness of the shape-stabilizing layer, wherein the cutting depth of the incised section is 150 µm to 300 µm. <6> Method for producing a decorative film according to <5> , where the base material layer contains at least one resin from the group consisting of vinyl chloride resin, acrylic resin and ABS resin, the top layer contains at least one resin from the group of fluoro resin, acrylic resin and vinyl chloride resin and the dimensionally stable layer contains at least one resin from the group of ABS resin and vinyl chloride resin. <7> Method for producing a foil-coated molded part, comprising the following steps: Preforming of a decorative film according to <1> , <2> , <3> or <4> , by a vacuum forming process into a mold, wherein the mold corresponds to the shape of a molded part; Removing a portion of the protective layer to shield the adhesive layer and a corresponding portion of the shape-stabilizing layer from the pre-formed decorative film, using the cut line as a boundary to expose a portion of the adhesive layer; and arranging the exposed portion of the adhesive layer on a surface of the molded part. wherein the removal and application are repeated successively, so that a multi-layered decorative film body, which has been prepared by removing the shape-stabilizing layer and the protective layer of the decorative film, is gradually arranged on the surface of the formed object.

[0011] Certain embodiments of the present invention can provide a decorative film with improved processability with respect to applying the decorative film to a molded part, a method for producing the decorative film, a filmed molded part produced using the decorative film, and a method for producing the filmed molded part. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 shows a schematic sectional view of a decorative film according to the invention. Fig. Figure 2 shows a schematic sectional view of a foiled molded part according to the invention. Fig. Figure 3 is a schematic diagram showing a cutting line formed in a shape-stabilizing layer of each of the decorative foils of examples 1 to 4. Fig. Figure 4 is a schematic diagram showing a cutting line formed in a shape-stabilizing layer of each of the decorative foils of examples 5 to 8. Fig. is a schematic diagram showing a cutting line formed in a shape-stabilizing layer of each of the decorative foils of Examples 9 to 12. Fig. Figure 6 is a schematic diagram showing a cutting line formed in a shape-stabilizing layer of each of the decorative foils of Examples 13 to 16. Fig. Figure 7 is a schematic diagram showing a cutting line formed in a shape-stabilizing layer of each of the decorative foils of Examples 17 to 20. Fig. Figure 8 is a schematic diagram of a decorative foil (without a cutting line) according to comparison example 1. DETAILED DESCRIPTION OF THE INVENTION

[0012] A decorative film, a method for producing a decorative film, a method for producing a foiled molded part and a foiled molded part according to the present invention are described in detail below.

[0013] The following essential elements are described with reference to representative embodiments of the present invention. However, the present invention is not limited to the embodiments described below.

[0014] In the context of the present invention, the word "to" is used to connect a pair of numbers in order to represent a range of values ​​that includes the numbers preceding and following "to" as lower and upper limits, respectively. With respect to the ranges of values ​​specified and described in a graduated manner within the scope of the invention, the upper limit of a range of numbers can be replaced by any other upper limit of the graduated ranges of numbers, or the lower limit of a range of numbers can be replaced by any other lower limit of the graduated ranges of numbers.

[0015] Furthermore, for the value ranges described within the scope of the present invention, the upper and / or the lower limit value in each of the value ranges can be replaced by the values ​​described in the examples.

[0016] Within the scope of the present invention, a combination of advantageous aspects of the invention is considered to be an even more advantageous aspect.

[0017] A quantity of a component in a composition specified within the scope of the present invention refers to the total quantity of the substances contained in the composition, wherein the substances correspond to the component, unless expressly stated otherwise.

[0018] Within the scope of the present invention, the term "step" is not limited to an independent step, but also includes a step that is not clearly distinguishable from another step if the purpose expected in connection with the steps is achieved.

[0019] Within the scope of the present invention, the phrase "a layer containing a resin" refers to a layer containing a resin as its main component. That is to say, within the scope of the present invention, the above expression refers both to a resin layer containing only the resin and to a layer formed using a resin composition that optionally includes, in addition to the resin as the main component, other components such as a plasticizer, a colorant, and an ultraviolet absorber.

[0020] Within the scope of the present invention, the term "resin as main component" refers to a resin that constitutes 60% or more of the mass of a resin composition, based on the total amount of the resin composition.

[0021] Within the scope of the present invention, vinyl chloride resin is sometimes referred to as "PVC resin". Furthermore, acrylonitrile / butadiene / styrene copolymer is sometimes referred to as "ABS resin".

[0022] Within the scope of the present invention, the terms "a molded part in three dimensions" or "a molded part" refer to a molded part in its unlaminated state, and the term "laminated molded part" refers to a molded part that is provided with a decorative film according to the present invention. Furthermore, the "three dimensions" of the molded part means that the surface of the molded part to which the decorative film is applied is not flat.

[0023] A multi-layered film body is used for attachment to a molded part and is formed by removing a protective layer and a dimensionally stable layer from a decorative film. The multi-layered film body comprises a top layer, a base material layer, and an adhesive layer.

[0024] When a decorative film according to the invention is used to cover a molded part, the dimensionally stable layer, which is provided on a surface of the protective layer facing away from the adhesive layer, prevents the protective layer from shrinking while the decorative film is preformed, for example, by a vacuum forming process. Furthermore, the shape of the preformed decorative film is maintained by the dimensionally stable layer even when the pressure exerted on the decorative film during the preforming process decreases.

[0025] When the multi-layered decorative film body is applied to a molded part, it is pre-formed to match the shape of the molded part. This facilitates the positioning of the multi-layered decorative film body on the molded part.

[0026] A decorative film according to the invention offers improved processability with regard to the application of the decorative film to molded parts. This facilitates the modification of the appearance of vehicles or the provision of a large number of designs for the surfaces of various molded parts.

[0027] The decorative film, the method for producing the decorative film, the method for producing the film-coated molded part, and the film-coated molded part, which are disclosed within the scope of the present invention, are described in detail below with reference to preferred embodiments. However, the present disclosure is in no way limited to the following embodiments. <dekorfolie>

[0028] The decorative film according to the present invention is a decorative film comprising, in the following order, a top layer, a base material layer, an adhesive layer, a protective layer for the adhesive layer, and a dimensionally stable layer. The dimensionally stable layer further comprises a cutting line, which has a cut section. The decorative film according to the invention is used for covering molded parts.

[0029] The decorative film according to the invention is described with reference to the drawings. Fig. Figure 1 shows a schematic sectional view representing a preferred embodiment of the layer structure of a decorative film 10 according to the invention. Fig. Figure 2 shows a schematic sectional view of a foiled molded part 30 with a multilayer decorative foil body 24 attached to a molded part 26, wherein the multilayer decorative foil body 24 is formed by removing a protective layer 20 and a dimensionally stabilizing layer 22 from a decorative foil 10 according to the invention.

[0030] The decorative film 10 comprises a top layer 12, a base material layer 14, an adhesive layer 18, a protective layer 20 covering the adhesive layer 18, and a dimensionally stabilizing layer 22, arranged in that order. A cut line 28 with a cut section 28A is provided on the dimensionally stabilizing layer 22.

[0031] The fact that the respective layers are arranged “in this order” means that the respective layers are arranged in the described order in the direction of the material thickness of the decorative foil 10 and does not exclude the possibility of providing a further optional layer if required.

[0032] For example, a primer layer can be provided between the base material layer 14 and the adhesive layer 18, which is a resin layer that increases the adhesion between the two layers.

[0033] In one embodiment, the Fig. The decorative foil 10 shown has a layered structure which, in addition to the protective layer 20 and the dimensionally stable layer 22, forms a multi-layered body (the one shown in Fig. 2 the multilayer decorative foil body 24 shown comprises several layers in the following order: the top layer 12, the base material layer 14 and the adhesive layer 18. The surface of the top layer 12 facing away from the base material layer 14 may have an uneven pattern, also referred to as a textured pattern.

[0034] The surface with the uneven pattern of the top layer is sometimes referred to as "the surface" in the following because the top layer forms the outermost surface of a foil-coated molded part. This surface is formed by applying the multilayer decorative foil body 24, which is created by removing the protective layer 20 and the dimensionally stable layer 22 from the decorative foil 10, to a molded part as described below. The uneven pattern is a pattern that characterizes the external appearance of a molded part as a result of the decorative foil. The uneven pattern can, for example, be an uneven pattern with the appearance of natural leather. The pattern can be provided as required.

[0035] Furthermore, the base material layer 14 can, for example, contain a dye to give the decorative film 10 any desired color. In this way, any foiled molded part to which the decorative film 10 according to the invention is applied can easily be given a desired color.

[0036] In the Fig. 1 and Fig. 2 are identical elements with the same reference symbol.

[0037] The following describes the components of a decorative film according to the invention and a method for producing a decorative film according to the invention. (1st top layer)

[0038] The top layer of a decorative film according to the invention is formed from a resin. With regard to its durability, the top layer preferably contains at least one resin selected from the group consisting of fluoropolymers, acrylic resins, and vinyl chloride resins. The top layer, which contains at least one resin from the group consisting of fluoropolymers, acrylic resins, and vinyl chloride resins, increases the durability of the decorative film and also the durability of the multi-layered decorative film body applied to a molded part.

[0039] The selection of the fluorinated resin that can be used for the top layer is not specifically limited, provided that the fluorinated resin is a resin obtained by polymerization of at least one polymerization component that is a fluorine-containing monomer. However, a fluorinated resin obtained by polymerization of a fluorine-containing olefin is preferred.

[0040] Examples of fluorinated resins are resins consisting of a polymerization component selected from the group consisting of tetrafluoroethylene, chlorotrifluoroethylene, vinyl fluoride, or vinylidene fluoride. More specific examples of fluorinated resins include homopolymers consisting of a fluorine-containing polymerization component, where the fluorine-containing polymerization component is, for example, a tetrafluoroethylene resin, a vinyl fluoride resin, or a vinylidene fluoride resin, and copolymers containing one of the polymerization components described above, such as chlorotrifluoroethylene-vinylidene fluoride-fluoride copolymer. Vinylidene fluoride-propylene hexafluoride copolymer and Vinylidene fluoride-propylene hexafluoride-tetrafluoroethylene copolymer. Among these is at least one fluorinated resin selected from the group chlorotrifluoroethylene-vinylidene fluoride-fluoride copolymer. Vinylidene fluoride-propylene hexafluoride copolymer and Vinylidene fluoride-propylene hexafluoride-tetrafluoroethylene copolymer, preferably contained as a resin.

[0041] The top layer can contain only one fluoropolymer or a combination of two or more fluoropolymers.

[0042] If the top layer contains two or more fluororesins, it may be preferable to use a mixture of two or more resins, wherein the resins are selected from the group consisting of vinylidene fluoride resin, chlorotrifluoroethylene vinylidene fluoride copolymer, vinylidene fluoride propylene hexafluoride copolymer and vinylidene fluoride propylene hexafluoride tetrafluoroethylene copolymer.

[0043] If the top layer contains two or more resins, it can have a layered structure consisting of two or more resins, or, as described above, a mixture of two or more resins. For example, the top layer can have a two-layered structure, consisting of one layer containing one or more fluorinated resins and one layer containing an acrylic resin. The layer containing the fluorinated resin(s) forms the top surface of the top layer, i.e., the outermost surface of the multi-layered decorative foil body applied to a molded part. The layer containing the acrylic resin, on the other hand, is brought into contact with the base material layer to further increase the adhesion between the top layer and the base material layer.

[0044] The top layer can be formed using any known film manufacturing process, e.g., extrusion using a T-nozzle, calendering, or casting. It can also be produced using a commercially available film.

[0045] An uneven pattern can be provided on the outer surface of the top layer (i.e., on the side of the top layer facing away from the base material layer).

[0046] The thickness of the top layer, from the point of view of mechanical strength and the ability to maintain a shaped, rough pattern, is preferably in the range of 5 µm to 100 µm, particularly preferably in the range of 10 µm to 60 µm.

[0047] In this context, and in the case of an uneven pattern on the top layer, the specification of the thickness of the top layer refers to the distance between the highest point of the uneven pattern and the underside of the top layer.

[0048] Regarding the ability to maintain an uneven pattern on the surface of the top layer facing away from the base material layer, the thickness of the top layer is preferably greater than the distance between the deepest and highest points of the uneven pattern. For example, the thickness of the top layer may be approximately 5 µm if the uneven pattern is formed by depressions with a depth of 1 µm or less. The thickness of the top layer is preferably 10 µm or more if the uneven pattern includes both shallow and deep depressions, such as those seen in natural leather, where the deep depressions have a depth of 2 µm to 5 µm.

[0049] The thickness of the top layer refers to the total thickness of several layers when the top layer, as described above, is composed of two or more layers.

[0050] The thickness of each layer in a decorative film according to the invention can be determined by measuring a cross-sectional area produced by cutting the decorative film perpendicular to the plane direction. The specification of a layer thickness, with respect to each layer of the decorative film according to the invention as described in this disclosure, refers to a layer thickness measured after drying.

[0051] Any method can be used to form the top layer on the surface of the base material layer facing away from the shape-stabilizing layer. For example, a previously formed top layer can be applied to a base material layer, or a base material layer can be formed on the surface of a top layer after the top layer has been formed.

[0052] Furthermore, any known method for forming an uneven pattern on the surface of the top layer facing away from the base material layer can be used. Examples of known methods include a method in which a top layer with an uneven pattern is formed on a release paper, and a method in which a top layer with a smooth surface is first formed and the surface is then embossed with an embossing roller. (2nd base material layer)

[0053] The base material layer comprises a resin. The base material layer preferably contains at least one resin from the group consisting of PVC resin, acrylic resin, and ABS resin.

[0054] A base material layer containing at least one resin from the group consisting of PVC resin, acrylic resin and ABS resin reduces the thermal stress exerted on the top layer and increases the ability to maintain an optional uneven pattern formed on the top layer.

[0055] The selection of PVC resin, acrylic resin, and ABS resin is not specifically limited. Any known film-forming resin can be used, selected appropriately from PVC resins, acrylic resins, and ABS resins.

[0056] The base material layer can contain components other than a resin. Examples of other components that the base material layer may contain include dyes, plasticizers, fillers, lubricants, and processing aids. These other components can be used in such a way that they do not impair the thermal processability of the base material layer.

[0057] The base material layer may contain a dye.

[0058] In the production of a foil-wrapped molded part, a base material layer containing a colorant can prevent the inherent color, design, or similar properties of the molded part from affecting the appearance of the foil-wrapped molded part in an area where the multi-layered decorative foil body is applied. Furthermore, a base material layer containing a colorant can impart any desired color to the foil-wrapped molded part with the attached multi-layered decorative foil body.

[0059] If the top layer has a high degree of transparency, the color of the base material layer, which is produced by a dye contained in the base material layer, can shape the appearance of the decorative film.

[0060] For example, if a decorative film with a base material layer containing a silver dye is used to wrap only the roof of a red vehicle as a molded part with a multi-layered decorative film body separated from the base film, the resulting vehicle body, except for the roof, will be red, and only the roof, where the multi-layered decorative film body is applied, will be silver. The red color, as the inherent hue of the molded part, is masked in the area where the decorative layer body is applied to the vehicle surface.

[0061] In cases where the base material layer contains a dye, the choice of dye is not specifically restricted and any dye, pigment or similar can be selected and used.

[0062] In addition, the base material layer may, if necessary, contain a filler such as calcium carbonate, silicon dioxide, aluminum oxide or barium sulfate.

[0063] The thickness of the base material layer is preferably in the range of 50 µm to 400 µm, and particularly preferably in the range of 100 µm to 350 µm. A base material layer thickness within the range described above effectively prevents melt fracture in the decorative film during pre-forming, for example, by a vacuum forming process. Furthermore, the decorative film allows for better coverage of the molded part.

[0064] Any known film manufacturing process can be used to form the base material layer, such as extrusion using a T-nozzle, calendering, or casting. The choice of process is not specifically restricted.

[0065] Calendering is preferred, among other reasons, for the simplicity of its manufacture and the ease of maintenance of the equipment. Particularly in cases where the base material layer contains a colorant, a softened resin and a solid colorant can be fed into a calender roll to form sheets or films, suggesting that a base material layer containing various colorants can be easily produced.

[0066] Furthermore, the interior of the system is easier to clean during calendering than with other forming processes, such as extrusion, where cleaning is always necessary before changes are made to the type and quantity of dye added. Thus, a calendering process used to form a base material layer with a dye allows for the easy production of different base material layers with desired shades. The calendering process is also suitable for the small-batch production of decorative films. (3rd adhesive layer)

[0067] The decorative film contains an adhesive layer which is arranged on the surface of the base material layer facing away from the top layer in order to increase adhesion to a molded part.

[0068] The adhesive layer can be formed by applying at least one known adhesive or bonding agent to the surface of the base material layer facing away from the top layer.

[0069] The choice of adhesive used to form an adhesive layer is not limited. The choice of adhesive depends on the type of molded part. For example, preferably (1) a polyester-based adhesive, (2) a urethane-based adhesive, (3) an acrylate-based adhesive, or the like is used.

[0070] The thickness of the adhesive layer is preferably in the range of 20 µm to 80 µm, particularly preferably in the range of 30 µm to 60 µm.

[0071] An adhesive layer can be formed on the surface of the base material layer by forming a primer layer between the base material layer and the adhesive layer to increase adhesion, and then applying at least either an adhesive or a bonding agent to the surface of the primer layer formed.

[0072] Any known method, such as a transfer or coating process, can be used to provide an adhesive layer on the base material layer or primer layer. For the simplest possible formation of an adhesive layer with a uniform thickness, a transfer process is preferably used. (4. Protective layer to protect the adhesive layer)

[0073] After the adhesive layer has been formed, a surface of the adhesive layer is covered with a protective layer (protective film) to protect the surface of the adhesive layer.

[0074] From the point of view of preformability, a resin film or a resin-paper laminate film is preferred as the material for the protective layer, with a resin film being particularly preferred with regard to preformability.

[0075] Examples of resin films are PP films and PET films, with PP films being preferred.

[0076] The thickness of the protective layer is not specifically limited, but with regard to improved preformability it is preferably in the range of 5 µm to 100 µm, more preferably in the range of 40 µm to 70 µm, and much more preferably in the range of 45 µm to 60 µm.

[0077] The protective layer is removed after the decorative film has been pre-formed and before the pre-formed decorative film is applied to a molded part. (5. Shape-stabilizing layer)

[0078] The dimensionally stable layer is located on the surface of the protective layer facing away from the adhesive layer. A cut line, which includes a cut section, is provided on the surface of the dimensionally stable layer facing away from the protective layer.

[0079] In the present disclosure, the “shape-stabilizing layer” refers to a layer that serves to maintain the shape of a decorative film after the decorative film has been preformed by a process involving heating the decorative film. That is, the shape-stabilizing layer functions as a layer that subsequently preserves the shape of a decorative film formed during a preforming process. The shape-stabilizing layer of the decorative film enables the decorative film as a whole to retain its shape formed during a preforming process due to the function of the shape-stabilizing layer. This also applies if the decorative film is preformed, for example, by a vacuum forming process under a temperature influence of 80°C to 150°C and then cooled to a normal temperature (25°C).In this context, "dimensionally stable" means that when a pre-formed 50 cm² decorative film is attached at one corner of its square shape, no gravity-induced deformation (e.g. sagging) of the unattached part occurs.

[0080] The shape-stabilizing layer contains a resin. The shape-stabilizing layer preferably contains at least one ABS resin and / or at least one PVC resin to better retain the shape formed during a pre-forming process.

[0081] A dimensionally stable layer, containing at least one ABS resin and / or at least one PVC resin, prevents the protective layer from shrinking while the decorative film is pre-formed, for example, by a vacuum forming process, and ensures that the decorative film better retains the shape formed during the pre-forming process. Furthermore, such a dimensionally stable layer effectively prevents localized cracks at points of elongation caused by stretching during the pre-forming process.

[0082] ABS and PVC resins can be used individually or in combination with, for example, AS resin, polycarbonate (PC) resin, or polypropylene (PP) resin. Furthermore, a combination of ABS and PVC resins can also be used.

[0083] Among other options, either a single ABS resin, a single PVC resin, or a mixture of PC and ABS resins (PC / ABS mixture) is used as the resin. However, the use of either a single ABS resin or a single PVC resin is preferred.

[0084] It is also possible to use only one ABS resin. However, two or more different ABS resins with different copolymerization ratios can also be used.

[0085] The choice of PVC resin is not restricted. Any well-known film-forming PVC resin can be used.

[0086] The dimensionally stable layer may optionally contain, in addition to at least one PVC resin or at least one ABS resin, further components, provided that the other components do not impair the effect of the invention. Examples of further components that the dimensionally stable layer may contain are plasticizers, fillers, lubricants, and processing aids.

[0087] To achieve improved dimensional stability, the thickness of the dimensionally stable layer is preferably in the range of 100 µm to 800 µm, and particularly preferably in the range of 200 µm to 600 µm. If the thickness of the dimensionally stable layer is within the range described above, the decorative film exhibits a better ability to retain a shape formed during a preforming process.

[0088] In principle, it is possible to impart a dimensionally stable function to the base material layer by selecting a suitable resin, layer thickness, and similar factors. However, it is necessary to keep the thickness and stiffness of the base material layer within certain limits to achieve this dimensionally stable function. The composition of the base material layer is limited to increasing either its thickness or stiffness. Such a composition can impair product properties, such as appearance, for example, due to the dispersibility of a dye.

[0089] However, a decorative film according to the invention contains, in addition to a base material layer, a dimensionally stable layer on the side of the base material layer facing away from the top layer, in order to give the decorative film a dimensionally stable function and to maintain the quality of the appearance, which mainly originates from the base material layer. Thus, a decorative film according to the invention contains, in addition to a base material layer, a dimensionally stable layer.

[0090] Accordingly, a decorative film according to the invention can be subjected to a forming process under the influence of heat and has excellent properties with regard to preforming the decorative film.

[0091] Furthermore, a cutting line with a cut section is provided in the dimensionally stable layer of a decorative film according to the invention. The cut section is a section that is cut in the thickness direction of the dimensionally stable layer. The cut section can be formed intermittently or continuously in the plane direction along the cutting line. By providing the cutting line, which contains a cut section in the dimensionally stable layer, the processability of the decorative film with regard to its application to a molded part can be significantly improved.

[0092] The cutting line can be formed by a continuous cut section. Preferably, however, the cutting line is formed by a cut section and an uncut section, with the cut and uncut sections alternating. Regarding the shape of the cutting line (defined by the length of the cut section and the length of the uncut section), the uncut section preferably has a length of 1.5 mm or less, and more preferably 1.0 mm or less, for improved processability.

[0093] In contrast, the length of the cut section is preferably 0.5 mm to 2.5 mm.

[0094] Although the depth of the incised section of the cut line varies depending on the thickness of the shape-stabilizing layer, the incised section of the cut line has a depth of 150 µm to 300 µm with respect to improved processing when the shape-stabilizing layer has a thickness within the range of 100 µm to 800 µm described above. (6. Further layers)

[0095] In addition to the described top layer, base material layer, adhesive layer, protective layer and shape-stabilizing layer, further layers may be included by the decorative film, provided that the other layers do not impair the effect of the invention.

[0096] Examples of the other layers are the primer layer and the design layer. (6-1. Primer layer)

[0097] To increase the adhesion between the base material layer and the adhesive layer adjacent to the base material layer, the decorative film can also contain a resin layer as a primer layer between the base material layer and the adhesive layer.

[0098] The primer layer can be formed by a coating process. That is, the primer layer can be formed by dissolving a primer-forming resin in a suitable solvent, coating the surface of the base material layer facing away from the topcoat with the resulting solution, and finally allowing the resulting resin layer to dry.

[0099] The primer layer is preferably formed using a resin, such as a polyester resin. This achieves better compatibility between the resin contained in the primer layer and, for example, a thermoplastic resin contained in the base material layer and an adhesive contained in the adjacent adhesive layer.

[0100] The amount of resin layer used as a primer is not specifically limited and is selected according to the application. Generally, the amount of resin layer is preferably in the range of 1 g / m² to 5 g / m², and particularly preferably in the range of 2 g / m² to 3 g / m², to improve adhesion. (6-2nd design layer)

[0101] A decorative film according to the invention can further comprise a design layer between the top layer and the base material layer. The design layer is a layer used to apply a design to the decorative film. The design layer can be a printed layer formed by printing, a colored layer containing a colorant, or a combination of both.

[0102] Depending on the application of the decorative film, a design layer according to the invention can apply various designs to molded parts and give the molded parts a well-designed appearance.

[0103] The design layer can, for example, be a printed layer formed on the surface of the top layer or the base material layer by a printing process. The printed layer can be a layer produced with a resin-containing printing ink using any known printing method. The resin-containing printing ink is preferably a printing ink containing, for example, an acrylic resin or a vinyl chloride / vinyl acetate copolymer to produce clear printed images.

[0104] The choice of printing method is not specifically limited and any printing method, such as gravure printing, letterpress printing, offset printing, inkjet printing or screen printing, can be used.

[0105] The design layer is preferably a printed color layer containing at least one acrylic resin or at least one vinyl chloride / vinyl acetate copolymer.

[0106] The design layer can be a colored layer. This colored layer can be formed from a resin composition containing any colorant. Examples of design layers are those formed by calendering, extruding, or casting a resin composition into a film mold, where the resin composition contains, for example, an acrylic resin and a colorant selected from those described above.

[0107] Specific examples of acrylic resins that can be used to form the design layer include a methacrylate or methacrylate polymer or copolymer, represented by polymethyl methacrylate (PMMA) and a copolymer of an alkyl methacrylate, an alkyl acrylate, and styrene. With regard to formability, a mixture of an alkyl methacrylate, an alkyl acrylate, and a styrene copolymer, or a copolymer of a methyl methacrylate and a methyl acrylate, is preferred as the acrylic resin.

[0108] Acrylic resins exhibit excellent properties in terms of weather resistance and deformability, resulting in better adhesion of the design layer to the adjacent resin layers.

[0109] Since acrylic resins are also highly transparent, a design with desired color and gloss properties can be achieved on the decorative film by mixing an acrylic resin with, for example, a dye or a light-scattering dye such as a metallic luster pigment or a pearlescent pigment.

[0110] If a printed color layer is formed with a printing ink containing an acrylic resin, any complex design can be applied to the decorative film, for example by printing characters and images.

[0111] The thickness of a design layer according to the invention is preferably in the range of 1 µm to 15 µm, more preferably in the range of 2 µm to 10 µm, and even more preferably in the range of 2 µm to 5 µm. If the thickness is within the range described above, any desired design can be applied to the decorative film, and an excellent bond between the top layer and the base material layer is maintained during pre-forming of the decorative film. Furthermore, the top layer exhibits improved ability to retain an uneven pattern.

[0112] Preferably, a decorative film according to the invention comprises as a top layer a layer with high heat resistance, which has an uneven pattern on its surface and contains a fluoropolymer. In a top layer containing a fluoropolymer, the uneven pattern preferably formed on the surface is less deformed when the decorative film is heated. Furthermore, the top layer is preferably arranged on a base material layer containing a PVC resin. In addition, a protective layer contains at least one resin from the group consisting of PP, PET, PEN, or PE, which has an advantageous effect on the preforming properties of the decorative film. A dimensionally stable layer preferably contains at least one ABS resin or at least one PVC resin and borders the protective layer.A decorative film according to the invention, which contains these layers, has an improved ability to retain a shape which was formed during preforming (for example by a vacuum forming process).

[0113] The presence of the top layer and the adjacent base material layer containing a PVC resin, both of which are flexible enough for deformation, as well as the presence of the shape-stabilizing layer containing at least an ABS resin or at least a PVC resin and arranged adjacent to the protective layer, prevents the protective layer from shrinking during a vacuum forming process and enables the formation of a preform true to design.

[0114] Thus, a multi-layered decorative film body, containing the top layer, the base material layer, and the adhesive layer, and produced by removing the protective layer after the vacuum forming process, exhibits a better ability to retain a shape that fits a molded part. This, in turn, can facilitate the application of the multi-layered decorative film body to a molded part.

[0115] A decorative film according to the invention has a top layer on its outermost surface, which is characterized by excellent transparency and durability and has an improved ability to retain an uneven pattern when heated. Furthermore, a decorative film according to the invention has a base material layer which enables excellent thermal processability. A decorative film according to the invention also has a protective layer and a shape-stabilizing layer, which exhibit excellent properties with regard to maintaining the shape imparted to the decorative film during a preforming process.Therefore, a multi-layered decorative film body, formed by removing the protective and shape-stabilizing layers from the decorative film after the decorative film has been placed in a mold during a preforming process, retains the shape formed during the preforming process better while still maintaining a certain degree of flexibility. Accordingly, the multi-layered decorative film body can be easily positioned during application to the surface of a molded part.

[0116] The foiled molded part, which results from the application of a multi-layered foil body to its surface, is characterized in its appearance by the design of the applied multi-layered foil body and also exhibits high resistance, e.g. to solvents.

[0117] Thus, the decorative film of the present disclosure can be used as a decorative film for applying designs to the surface of molded articles in various applications. <Verfahren zur Herstellung einer Dekorfolie>

[0118] Any known manufacturing process can be used in a suitable manner as a method for producing a decorative film according to the invention. The choice of manufacturing process is not specifically limited.

[0119] Among other things, the method described below is preferably used for the production of a decorative film according to the invention, which comprises the following steps: Applying a top layer to one surface side of a base material layer; Applying an adhesive layer to another surface side of the base material layer; Covering the adhesive layer with a protective layer to protect the adhesive layer; Applying a dimensionally stable layer using an adhesive to a surface of the protective layer facing away from the adhesive layer; and Forming a cutting line with an incised section in the shape-stabilizing layer.

[0120] As a specific example, the inventive method for producing the decorative film comprises the following steps (I) to (X): Step (I), production of a top layer containing at least one resin selected from the group consisting of fluorinated resin, acrylic resin and vinyl chloride resin; Step (II), production of a base material layer containing at least one resin selected from the group consisting of vinyl chloride resin, acrylic resin and ABS resin; Step (III), applying the top layer to one surface side of the base material layer; Step (IV), forming an adhesive layer on the other surface side of the base material layer; Step (V), creating a protective layer; Step (VI), covering the adhesive layer with the protective layer; Step (VII), producing a dimensionally stable layer comprising at least one resin from the group consisting of ABS resin and vinyl chloride resin; Step (VIII), applying the shape-stabilizing layer with the aid of an adhesive to the surface of the protective layer facing away from the adhesive layer to form a decorative film; Step (IX), cutting the decorative film into a desired shape; and Step (X), forming a cutting line with an incised section in the shape-stabilizing layer.

[0121] In addition to the steps (I) to (X) above, other steps may also be included.

[0122] For example, step (III) may further include a step in which, while the top layer and the base material layer are being layered, an uneven pattern is formed on the surface of the top layer facing away from the base material layer. In this step, an embossing roller is brought into contact with the top layer surface to perform laminate embossing (step (III-2)).

[0123] Additionally, for example, a step to form a primer layer between the base material layer and the adhesive layer (step (XI)) and a step to form a design layer between the top layer and the base material layer (step (XII)) may be included. Step (I):

[0124] In step (I), a topcoat is formed containing at least one resin from the group consisting of fluoropolymers, acrylic resins, and vinyl chloride resins. A topcoat can be formed from scratch or a commercially available topcoat can be used.

[0125] The top layer can be produced by calendering, extrusion, casting or similar processes.

[0126] If a top layer with a layered structure is formed, a combination of two or more resins can be formed into a laminated film by coextrusion or similar processes. Step (II):

[0127] In step (II) a base material layer is produced which contains at least one resin from the group consisting of vinyl chloride resin, acrylic resin and ABS resin.

[0128] The base material layer is formed, for example, using a resin composition containing at least one resin selected from the group consisting of vinyl chloride resin, acrylic resin, and ABS resin. The base material layer can be produced by any known process, such as calendering, extrusion, or casting. However, among these processes, calendering is preferred for producing the base material layer due to its processability, as a base material layer with a uniform thickness is more easily produced by calendering than, for example, by extrusion. Furthermore, the interior of the calendering unit can be easily cleaned if a colorant is added during the calendering process. In this case, cleaning is always necessary before any changes are made to the type and quantity of colorant used for the base material layer.

[0129] A process for forming a base material layer using, for example, a PVC resin and a pigment dye involves adding a specific amount of the pigment to the PVC resin, mixing the resulting mixture while it is heated in a heating roller mixer, and using the resulting colored PVC resin composition to form a base material layer by calendering. If no dye is used, the same process can be carried out without adding the pigment.

[0130] Step (I) can precede step (II), or vice versa, or the steps can occur simultaneously. Step (III):

[0131] In step (III) the top layer produced in step (I) is layered onto a surface of the base material layer obtained in step (II).

[0132] In step (III) the base material layer is arranged on a surface of the top layer and the two layers are then laminated with a pair of rollers, which allows the top layer and the base material layer to be bonded together under the influence of heat and pressure.

[0133] The heating temperature for lamination is preferably between 100°C and 190°C. Within the scope of the present invention, the heating temperature for lamination refers to the temperature at the surface of a roller.

[0134] In this context, lamination refers to a process in which several layers in a stack are laminated under the influence of heat and pressure by using a pair of rollers to bond the resin-containing films together.

[0135] In addition to laminating the top layer with the base material layer, step (III) may include a step in which an uneven pattern is formed on the surface of the top layer facing away from the base material layer, which is introduced into the top layer using an embossing roller (step (III-2)).

[0136] By performing step (III-2), the lamination of the top layer and base material layer can be carried out simultaneously with the formation of an uneven pattern on the surface of the top layer. That is, the base material layer is placed on the surface of the top layer, and the stack is then laminated and embossed with an embossing roller, thus allowing the lamination of the layers under the influence of heat and pressure to be carried out simultaneously with the formation of a desired uneven pattern on the surface of the top layer.

[0137] The lamination coupled with embossing in step (III-2) relates, within the scope of the present invention, to the joining of several resin-containing films under the influence of heat and pressure by means of a pair of embossing rollers, and the simultaneous formation of an uneven pattern on the surface of a resin-containing film by contact with an embossing roller, wherein the embossing roller is one of the pair of embossing rollers. In step (III-2), the lamination, coupled with the embossing, takes place between two embossing rollers that are in contact with the top layer and the base material layer, respectively, wherein one embossing roller is designed as a smooth roller. In this process, the lamination of the two layers and the formation of an uneven pattern on the top layer can take place sequentially or simultaneously in one step.

[0138] An embossing roller, on whose surface an uneven pattern with any design, such as a natural leather-like pattern, is formed, is used to emboss the uneven pattern onto the surface of the top layer as part of a multi-layered decorative foil body, whereby the bonding with the base material layer and the embossing (formation of an uneven pattern) on the top layer are carried out in one step and the uneven pattern is transferred to the outermost surface of the top layer.

[0139] Not only a leather-like pattern, but also an uneven pattern with any design can be embossed onto the surface of the decorative foil by selecting the uneven pattern as a pattern formed on the surface of an embossing roller.

[0140] The heating temperature for laminating in conjunction with embossing is preferably between 100°C and 190°C.

[0141] The method for forming an uneven pattern on the surface of the top layer is not limited to the method described above. For example, in cases where the top layer is formed by a coating process, another method may be used in which a composition forming the top layer is applied to a release paper sheet with an uneven pattern, and the uneven pattern is transferred from the release paper sheet to the top layer. Step (IV):

[0142] In step (IV) an adhesive layer is formed on the surface of the base material layer formed in step (II) on the side facing away from the top layer.

[0143] The adhesive layer can be formed by applying at least one known adhesive or bonding agent to the surface of the base material layer facing away from the top layer.

[0144] The choice of adhesive used to form an adhesive layer is not particularly limited, but is made according to the molded part. Preferably, (1) a polyester-based adhesive, (2) a urethane-based adhesive, (3) an acrylate-based adhesive, or the like is used.

[0145] The thickness of the adhesive layer is preferably in the range of 20 µm to 80 µm. Step (V):

[0146] In step (V) a protective layer is formed to protect the adhesive layer.

[0147] A resin film is preferably used as a protective layer.

[0148] Examples of resin films are PP films and PET films, with PP films being preferred.

[0149] The thickness of the protective layer is not specifically limited, but to allow for better pre-forming, it is preferably in the range of 5 µm to 100 µm, and particularly preferably in the range of 40 µm to 70 µm.

[0150] If the decorative film is applied to a molded part after pre-forming, as described below, parts of the protective layer and the corresponding parts of the adjacent shape-stabilizing layer are gradually removed until the protective layer or the shape-stabilizing layer is completely removed, with a cut line in the shape-stabilizing layer serving as the boundary between these parts. Step (VI):

[0151] In step (VI) the protective layer formed in step (V) is brought into contact with the adhesive layer formed in step (IV) in order to cover the adhesive layer with the protective layer.

[0152] As described above, the protective layer is preferably an easily removable resin film, for example a PP film.

[0153] Step (VI) may include a step in which an adhesive layer is formed, preferably by applying an adhesive to the base material layer (step (IV)) and applying the protective layer to cover the surface of the adhesive layer before the adhesive layer has cured. Step (VII):

[0154] In step (VII), a dimensionally stable layer is produced, containing at least one ABS resin and / or at least one vinyl chloride resin. The dimensionally stable layer is formed, for example, using a resin composition containing at least one ABS resin and / or at least one vinyl chloride resin. Known processes such as calendering, extrusion, and casting are available for forming the dimensionally stable layer. Of these, a calendering process is preferred for forming the dimensionally stable layer due to its improved processability.

[0155] The process for forming a shape-stabilizing layer by calendering can be carried out similarly to the process for forming a base material layer in step (II), except that the resins used are different. Step (VIII):

[0156] In step (VIII) the shape-stabilizing layer produced in step (VII) is attached to the surface of the protective layer facing away from the adhesive layer using an adhesive.

[0157] A silicone resin-based adhesive is preferably used. An adhesive used for forming an adhesive layer can also be used.

[0158] The amount of adhesive applied is preferably in the range of 20 g / m2 to 70 g / m2.

[0159] The steps described above result in a decorative film which contains, in the following order, a top layer, a base material layer, an adhesive layer, a protective layer and a dimensionally stabilizing layer. Step (IX):

[0160] In step (IX), the decorative film is cut into a desired shape.

[0161] The decorative foil obtained in step (VIII) is cut with a cutting device into a shape that fits the surface of a molded part on which the decorative foil is to be applied. Step (X):

[0162] In step (X), a cut line with an incised section is formed in the shape-stabilizing layer.

[0163] The choice of method for forming the cutting line, which contains a cut section in the shape-stabilizing layer, is not particularly limited and the cutting line can, for example, be formed with a cutting device.

[0164] The choice of device used is not limited, provided that the cutting device is suitable for creating a cut line in the dimensionally stable layer. For example, commercially available cutting devices can be used to create a cut line with a notched section on the side of the dimensionally stable layer facing away from the protective layer.

[0165] An eccentric cutter is a preferred type of blade for use in cutting devices. For example, while an eccentric blade held by a cutter head is brought into contact with the dimensionally stable layer by a vertical movement, the pressure exerted on the blade is continuously reduced after a defined time interval as the cutter head moves across the decorative film in the XY direction. In this way, the dimensionally stable layer is cut to a desired depth in the form of a dotted line (i.e., intermittently). Thus, a cut line with cut and uncut sections is formed on the decorative film.

[0166] In a case where the decorative film is used to attach a decorative layer body to a shaped object, a portion of the adhesive layer's protective film and the corresponding portion of the shape-stabilizing layer, delimited by the cut line in the shape-stabilizing layer, are removed from the decorative film, and the exposed portion of the adhesive layer is brought into contact with the shaped object. Subsequently, the remaining portions of the adhesive layer's protective film and the shape-stabilizing layer are removed, and the exposed adhesive layer is attached to the shaped object.

[0167] The inventive method for producing the decorative film may include further steps.

[0168] For example, the method according to the invention can include the step of forming a primer layer between the base material layer and the adhesive layer (step (XI)) and the step of forming a design layer between the top layer and the base material layer (step (XII)). Step (XI):

[0169] In step (XI), a primer layer can be formed by a coating process. That is, a primer layer can be formed by dissolving a primer-forming resin in a suitable solvent, coating the surface of the base material layer facing away from the topcoat with the resulting solution, and finally drying the resulting resin layer.

[0170] If a primer layer is formed, the above described step (IV) can be carried out after step (XI) to form an adhesive layer on the primer layer. Step (XII):

[0171] Step (XII) is an optional step in the inventive method for producing the decorative film, in which a further design layer is formed.

[0172] In step (XII) a design layer can be formed on a surface of either the top layer produced in step (I) or the base material layer produced in step (II).

[0173] Examples of a method for forming a design layer include a method in which a pre-formed design layer is applied to a surface of either the top layer or the base material layer, and a method in which a surface of either the top layer or the base material layer is printed using a printing ink containing an acrylic resin or a vinyl chloride / vinyl acetate copolymer.

[0174] Printing is a preferred method for creating a design layer because it offers flexibility in terms of design. Printing is used to create a patterned design layer. In contrast, a process in which, for example, a resin composition with a dye is formed into a film using any known method, which then serves as the design layer, can be used to create a colored design layer.

[0175] The printing process is a known method in which any pattern is printed using a resin-based printing ink. Examples of the printing process include a method in which a resin-based printing ink, containing, for example, acrylic resin or a vinyl chloride / vinyl acetate copolymer, is applied by any known printing method, such as gravure (intaglio), letterpress, offset printing, inkjet printing, or screen printing, to form a design layer.

[0176] Specific examples of the printing process include a method in which an ink containing an acrylic resin is printed onto the surface of the top layer using gravure printing. The size of patterns incorporated into a printing roller used for gravure printing can be adjusted to create a design layer with a desired design and to allow printing with a controlled coating amount of ink.

[0177] The design layer can optionally be applied independently as a separate layer on the surface of either the top layer or the base material layer, thus creating a layer with a desired design and any color. Therefore, by using a design layer, various designs can be applied to the decorative film. <Foliertes Formteil>

[0178] A foiled molded part according to the invention comprises a molded part and a multi-layered decorative foil body, which is formed by removing the protective layer and the dimensionally stabilizing layer from a decorative foil according to the invention and which is arranged on the molded part via the adhesive layer.

[0179] As in Fig. As shown in Figure 2, the foiled molded part 30 comprises a molded part 26 to be foiled and a multilayer decorative foil body 24, which is attached to the surface of the molded part, wherein the multilayer decorative foil body is formed by removing the protective layer and the dimensionally stable layer from a decorative foil according to the invention. The multilayer decorative foil body 24 has the same layer structure as a decorative foil according to the invention, with the exception that the multilayer decorative foil body lacks a protective layer and a dimensionally stable layer. As shown in Fig. As shown in Figure 2, the multilayer decorative foil body 24 thus comprises the top layer 12, the base material layer 14, and the adhesive layer 18. Fig. 2 An optional primer layer may be provided to increase the adhesion between the base material layer 14 and the adhesive layer 18. <Verfahren zur Herstellung eines folierten Formteils>

[0180] A design is applied to the surface of a molded part by applying a decorative film according to the invention when the molded object is produced by hot forming.

[0181] An inventive method for producing a foil-coated molded part comprises a pre-forming step (A) in which a decorative foil according to the invention is pre-formed by a vacuum forming process according to the shape of a molded part. The inventive method further comprises a partial removal step (B) in which a portion of the protective layer and the corresponding portion of the shape-stabilizing layer are removed from the pre-formed decorative foil using the cut line as a boundary line in order to expose a portion of the adhesive layer. The inventive method further comprises a partial bonding step (C) in which the portion of the adhesive layer exposed by removing the protective layer and the shape-stabilizing layer is applied to the surface of the molded part.The partial removal step (B) and the partial attachment step (C) are repeated successively, so that the multi-layered decorative film body, which was formed by removing the shape-stabilizing layer and the protective layer from the decorative film, is gradually attached to the surface of the molded part.

[0182] In step (A) a decorative film according to the invention is preformed by a vacuum forming process, using a mold that corresponds to the shape of a molded part.

[0183] For preforming, a vacuum forming process is preferred with regard to the subsequent maintenance of a given shape. Any known vacuum forming process can be used. If the decorative film is preformed by vacuum forming, it is preferably heated in a temperature range of 80°C to 150°C.

[0184] In step (A) the decorative film (10) is placed on the surface of a mold which corresponds to the shape of the molded part and is then pre-formed by a conventional vacuum process such that the pre-formed decorative film corresponds in shape to the mold.

[0185] The layered structure of the decorative film according to the invention, as described above, enables rapid pre-forming of the decorative film by a vacuum forming process and gives the decorative film excellent properties with regard to maintaining a given shape.

[0186] In step (B), a portion of the protective layer and the corresponding portion of the shape-stabilizing layer are removed from the pre-formed decorative film, using the cut line as a boundary, to expose part of the adhesive layer. In step (C), the portion of the adhesive layer exposed by removing the protective and shape-stabilizing layers from the pre-formed decorative film is applied to the surface of the molded part.

[0187] Steps (B) and (C) are then repeated manually, alternating between them. A decorative foil 32, which is cut from the rectangular decorative foil 10 into a shape 32, wherein the shape 32 corresponds to a molded part and which is provided with a single linear cutting line 28 ( Fig. 3) is divided into areas bounded by the cut line 28. The removal of the protective layer and the shape-stabilizing layer, combined with the application of the adhesive layer, is then carried out step by step for each area. Specifically, the following application steps (1) to (4) are performed. Procedure (1) for step (B)

[0188] For the partial preparation of a multi-layered decorative film body and the exposure of part of the adhesive layer, the protective layer and the dimensionally stable layer are removed from the decorative film in the smaller area of ​​"A-section". Since the cutting line, which is incised in the direction of the plane as a dotted line, is formed in the dimensionally stable layer, the removal of the dimensionally stable layer and the protective layer is straightforward. Procedure (2) for step (C)

[0189] The adhesive layer in the “A-part” of the multilayer decorative foil body, which was exposed in process (1), is positioned opposite the surface of a molded part and the multilayer decorative foil body is then pressed onto the surface of the molded part and attached to it via the exposed part of the adhesive layer. Procedure (3) for step (B)

[0190] The protective layer and the shape-stabilizing layer in the larger "B-part" are removed to fully expose the multi-layered decorative foil body or the remaining part of the adhesive layer. Procedure (4) for step (C)

[0191] The adhesive layer of the multilayer decorative foil body, which was exposed in process (3), is positioned opposite the surface of the molded part and the multilayer decorative foil body is then pressed onto the surface of the molded part and attached to it via the adhesive layer.

[0192] This process allows for the gradual attachment of the multi-layered decorative foil body and improves the processability of the decorative foil with regard to its application to a molded part.

[0193] The inventive method for producing a foil-coated molded article is not limited to the sequence of steps described above. For example, the cutting line 28 can be formed in the shape-stabilizing layer of the decorative foil 10 before the decorative foil 10 is cut into a mold, wherein the mold corresponds to the mold of a molded part.

[0194] Using cutting line 28 as a boundary line improves processability if the smaller A-part is attached to a molded part first. However, the larger B-part can also be attached first.

[0195] A foil-coated molded part according to the invention can be produced by a simple method according to the invention, since the multi-layered decorative foil body, as described above, can be easily applied to a molded part. Using this method, various colors, designs, and the like can be easily embossed onto a molded part. Furthermore, the method can be used in various applications. In addition, the multi-layered decorative foil body, which is formed by removing the protective layer and the shape-stabilizing layer from the pre-formed decorative foil, is flexible and enables the production of foil-coated molded parts with different designs and excellent appearance using this method. Accordingly, the method according to the invention is also suitable for producing foil-coated molded parts according to the invention in the context of small-batch production of foil-coated molded parts with different designs.

[0196] Furthermore, the cut line, which includes a cut section provided in the shape-stabilizing layer, increases the processability with regard to application to a molded part and can, for example, prevent material losses due to application errors or the creation of a defective optical appearance.

[0197] The selection of molded parts onto which the multilayer decorative foil body of the present invention can be applied is not particularly limited. Examples include cars, railway carriages or the like, furniture, aircraft, watercraft, building materials, wall materials and the like. EXAMPLES

[0198] The decorative film according to the invention is described below using examples. However, the present invention is not limited to these examples. <Herstellung von Dekorfolien> Step (I): Preparation of the top layer

[0199] The KFC film FT-50Y (product name) from Kureha Extech Co. Ltd (a layered body comprising a layer containing polyvinylidene fluoride as a fluorinated resin and a layer containing poly(methyl methacrylate) as an acrylic resin; thickness: 50 µm) was used as the top layer. Step (II): Formation of the base material layer

[0200] To 100 kg of a PVC resin (TH800 (product name); Taiyo Vinyl Corporation) 2 kg of a pigment (PV MAF 725 (product name); Dainichiseika Color & Chemicals Mfg. Co., Ltd.) were added and the resulting mixture was formed by calendering into the shape of a sheet with a dry thickness of 150 µm to obtain a base material layer. Step (III): Applying the base material layer to the top layer

[0201] The base material layer was placed on the surface of the top layer on the side containing the poly(methyl methacrylate) layer. The resulting stack was laminated between a pair of rollers at a lamination temperature of 150 °C to form a sheet. Step (XI): Formation of the primer layer

[0202] A urethane resin (LEATHEROID (product name); Dainichiseika Color & Chemicals Mfg. Co., Ltd.) was applied to the surface of the base material layer facing away from the top layer to form a primer layer with a dry film thickness of 3 µm. Step (IV): Formation of the adhesive layer

[0203] An acrylate adhesive (ORIBAIN BPS (product name); TOYOCHEM Co., Ltd.) was applied to the primer layer in an amount sufficient to achieve a dry film thickness of 55 µm. The acrylate adhesive was then allowed to dry to form an adhesive layer with a thickness of 55 µm. Step (V): Formation of the protective layer

[0204] A flat PP resin film (Fujico Co., Ltd.; BK0A (product name); thickness: 60 µm) was prepared as a protective layer. Step (VI): Covering the adhesive layer with the protective layer

[0205] The surface of the adhesive layer formed in step (VI) was covered with the protective layer produced in step (V). Step (VII): Formation of the shape-stabilizing layer

[0206] A 100 kg ABS resin [TM-30G6 (product name); UMG-ABS Ltd.] was calendered into the shape of a plate with a dry thickness of 500 µm to create a shape-stabilizing layer. Step (VIII): Arrangement of the shape-stabilizing layer and the protective layer

[0207] The protective layer for the adhesive layer, which was used to cover the adhesive layer in step (VI), was arranged with a silicone resin-based adhesive (CEMEDINE PM165-R (product name); CEMEDINE Co: 5 g / m2) on the shape-stabilizing layer formed in step (VII) to obtain a decorative film according to the invention. Step (IX): Cutting the decorative foil

[0208] The decorative foil was cut to a size of 1260 mm (in the direction of L (length)) × 810 mm (in the direction of W (width)).

[0209] The decorative foil thus produced was used to manufacture each of the decorative foils of Examples 1 to 20, modifying the shape of a cut line (length of the cut section, length of the uncut section) and the depth of each cut section in the shape-stabilizing layer as described below. [Example 1]Step (X): Formation of the cutting line in the shape-stabilizing layer

[0210] For this purpose, a cutting device (Kongsberg, blade type: eccentric cutter) was used. The decorative film was placed on the designated part of the cutting device, with the dimensionally stable layer of the decorative film facing the cutting part of the device. This created a cut line (cut depth: 150 µm) with which in Fig. 3 shown shape (length of the cut section: 0.5 mm, length of the uncut section: 0.5 mm). [Example 2]

[0211] The decorative foil according to Example 2 was produced in the same way as in Example 1, except that the depth of each cut section in the cut line was changed to 200 µm. [Example 3]

[0212] The decorative foil according to Example 3 was produced in the same way as in Example 1, except that the depth of each cut section in the cut line was changed to 250 µm. [Example 4]

[0213] The decorative foil according to Example 4 was produced in the same way as in Example 1, except that the depth of each cut section in the cut line was changed to 300 µm. [Example 5]

[0214] The decorative foil according to Example 5 was produced in the same way as in Example 1, except that the cut line formed in step (X) in Example 1 was converted into a cut line (depth of the cut section: 150 µm) with the one in Fig. The shape shown in 4 (length of the incised section: 2.5 mm, length of the unincised section: 0.5 mm) has been changed. [Example 6]

[0215] The decorative foil according to Example 6 was produced in the same way as in Example 5, except that the depth of each cut section in the cut line was changed to 200 µm. [Example 7]

[0216] The decorative foil according to Example 7 was produced in the same way as in Example 5, except that the depth of each cut section in the cut line was changed to 250 µm. [Example 8]

[0217] The decorative foil according to Example 8 was produced in the same way as in Example 5, except that the depth of each cut section in the cut line was changed to 300 µm. [Example 9]

[0218] The decorative foil according to Example 9 was produced in the same way as in Example 1, except that the cut line formed in step (X) in Example 1 was converted into a cut line (depth of the cut section: 150 µm) with the one in Fig. The shape shown in Figure 5 (length of the incised section: 1.5 mm, length of the unincised section: 1.5 mm) has been changed. [Example 10]

[0219] The decorative foil according to Example 10 was produced in the same way as in Example 9, except that the depth of each cut section in the cut line formed in step (X) in Example 9 was changed to 200 µm. [Example 11]

[0220] The decorative foil according to Example 11 was produced in the same way as in Example 9, except that the depth of each cut section in the cut line formed in step (X) in Example 9 was changed to 250 µm. [Example 12]

[0221] The decorative foil according to Example 12 was produced in the same way as in Example 9, except that the depth of each cut section in the cut line formed in step (X) in Example 9 was changed to 300 µm. [Example 13]

[0222] The decorative foil according to Example 13 was produced in the same way as in Example 1, except that the cut line formed in step (X) in Example 1 was converted into a cut line (depth of the cut section: 150 µm) with the one in Fig. The shape shown in Figure 5 (length of the incised section: 0.5 mm, length of the unincised section: 2.5 mm) has been changed. [Example 14]

[0223] The decorative foil according to Example 14 was produced in the same way as in Example 13, except that the depth of each cut section in the cut line formed in step (X) in Example 13 was changed to 200 µm. [Example 15]

[0224] The decorative foil according to Example 15 was produced in the same way as in Example 13, except that the depth of each cut section in the cut line formed in step (X) in Example 13 was changed to 250 µm. [Example 16]

[0225] The decorative foil according to Example 16 was produced in the same way as in Example 13, except that the depth of each cut section in the cut line formed in step (X) in Example 13 was changed to 300 µm. [Example 17]

[0226] The decorative foil according to Example 17 was produced in the same way as in Example 1, except that the cut line formed in step (X) in Example 1 was converted into a cut line (depth of the cut section: 150 µm) with the one in Fig. The shape shown in Figure 5 (length of the incised section: 2.5 mm, length of the unincised section: 2.5 mm) has been changed. [Example 18]

[0227] The decorative foil according to Example 18 was produced in the same way as in Example 17, except that the depth of each cut section in the cut line formed in step (X) in Example 13 was changed to 200 µm. [Example 19]

[0228] The decorative foil according to Example 19 was produced in the same way as in Example 17, except that the depth of each cut section in the cut line formed in step (X) in Example 13 was changed to 250 µm. [Example 20]

[0229] The decorative foil according to Example 20 was produced in the same way as in Example 17, except that the depth of each cut section in the cut line formed in step (X) in Example 13 was changed to 300 µm. [Comparison example 1]

[0230] A decorative film with a dimensionally stable layer without a cut line (length of the cut section: 0 mm, length of the uncut section: 0 mm) according to Fig. 8. <Herstellung folierter Formartikel>

[0231] Each of the decorative films in the examples and the comparison example was pre-formed using a vacuum forming machine to match the shape of a molded part. A side roof panel for vehicles was used as the molded part. A portion of the protective layer and the corresponding portion of the shape-stabilizing layer, with the cut line in the shape-stabilizing layer as the boundary, were removed from each of the pre-formed decorative films (processability with respect to cutting was evaluated), and the exposed portion of the adhesive layer was applied to the molded part (processability with respect to application was evaluated) to produce a filmed molded part. [Review of the decorative films]

[0232] The processability with regard to cutting away the protective layer and the shape-stabilizing layer before applying the pre-formed decorative film to the molded part, and the processability with regard to applying the pre-formed decorative film to the molded part, were evaluated by 10 workers who acted as testers and actually carried out the test procedures, according to the following criteria: The most frequent assessment result among the 10 assessors was adopted as the overall result. In cases where an equal number of assessors gave differing assessments, the more favorable overall result was adopted. < Processability in terms of cutting away > A: unproblematic - very easy cutting of the protective layer and the shape-stabilizing layer; B: unproblematic - easy cutting of the protective layer and the shape-stabilizing layer; C: unproblematic - slightly more difficult cutting of the protective layer and the shape-stabilizing layer; D: problematic - the protective layer and the shape-stabilizing layer cannot be cut off.

[0233] When assessing processability in terms of cutting, decorative films classified as A, B or C present virtually no problems. < Processability in terms of application > A: unproblematic - the multi-layered decorative foil body can be easily attached to the molded part; B: problematic - the multi-layered decorative foil body is difficult to bond to the molded part.

[0234] When assessing the ease of application, decorative films rated A are practically problem-free.

[0235] The results are listed in Table 1 below.

[0236] Both the processability in terms of cutting and the processability in terms of application were rated highly for each of the decorative films in the examples compared to the decorative film of the comparison example.

[0237] In particular, the decorative films, which are one of the Fig. 3, Fig. 4 and Fig. The 5 shown cutting lines, i.e., a cutting line with a length of the cut section in the range of 0.5 mm to 2.5 mm and a length of the uncut section of 1.5 mm or less, were rated as excellent.< / dekorfolie>

Claims

[1] Decorative film for covering a molded part, comprising the following layers, wherein the layers are arranged in the specified order in the direction of the material thickness of the decorative film: a top layer; a base material layer; an adhesive layer; a protective layer to protect the adhesive layer; and a shape-stabilizing layer comprising a cutting line, wherein the cutting line has an incised section, wherein the incised section extends from the side of the shape-stabilizing layer facing away from the protective layer only over a part of the layer thickness of the shape-stabilizing layer, wherein the cutting depth of the incised section is 150 µm to 300 µm. [2] Decorative film according to claim 1, characterized bythat the incised portion alternates with a non-incised portion along the cutting line and wherein a length of the non-incised portion is 1.5 mm or less. [3] Decorative film according to one of claims 1 to 2, characterized by that the incised portion alternates with a non-incised portion along the cutting line and wherein a length of the incised portion is 0.5 mm to 2.5 mm. [4] Decorative film according to one of claims 1 to 3, characterized by that the base material layer contains at least one resin from the group consisting of vinyl chloride resin, acrylic resin and ABS resin, the cover layer contains at least one resin from the group consisting of fluororesin, acrylic resin and vinyl chloride resin, the shape-stabilizing layer contains at least one resin from the group ABS resin and vinyl chloride resin. [5] A method for producing a decorative film for foiling a molded part, comprising the following steps: Applying a cover layer to a surface side of a base material layer; Applying an adhesive layer on another surface side of the base material layer; Covering the adhesive layer with a protective layer to protect the adhesive layer; Applying a shape-stabilising layer using an adhesive to a surface of the protective layer facing away from the adhesive layer; and Forming a cutting line having a cut section in the shape-stabilizing layer, wherein the incised section extends from the side of the shape-stabilizing layer facing away from the protective layer only over a part of the layer thickness of the shape-stabilizing layer, wherein the cutting depth of the incised section is 150 µm to 300 µm. [6] A method for producing a decorative film according to claim 5, characterized by that the base material layer contains at least one resin from the group consisting of vinyl chloride resin, acrylic resin and ABS resin, the cover layer contains at least one resin from the group consisting of fluororesin, acrylic resin and vinyl chloride resin, the shape-stabilizing layer contains at least one resin from the group ABS resin and vinyl chloride resin. [7] A method for producing a foil-coated molded part, comprising the following steps: Preforming a decorative film according to one of claims 1 to 4 by a vacuum forming process into a shape corresponding to a molded part; Removing a portion of the protective layer for protecting the adhesive layer and a corresponding portion of the shape-stabilizing layer from the preformed decorative film using the cutting line as a boundary line to expose a portion of the adhesive layer; and Arranging the exposed part of the adhesive layer on a surface of the molded part, wherein the removal and attachment are repeated successively so that a multi-layer decorative film body prepared by removing the shape-stabilizing layer and the protective layer of the decorative film is gradually arranged on the surface of the shaped article.

Images