Decorative film, decorative molding, decorative display component, decorative display system, and production method of decorative display component

Abstract

To provide a decorative film developed in designability of a decorative display component.SOLUTION: A decorative film 40 is subjected to laser etching. The decorative film 40 includes: a first top layer 50 containing a cured product of an ionizing radiation-curable resin; a second top layer 55 laminated with the first top layer 50; and a design layer 60 positioned between the first top layer 50 and the second top layer 55.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The present invention relates to a decorative film, a decorative molded product, a decorative display part, a decorative display system, and a method for manufacturing a decorative display part. [Background technology]

[0002] As disclosed in Patent Document 1 (JP2002-46145A), a decorative film having a printed decorative portion and an unprinted non-decorated portion is known. The decorative film of Patent Document 1 is joined to a resin portion formed by injection molding, and together with the resin portion constitutes a decorative display component. In Patent Document 1, the decorative display component is disposed facing a light source. The decorative sheet is illuminated from behind by light from the light source. At this time, a display is made in a pattern corresponding to the pattern of the non-decorated portion.

[0003] In Patent Document 1, a decorative display part is manufactured by insert molding. In this example, it is necessary to position a decorative film having a decorated portion and a non-decorated portion relative to a mold used for insert molding. Also, instead of the manufacturing method of Patent Document 1, a decorative display part can also be manufactured by attaching a decorative film to a pre-formed resin part. However, even in this manufacturing method, it is necessary to position the decorative film relative to the resin part. If the positional relationship between the decorative film and the resin part is not appropriate, the decorative display part will not have the design expected. DISCLOSURE OF THEINVENTION

[0004] The present disclosure aims to improve the design of decorative display components.

[0005] The first decorative film according to an embodiment of the present disclosure includes: A decorative film to be laser etched, a first top layer including a cured product of an ionizing radiation curable resin; a transparent second top layer laminated to the first top layer; and a design layer located between the first top layer and the second top layer.

[0006] The second decorative film according to an embodiment of the present disclosure includes: a first top layer including a cured product of an ionizing radiation curable resin; a transparent second top layer laminated to the first top layer; a design layer positioned between the first top layer and the second top layer; a thermoplastic resin layer laminated with the second top layer and containing a thermoplastic resin; The second top layer is located between the design layer and the thermoplastic resin layer.

[0007] The decorated molded product according to one embodiment of the present disclosure includes: A decorative film according to one embodiment of the present disclosure; The decorative film further includes a resin portion that is laminated with the decorative film and contains a thermoplastic resin.

[0008] A first decorative display component according to an embodiment of the present disclosure includes: A decorated molded product according to an embodiment of the present disclosure is provided, The second top layer is exposed through a hole that penetrates the first top layer and the design layer.

[0009] A second decorative display component according to an embodiment of the present disclosure includes: Decorative film and A resin portion that is laminated with the decorative film and contains a thermoplastic resin, The decorative film is a first top layer including a cured product of an ionizing radiation curable resin; a transparent second top layer laminated to the first top layer; a design layer located between the first top layer and the second top layer, The second top layer is located between the design layer and the resin part, The second top layer is exposed through a hole that penetrates the first top layer and the design layer.

[0010] A decorative display system according to an embodiment of the present disclosure includes: A first or second decorative display component according to an embodiment of the present disclosure; A light source that irradiates the decorative display component with light.

[0011] A method for manufacturing a decorative display component according to an embodiment of the present disclosure includes: A step of manufacturing a decorated molded product by joining a decorative film according to an embodiment of the present disclosure and a resin part formed by injection molding; The method includes a step of partially removing the first top layer and the design layer by laser etching, and forming a portion of the surface by the second top layer.

[0012] According to the present disclosure, the design of decorative display components can be improved. [Brief description of the drawings]

[0013] [Figure 1] FIG. 1 is a diagram for explaining an embodiment, and is a perspective view that illustrates an example of a decoration system. [Diagram 2] FIG. 2 is a plan view showing the decorative display system of FIG. 1 from the front, showing a state when the light source is turned off. [Diagram 3] FIG. 3 is a plan view showing the decorative display system of FIG. 1 from the front, showing the state when the light source is turned on. [Figure 4] FIG. 4 is a partial cross-sectional view showing the decorative display system of FIG. [Diagram 5] FIG. 5 is a diagram showing an example of a method for manufacturing the decorative film shown in FIG. [Figure 6] FIG. 6 is a diagram showing an example of a method for manufacturing the decorative film shown in FIG. [Figure 7] FIG. 7 is a diagram showing an example of a method for manufacturing the decorative film shown in FIG. [Figure 8] FIG. 8 is a diagram showing an example of a method for manufacturing the decorative film shown in FIG. [Figure 9]FIG. 9 is a diagram showing an example of a method for producing the decorative display component shown in FIG. 4, illustrating preforming. [Figure 10] FIG. 10 is a diagram showing an example of a method for producing the decorative display component shown in FIG. 4, illustrating preforming. [Figure 11] FIG. 11 is a diagram showing an example of a method for producing the decorative display component shown in FIG. 4, illustrating preforming. [Figure 12] FIG. 12 is a diagram showing an example of a method for producing the decorative display component shown in FIG. 4, and is a diagram illustrating preforming. [Figure 13] FIG. 13 is a diagram showing an example of a method for manufacturing the decorative display component shown in FIG. 4, and is a diagram illustrating insert molding. [Figure 14] FIG. 14 is a diagram showing an example of a method for manufacturing the decorative display component shown in FIG. 4, and is a diagram illustrating insert molding. [Figure 15] FIG. 15 is a diagram showing an example of a method for manufacturing the decorative display component shown in FIG. 4, and is a diagram illustrating insert molding. [Figure 16] FIG. 16 is a diagram showing an example of a method for manufacturing the decorative display component shown in FIG. 4, illustrating insert molding. [Figure 17] FIG. 17 is a diagram showing an example of a method for manufacturing the decorative display component shown in FIG. 4, illustrating laser etching. [Figure 18] FIG. 18 is a cross-sectional view showing a cross section similar to that of FIG. 4, illustrating a modified example of the decorative film. [Figure 19] FIG. 19 is a cross-sectional view showing a cross section similar to that of FIG. 4, illustrating another modified example of the decorative film. [Figure 20] FIG. 20 is a cross-sectional view showing a cross section similar to that of FIG. 4, illustrating still another modified example of the decorative film. [Figure 21] FIG. 21 is a cross-sectional view showing a cross section similar to that of FIG. 4, illustrating still another modified example of the decorative film. [Figure 22]FIG. 22 is a cross-sectional view showing a cross section similar to that of FIG. 4, illustrating still another modified example of the decorative film. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] One embodiment of the present disclosure relates to the following [1] to

[22] .

[0015] [1] A decorative film that is laser etched, a first top layer including a cured product of an ionizing radiation curable resin; a transparent second top layer laminated to the first top layer; A decorative film comprising a design layer located between the first top layer and the second top layer.

[0016] [2] The decorative film of [1], wherein the second top layer forms a surface together with the first top layer after the first top layer and the design layer are partially removed by the laser etching.

[0017] [3] A thermoplastic resin layer laminated with the second top layer and containing a thermoplastic resin, The decorative film of [1] or [2], wherein the second top layer is located between the design layer and the thermoplastic resin layer.

[0018] [4] A first top layer comprising a cured product of an ionizing radiation curable resin; a transparent second top layer laminated to the first top layer; a design layer positioned between the first top layer and the second top layer; a thermoplastic resin layer laminated with the second top layer and containing a thermoplastic resin; The second top layer is located between the design layer and the thermoplastic resin layer, forming a decorative film.

[0019] [5] The decorative film according to [3] or [4], wherein the thickness of the thermoplastic resin layer is 100 μm or more and 1000 μm or less.

[0020] [6] The decorative film according to any one of [1] to [5], wherein the second top layer contains an acrylic resin.

[0021] [7] The second top layer has a base layer containing an acrylonitrile butadiene styrene copolymer and a coating layer coating the base layer, The decorative film according to any one of [1] to [6], wherein the covering layer is located between the base layer and the design layer.

[0022] [8] The second top layer has a base layer containing an acrylic resin and a coating layer coating the base layer, The decorative film according to any one of [1] to [6], wherein the covering layer is located between the base layer and the design layer.

[0023] [9] The first top layer has a first layer and a second layer laminated to a portion of the first layer, The first layer and the second layer are laminated with the design layer in this order, The decorative film according to any one of [1] to [8], wherein the first layer has a glossiness different from that of the second layer.

[0024]

[10] The first top layer further has a protruding layer having a plurality of protrusions, The plurality of protrusions are arranged at intervals, The decorative film according to [9], wherein the thickness of the convex portion is 5 μm or more and 50 μm or less.

[0025]

[11] The decorative film according to one embodiment of the present disclosure, wherein the surface formed by the first top layer has projections and recesses.

[0026]

[12] Further comprising a second design layer laminated on the second top layer; The decorative film according to any one of [1] to

[11] , wherein the second top layer is positioned between the design layer and the second design layer.

[0027]

[13] Any of the decorative films [1] to

[12] ; A decorated molded product comprising: a resin portion laminated with the decorative film and containing a thermoplastic resin.

[0028]

[14]

[13] equipped with a decorative molding, The second top layer is a decorative display component exposed from a hole penetrating the first top layer and the design layer.

[0029]

[15] A decorative film; A resin portion that is laminated with the decorative film and contains a thermoplastic resin, The decorative film is a first top layer including a cured product of an ionizing radiation curable resin; a transparent second top layer laminated to the first top layer; a design layer located between the first top layer and the second top layer, The second top layer is located between the design layer and the resin part, The second top layer is a decorative display component exposed from a hole penetrating the first top layer and the design layer.

[0030]

[16] A decorative display part as described in

[14] or

[15] , wherein the second top layer is exposed through holes provided in the first top layer and the design layer to form a surface of the decorative display part.

[0031]

[17] The decorative display part of any one of

[14] to

[16] , wherein the thickness of the resin portion is greater than the thickness of the second top layer.

[0032]

[18] Any of the decorative display parts

[14] to

[17] ; A decorative display system comprising: a light source that irradiates light onto the decorative display component.

[0033]

[19] A process of producing a decorated molded product by bonding a decorative film according to any one of [1] to

[12] and a resin part formed by injection molding; A method for manufacturing a decorative display component, comprising a step of partially removing the first top layer and the decorative layer by laser etching, and forming a portion of the surface with the second top layer.

[0034]

[20] The method for manufacturing a decorative display part according to

[19] , wherein in the step of producing the decorative molded product, heated thermoplastic resin is supplied into a cavity containing the decorative film to produce the decorative molded product.

[0035]

[21] The method further comprises the step of preforming and deforming the decorative film, The method for manufacturing a decorative display part according to

[20] , wherein the preformed decorative film is contained within the cavity.

[0036]

[22] The method further comprises the step of producing the decorative film, The method for producing a decorative display part according to

[19] to

[21] , wherein the process for producing the decorative film includes a process for forming the design layer on a second top layer by printing, and a process for applying and curing a composition containing an ionizing radiation curable resin onto the design layer.

[0037] Hereinafter, an embodiment of the present disclosure will be described with reference to the drawings. In the drawings attached to this specification, the scale and aspect ratio are appropriately changed and exaggerated from those of the actual objects for the convenience of illustration and understanding. In addition, the scale and aspect ratio may differ between the drawings.

[0038] As used in this specification, terms such as "orthogonal" and "same" that specify shapes, geometric conditions, and the extent thereof, as well as length values, are not limited to their strict meanings, but are interpreted to include a range within which similar functions can be expected.

[0039] In this specification, terms such as "film," "sheet," and "plate" are not distinguished from one another solely on the basis of differences in name. For example, a "decorative film" cannot be distinguished from a member called a decorative sheet or decorative plate solely on the basis of differences in name.

[0040] In order to clarify the relationship between directions between the drawings, common directions are indicated in several drawings by arrows with common symbols. The tip of the arrow is one side of each direction. An arrow pointing toward the viewer in a direction perpendicular to the surface of the drawing is indicated by a symbol with a dot in a circle, as shown in Figure 2, for example. An arrow pointing toward the viewer in a direction perpendicular to the surface of the drawing is indicated by a symbol with an x ​​in a circle, as shown in Figure 4, for example.

[0041] 1 to 22 are diagrams for explaining an embodiment of the present invention. Fig. 1 is a perspective view showing a schematic diagram of a specific example of a decorative display system.

[0042] The decorative display component 20 includes a decorative film 40. The decorative film 40 displays a design. The decorative film 40 includes a design layer 60 on which a design expressed by the decorative film 40 is formed. As shown in Figures 1 to 4, the decorative display component 20 includes a design portion 21 and a display portion 22. The design portion 21 is an area in which the design layer 60 is provided. The design portion 21 displays a design by the design layer 60. As shown in Figure 4, the decorative film 40 includes a non-formed portion 42 in which the design layer 60 is not present. The display portion 22 is an area in which the non-formed portion 42 is located. The display portion 22 and the non-formed portion 42 are formed by holes 43 provided in the design layer 60.

[0043] As shown in FIG. 1, the decorative display system 10 has a light source 15 and a decorative display component 20. The light source 15 may be a light emitter such as a light emitting diode (LED) or a cold cathode fluorescent lamp. The light source 15 may have a light emitter and an optical member that adjusts the orientation of light from the light emitter. The light source 15 may be a surface light source device that emits light in a planar manner. As shown in FIG. 1 and FIG. 4, the light source 15 is covered by the decorative display component 20 from the third direction D3. The light source 15 is hidden by the decorative film 40 from an observer who observes the decorative film 40. As shown in FIG. 4, the light source 15 faces the display unit 22 of the decorative display component 20 in the third direction D3.

[0044] FIG. 2 shows a state in which the light source 15 is turned off. The area in which the light source 15 is arranged may be covered by the decorative display component 20 or a member located around the decorative display component 20. The area in which the light source 15 is arranged is covered and darkened by the decorative display component 20. At this time, the design portion 21 of the decorative display component 20 is observed as being dark. Therefore, the decorative display component 20 conceals the light source 15, and the display portion 22 becomes less noticeable. The observer can easily observe the design displayed by the decorative film 40 on the design portion 21 of the decorative display component 20. In the illustrated example, a wood grain pattern is expressed by the decorative film 40.

[0045] 3 shows a state in which the light source 15 is turned on. The display portion 22 of the decorative display component 20 is transparent to visible light. Therefore, the light from the light source 15 passes through the design portion 21. This allows the observer to observe the display portion 22 brightly. That is, the pattern of the display portion 22 is displayed. In the illustrated example, a cross, a triangle, and a square are displayed.

[0046] As used herein, the term "visible light transmissive" means that the visible light transmittance is 50% or more, and preferably 80% or more. The term "transparent" used for the components included in the decorative display component means that the display unit 22 has a transmissivity that can impart visible light transmissivity. The second top layer 55 described later is transparent if the display unit 22 partially constituted by the second top layer 55 has visible light transmissivity. The term "visible light blocking" means that the visible light transmittance is 5% or less, and preferably 1% or less. The visible light transmittance is specified as the average value of the total light transmittance at each wavelength when measured at an incident angle of 0° at every 1 nm within a measurement wavelength range of 380 nm to 780 nm using a spectrophotometer (Shimadzu Corporation's "UV-3100PC", compliant with JIS K 0115).

[0047] The decorative display system 10 can be applied to various applications. The decorative display system 10 may be applied to the interior or exterior of a moving body. A moving body is a device that can move. Examples of moving bodies include automobiles, ships, airplanes, railroad cars, drones, robots, and the like. As a specific example, the decorative display system 10 may be applied to the interior or exterior of an automobile. The decorative display system 10 may be applied to walls, doors, ceilings, and the like as the interior of a building. The decorative display system 10 may be applied to various devices such as furniture and home appliances. As a more specific example, the decorative display system 10 may be applied to a desk. The decorative display system 10 may be applied to the casing of equipment such as a refrigerator.

[0048] In one embodiment, which will be described in detail below, a measure is taken to improve the design of the decorative display component 20. More specifically, the measure is taken to arrange the display unit 22 at an appropriate position on the decorative display component 20. In this embodiment, the display unit 22 of the decorative display component 20 is arranged at an appropriate position, and this makes it possible to avoid deterioration of the design of the decorative display component 20.

[0049] Hereinafter, an embodiment will be described in detail with reference to the illustrated example.

[0050] The decorative display component 20 shown in FIG. 1 is spread out in a sheet-like shape when observed from a global perspective. The decorative display component 20 spreads out in a first direction D1 and a second direction D2. The components 32 and 40 of the decorative display component 20 are stacked in a third direction D3. The components 50, 60, 55 and 70 of the decorative film 40 are stacked in the third direction D3. That is, the third direction D3 is the stacking direction. In the illustrated example, the first direction D1, the second direction D2 and the third direction D3 are perpendicular to each other.

[0051] The decorative display component 20 is disposed so as to overlap the light source 15. As shown in FIG. 3, the decorative display component 20 has a design portion 21 and a display portion 22. The display portion 22 faces the light source 15 in the third direction D3. The display portion 22 has visible light transmissivity. When the display portion 22 is illuminated by light from the light source 15, the pattern of the display portion 22 is observed brightly. Meanwhile, the decorative display component 20 displays a design in the design portion 21. That is, the decorative display component 20 displays a design in the design portion 21 and a specific pattern in the display portion 22. The decorative display component 20 may have visible light blocking properties in the design portion 21. According to this example, when the light source 15 is turned on, the clarity of the display in the pattern corresponding to the pattern of the display portion 22 can be improved. The thickness of the decorative display component 20 in the third direction D3 may be 0.5 mm or more and 10 mm or less.

[0052] There is no particular limitation on the pattern of the display unit 22. The pattern of the display unit 22 can be appropriately selected depending on the target to be displayed by lighting the light source 15. The display unit 22 may have a pattern that represents a figure, a design, a character, a mark, a pictogram, letters, numbers, or the like.

[0053] As shown in FIG. 4, the decorative display component 20 has a decorative film 40 and a resin part 32. The resin part 32 may be formed by injection molding. The decorative film 40 and the resin part 32 are laminated in the third direction D3. The decorative film 40 has a first top layer 50, a design layer 60, and a second top layer 55. The first top layer 50, the design layer 60, and the second top layer 55 are laminated in this order in the third direction D3. In the illustrated example, the decorative film 40 further has a thermoplastic resin layer 70. The thermoplastic resin layer 70 functions as a backer layer that reinforces the decorative film 40. The thermoplastic resin layer 70 is laminated with the second top layer 55 in the third direction D3. The thermoplastic resin layer 70 is located between the second top layer 55 and the resin part 32 in the third direction D3.

[0054] The first top layer 50 forms the surface of the decorative display component 20 facing the viewer. The first top layer 50 is transparent. The transparent first top layer 50 allows for transmission observation of the design layer 60. That is, the viewer can observe the design displayed by the design layer 60 through the first top layer 50. The first top layer 50 has physical properties required for a surface. For example, the first top layer 50 may be excellent in one or more of scratch resistance, abrasion resistance, chemical resistance, stain resistance, light resistance, heat resistance, and moisture resistance. The thickness of the first top layer 50 in the third direction D3 may be 1 μm or more and 1000 μm or less.

[0055] The first top layer 50 contains a cured product of an ionizing radiation curable resin. The cured product of an ionizing radiation curable resin is a product obtained by curing a composition containing an ionizing radiation curable resin through crosslinking. The ionizing radiation curable resin has an energy quantum capable of crosslinking and polymerizing molecules in electromagnetic waves or charged particle beams. The ionizing radiation curable resin is cured through crosslinking by irradiation with ultraviolet rays, electron beams, or the like. The cured product of an ionizing radiation curable resin is a product obtained by curing a composition containing an ionizing radiation curable resin through crosslinking.

[0056] The ionizing radiation curable resin may be appropriately selected from commonly used polymerizable monomers and polymerizable oligomers or prepolymers. The ionizing radiation curable resin may be an ultraviolet curable resin that is cured by irradiation with ultraviolet rays or an electron beam curable resin that is cured by irradiation with electron beams. The composition containing the ionizing radiation curable resin may also contain a thermoplastic resin or a thermosetting resin.

[0057] The composition containing the ionizing radiation curable resin may contain additives according to the physical properties required for the first top layer 50 depending on the application of the decorative display component 20. Examples of additives include abrasion resistance improvers, polymerization inhibitors, crosslinking agents, ultraviolet absorbers, infrared absorbers, antistatic agents, adhesion improvers, light stabilizers, leveling agents, coupling agents, plasticizers, colorants, and the like.

[0058] The composition containing the ionizing radiation curable resin may contain a matting agent. The matting agent can adjust the gloss of the first top layer 50. Examples of the matting agent include inorganic particles such as silica particles, calcium carbonate particles, barium sulfate particles, alumina particles, and glass balloon particles, and resin particles such as urethane beads, acrylic beads, silicone beads, and styrene beads.

[0059] The design layer 60 has a design formed thereon. The design layer 60 may have a design such as a figure, a pattern, a design, a color, a picture, a photograph, a character, a mark, a pictogram, a letter, or a number. The design layer 60 may have a design expression that displays a background. For example, the design layer 60 may display a wood grain or marble pattern, a metallic texture, or a geometric pattern as a design that can harmonize the decorative film 40 with the surrounding environment in which the decorative display system 10 is installed. The design layer 60 may be formed by printing. The design layer 60 may also be formed by transfer printing. The thickness of the design layer 60 in the third direction D3 may be 1 μm or more and 30 μm or less.

[0060] The design layer 60 may have a binder resin and a coloring material dispersed in the binder resin. The coloring material may be a pigment, a dye, or a combination of a pigment and a dye. Examples of binder resins include acrylic resins such as polymethyl methacrylate, polyurethane resins, vinyl chloride-vinyl acetate copolymers, vinyl chloride-vinyl acetate-acrylic copolymers, chlorinated polypropylene resins, polyester resins, polyamide resins, butyral resins, polystyrene resins, nitrocellulose resins, and cellulose acetate resins. These materials may be used alone or in combination of two or more.

[0061] As shown in FIG. 2 to FIG. 4, the decorative film 40 has a non-forming portion 42 where the first top layer 50 and the design layer 60 are not provided. The first top layer 50 and the design layer 60 are provided with holes 43. The non-forming portion 42 may be constituted by the holes 43. The first top layer 50 and the design layer 60 are not laminated on the entire surface of the second top layer 55. The first top layer 50 and the design layer 60 are laminated on a part of the second top layer 55. The display portion 22 of the decorative display component 20 is formed in the region where the non-forming portion 42 of the decorative film 40 is located. In other words, the display portion 22 of the decorative display component 20 is formed in the region where the holes 43 are provided in the first top layer 50 and the design layer 60. In the display portion 22, the second top layer 55 is exposed. In the display portion 22, the second top layer 55 forms the surface of the decorative display component 20 together with the first top layer 50. The decorative display component 20 has visible light transparency in the display portion 22. The design portion 21 of the decorative display component 20 is formed in the region where the first top layer 50 and the design layer 60 are located.

[0062] The second top layer 55 is transparent and provides visible light transmittance to the display portion 22 of the decorative display component 20. The visible light transmittance of the second top layer 55 may be 50% or more. The thickness of the second top layer 55 along the third direction D3 may be 1 μm or more, or 5 μm or more. By setting a lower limit to the thickness of the second top layer 55, it is possible to suppress the formation of through holes in the second top layer 55 by laser etching, which will be described later. The thickness of the second top layer 55 along the third direction D3 may be 500 μm or less, or 300 μm or less. By setting an upper limit to the thickness of the second top layer 55, it is possible to improve the formability of the decorative film 40.

[0063] The second top layer 55 forms the viewer-side surface of the display part 22 of the decorative display component 20. The second top layer 55 has physical properties required for a surface. For example, the second top layer 55 may be excellent in one or more of scratch resistance, abrasion resistance, chemical resistance, stain resistance, light resistance, heat resistance, and moisture resistance.

[0064] The second top layer 55 may be a film. The second top layer 55 as a film is easy to handle. The second top layer 55 may be a resin film. The second top layer 55 preferably contains a thermoplastic resin in terms of excellent formability, and is more preferably made of a thermoplastic resin. Examples of thermoplastic resins include acrylic resins, polyolefin resins such as polypropylene and polyethylene, polycarbonate, acrylonitrile butadiene styrene copolymers (hereinafter also referred to as "ABS resins"), and vinyl chloride resins. The second top layer 55 may include two or more layers formed of these materials.

[0065] In applications to automobile interior materials, the second top layer 55 may be an acrylic resin film, more specifically, a polymethyl methacrylate film. Acrylic resins such as polymethyl methacrylate have the physical properties required for the surface layer of automobile interior materials.

[0066] The second top layer 55 may contain additives according to the physical properties required for the second top layer 55 depending on the application of the decorative display component 20. Examples of additives include abrasion resistance improvers, ultraviolet absorbers, infrared absorbers, antistatic agents, adhesion improvers, colorants, and the like. The second top layer 55 may contain a matting agent. The gloss level of the design layer 60 can be adjusted by the matting agent. Examples of matting agents include inorganic particles such as silica particles, calcium carbonate particles, barium sulfate particles, alumina particles, and glass balloon particles, and resin particles such as urethane beads, acrylic beads, silicone beads, and styrene beads.

[0067] As shown by the two-dot chain line in FIG. 4, the second top layer 55 may have a base layer 55a and a covering layer 55b covering the base layer 55a. As shown by the two-dot chain line in FIG. 4, the covering layer 55b is located between the design layer 60 and the base layer 55a in the third direction D3. The covering layer 55b forms the surface of the decorative display component 20 in the display section 22 of the decorative display component 20. The covering layer 55b has physical properties required for the surface. An acrylic resin is exemplified as a material for the base layer 55a from the viewpoint of obtaining good transparency. On the other hand, the base layer 55a may have physical properties with excellent moldability. An ABS resin or a vinyl chloride resin, which has better moldability than an acrylic resin, is exemplified as a material for the base layer 55a.

[0068] The base layer 55a may be a film. The second top layer 55 as a film is easy to handle. The second top layer 55 may be a resin film. The cover layer 55b may be formed on the base layer 55a made of a resin film.

[0069] The coating layer 55b may include a cured product of a resin composition including a thermoplastic resin and an ionizing radiation curable resin. The ratio of the ionizing radiation curable resin to the thermoplastic resin may be 10:90 to 25:75 by mass.

[0070] Examples of the thermoplastic resin include acrylic resin, acrylic-modified polyolefin resin, chlorinated polyolefin resin, vinyl chloride-vinyl acetate copolymer, thermoplastic urethane resin, thermoplastic polyester resin, polyamide resin, etc. As the thermoplastic resin, acrylic resin is particularly preferable. Examples of the acrylic resin include a homopolymer of (meth)acrylic acid ester, a copolymer of two or more different (meth)acrylic acid ester monomers, or a copolymer of (meth)acrylic acid ester and another monomer.

[0071] The ionizing radiation curable resin may contain one or more of a polyfunctional (meth)acrylate oligomer and a polyfunctional (meth)acrylate monomer. The ionizing radiation curable resin may contain an oligomer and / or a monomer having a polymerizable unsaturated bond in the molecule.

[0072] As the oligomer, a (meth)acrylate oligomer having a radical polymerizable unsaturated group in the molecule is suitable, and among them, a polyfunctional (meth)acrylate oligomer having two or more (two or more functional) polymerizable unsaturated bonds in the molecule is preferred. Examples of the polyfunctional (meth)acrylate oligomer include polycarbonate (meth)acrylate, urethane (meth)acrylate, epoxy (meth)acrylate, polyester (meth)acrylate, and polyether (meth)acrylate.

[0073] As the monomer used as the ionizing radiation curable resin, a (meth)acrylate monomer having a radical polymerizable unsaturated group in the molecule is suitable, and among them, a polyfunctional (meth)acrylate monomer is preferred. Examples of the polyfunctional (meth)acrylate monomer include ethylene glycol di(meth)acrylate, propylene glycol di(meth)acrylate, 1,4-butanediol di(meth)acrylate, 1,6-hexanediol di(meth)acrylate, neopentyl glycol di(meth)acrylate, trimethylolpropane tri(meth)acrylate, dipentaerythritol tri(meth)acrylate, pentaerythritol tri(meth)acrylate, and dipentaerythritol hexa(meth)acrylate.

[0074] The thermoplastic resin layer 70 provides strength to the decorative film 40. The thickness of the thermoplastic resin layer 70 along the third direction D3 may be 100 μm or more, 200 μm or more, 350 μm or more, or 450 μm or more. The thickness of the thermoplastic resin layer 70 may be determined so that the total thickness of the decorative film 40 along the third direction D3 is 200 μm or more, 300 μm or more, 450 μm or more, 475 μm or more, or 600 μm or more. The thickness of the thermoplastic resin layer 70 may be 1000 μm or less. The thermoplastic resin layer 70 is transparent and provides visible light transmittance to the display portion 22 of the decorative display component 20. The visible light transmittance of the thermoplastic resin layer 70 may be 50% or more.

[0075] The thermoplastic resin layer 70 preferably contains a thermoplastic resin, and more preferably is made of a thermoplastic resin, in terms of excellent moldability. Examples of the thermoplastic resin include acrylic resin, polyolefin resin such as polypropylene or polyethylene, polycarbonate, ABS resin, and polyvinyl chloride resin. The thermoplastic resin layer 70 may include two or more of these layers.

[0076] As indicated by the two-dot chain line in Fig. 4, the thermoplastic resin layer 70 may have a main body portion 70a and an adhesive layer 70b. In this example, the thermoplastic resin layer 70 is bonded to the second top layer 55 by the adhesive layer 70b. The main body portion 70a may be made of the same material as that of the thermoplastic resin layer 70 described above. The adhesive layer 70b may be made of a material having self-adhesive properties, such as polypropylene or polyethylene.

[0077] In the present specification, there is no distinction between "adhesion" and "bonding." Furthermore, "bonding" includes "adhesion," "adhesion," "welding," and the like.

[0078] The resin part 32 is bonded to the decorative film 40. The resin part 32 is produced by injection molding in a state where it is bonded to the decorative film 40. In the illustrated example, the resin part 32 is bonded to the thermoplastic resin layer 70. The resin part 32 is transparent and provides visible light transmittance to the display part 22 of the decorative display component 20. The visible light transmittance of the resin part 32 may be 50% or more. The resin part 32 is made of a thermoplastic resin suitable for injection molding. Examples of materials for the resin part 32 include polycarbonate resin, acrylic resin such as polymethyl methacrylate, ABS resin, etc.

[0079] The decorative display component 20 shown in FIG. 1 is spread out in a sheet-like shape when observed from a global perspective. The decorative display component 20 spreads out in a first direction D1 and a second direction D2. The components 32 and 40 of the decorative display component 20 are stacked in a third direction D3. The components 50, 60, 55 and 70 of the decorative film 40 are stacked in the third direction D3. That is, the third direction D3 is the stacking direction. In the illustrated example, the first direction D1, the second direction D2 and the third direction D3 are perpendicular to each other.

[0080] As shown in Fig. 1, the decorative display component 20 has a three-dimensional shape. More specifically, the decorative display component 20 is bent on both sides in the first direction D1. The decorative display component 20 can have various shapes, without being limited to the illustrated example. In the example shown in Fig. 1, the resin part 32 is in the form of a sheet that spreads along the decorative display component 20. The resin part 32 is not limited to the illustrated example, and may have a part that extends independently of the decorative display component 20, such as a fixing claw for attaching the decorative display component 20 to an installation target location.

[0081] Next, an example of a method for manufacturing the decorative display component 20 will be described.

[0082] In the method described below, a decorative film 40 without holes 43 is first produced. That is, the produced decorative film 40 does not include a non-forming portion 42. Next, the decorative film is joined to a resin portion 32 formed by injection molding to produce a decorative molded product 30. After that, the first top layer 50 and the design layer 60 of the decorative film 40 are partially removed by laser etching. A hole 43 is formed in the decorative film 40 by laser etching. This hole 43 constitutes the non-forming portion 42. In this manner, the decorative display component 20 is produced. A portion of the surface of the decorative display component 20 that faces the viewer is formed by the second top layer 55 exposed in the hole 43 that constitutes the non-forming portion 42.

[0083] In the manufacturing method described below, heated thermoplastic resin is supplied into the cavity 92 containing the decorative film 40 to produce the decorated molded product 30. In addition, in the manufacturing method described below, the decorative film 40 is preformed and deformed, and the deformed decorative film 40 is contained in the cavity 92. Each step will be described in more detail.

[0084] First, a sheet for forming the second top layer 55 is prepared. The material and thickness of the second top layer 55 are as described above. Next, as shown in FIG. 5, the design layer 60 is formed on the second top layer 55 by printing, transfer, or the like. The material and thickness of the design layer 60 are as described above. Thereafter, as shown in FIG. 6, the first top layer 50 is formed on the design layer 60. The first top layer 50 is formed by applying a composition containing an ionizing radiation curable resin to the design layer 60. Next, the composition on the design layer 60 is cured by irradiating the composition with ionizing radiation. This results in the first top layer 50 made of a cured product of the ionizing radiation curable resin. As a result, the laminate 35 shown in FIG. 6 is obtained. The obtained laminate 35 has the second top layer 55, the design layer 60, and the first top layer 50 laminated in the following order in the third direction D3.

[0085] Thereafter, as shown in FIG. 7, a thermoplastic resin layer 70 is provided on the second top layer 55 of the laminate 35. As an example, the sheet-like thermoplastic resin layer 70 may be bonded to the second top layer 55 by thermal lamination. In this example, a sheet of thermoplastic resin for forming the thermoplastic resin layer 70 is first prepared. The material and thickness of the thermoplastic resin layer 70 are as described above. In the example shown in FIG. 8, the laminate 35 and the thermoplastic resin layer 70 are transported between the first roll 81 and the second roll 82. The first roll 81 and the second roll 82 are heated, for example, by a built-in heating device (not shown). The first roll 81 and the second roll 82 push the laminate 35 and the thermoplastic resin layer 70 toward each other. When passing between the first roll 81 and the second roll 82, the thermoplastic resin layer 70 is pushed toward the laminate 35 while being heated. This causes the laminate 35 and the thermoplastic resin layer 70 to be welded together. As a result, the decorative film 40 shown in FIG. 7 is obtained. The obtained decorative film 40 has a thermoplastic resin layer 70, a second top layer 55, a design layer 60, and a first top layer 50 laminated in the following order in the third direction D3. However, the obtained decorative film 40 does not have holes 43 and non-formed portions 42.

[0086] As described above, the thermoplastic resin layer 70 may have the main body portion 70a and the adhesive layer 70b. By using the adhesive layer 70b, the adhesion between the laminate 35 and the thermoplastic resin layer 70 can be improved.

[0087] Next, as shown in Figs. 9 to 12, the decorative film 40 is preformed. In this preformation, the decorative film 40 is plastically deformed to give the decorative film 40 a desired shape. The decorative film 40 is plastically deformed by the preformation. The decorative film 40 has a large thickness due to the thermoplastic resin layer 70. Therefore, the decorative film 40 can maintain the shape after the preformation. The decorative film 40 after the preformation has a shape close to the shape of the intended decorative display component 20. In the example shown in Figs. 9 to 12, vacuum forming is performed as the preformation. However, this is not limited to this example, and various forming processes such as compressed air forming, TOM forming, and bending forming may be performed as the preformation. In addition, machining such as cutting may be performed on the decorative film 40. Furthermore, the preformation may be omitted.

[0088] In the illustrated vacuum forming of the decorative film 40, as shown in FIG. 9, the decorative film 40 is heated and softened by a heater 86 of a vacuum forming device 85. The decorative film 40 is placed near a mold 87 of the vacuum forming device 85. Next, as shown in FIG. 10, the decorative film 40 is vacuum-suctioned through a large number of small holes (not shown) provided in the mold 87. As a result, the decorative film 40 can be formed into a shape that matches the shape of the mold 87. That is, the shape of the decorative film 40 is a shape that follows the mold 87. Then, the temperature of the decorative film 40 is lowered. The decorative film 40 solidifies in the shape after molding. Next, as shown in FIG. 11, the decorative film 40 is removed from the mold 87. Then, as shown in FIG. 12, unnecessary parts are removed from the decorative film 40 removed from the mold 87.

[0089] Up to the trimming in the preliminary forming step shown in FIG. 12, multiple decorative films 40 can be manufactured as long, unseparated sheets by roll-to-roll. According to the roll-to-roll manufacturing method, a long decorative film 40 can be supplied to the preliminary forming step. Therefore, the yield can be improved and the manufacturing cost can be reduced. In particular, when the design layer 60 is produced by printing using a roll plate, a high yield can be achieved regardless of the relationship between the diameter of the roll plate and the dimensions of the final product. However, unlike the above description, the decorative film 40 may be produced in a sheet form up to the trimming in the forming step.

[0090] Next, the decorated molded product 30 is manufactured using the preformed decorative film 40. First, as shown in FIG. 13, an injection molding apparatus 90 is prepared. The injection molding apparatus 90 has a molding die 91. The molding die 91 includes a first die 91A and a second die 91B. The first die 91A and the second die 91B can be separated from each other as shown in FIG. 13, and can be brought close to each other as shown in FIG. 14. As shown in FIG. 14, in a closed mold state in which the first die 91A and the second die 91B are in contact with each other, a cavity 92 is formed between the first die 91A and the second die 91B. The molding die 91 has a gate 93 that communicates with the cavity 92. The gate 93 is connected to a supply device for the injection resin 33 (not shown). The injection resin 33 is supplied into the cavity 92 through the gate 93. The first die 91A and the second die 91B are heated by a heater (not shown) and maintained at a high temperature.

[0091] As shown in FIG. 14, the decorative film 40 is accommodated in a cavity 92 in a molding die 91. In the illustrated example, the decorative film 40 is placed in the cavity 92 so that the decorative film 40 contacts the first die 91A and the thermoplastic resin layer 70 is exposed in the cavity 92. Next, as shown in FIG. 15, the molten injected resin 33 is injected into the cavity 92 through a gate 93. The injected resin 33 is cooled in the cavity 92 and melted to the decorative film 40 to solidify. From the solidified injected resin 33, a resin part 32 bonded to the thermoplastic resin layer 70 of the decorative film 40 is obtained. The material and thickness of the resin part 32 are as described above.

[0092] 16, the first die 91A and the second die 91B are separated from each other. The decorated molded article 30 including the decorative film 40 and the resin part 32 is removed from the cavity 92. In this manner, the decorated molded article 30 having the decorative film 40 and the resin part 32 is obtained.

[0093] Next, a hole 43 is formed in the decorative film 40. By providing the hole 43 in the decorative film 40, a non-forming portion 42 is formed in the decorative film 40. As an example, as shown in FIG. 17, the hole 43 and the non-forming portion 42 may be formed by laser etching using a laser irradiation device 80. In the example shown in FIG. 17, the laser light emitted from the laser irradiation device 80 is irradiated onto the decorative film 40 of the decorative molded product 30. In the illustrated example, the laser light is incident on the decorative molded product 30 from the first top layer 50 of the decorative film 40. By adjusting the focusing position of the laser light emitted from the laser irradiation device 80 according to the distance from the laser irradiation device 80 to the first top layer 50 and the design layer 60 of the decorative molded product 30, only the first top layer 50 and the design layer 60 can be removed. In addition, the second top layer 55 has transparency to the laser light, so that the removal of the second top layer 55 can be suppressed. This allows the first top layer 50 and the design layer 60 to be removed while leaving the second top layer 55. When the first top layer 50 and the design layer 60 are removed, the second top layer 55 is exposed. The second top layer 55 exposed in the holes 43 and non-forming portions 42 of the decorative film 40 forms the surface of the decorative display component 20.

[0094] The laser light used for the laser etching is not particularly limited. Laser light emitted from various types of laser light sources can be used. The wavelength of the laser light used for the laser etching is also not particularly limited. The laser light may have a wavelength in the visible light range or in the infrared range. Preferably, a laser light having a high absorption rate in the design layer 60 and a low absorption rate in the second top layer 55 is used.

[0095] The above-described laser etching allows the holes 43 and the non-formed portions 42 to be formed in the decorative film 40. This allows the decorative display component 20 to be produced from the decorative molded product 30. The decorative display component 20 produced in this manner, together with the light source 15, constitutes the decorative display system 10 shown in Figs. 1 to 4. As shown in Fig. 4, the light source 15 faces the display section 22 of the decorative display component 20 in the third direction D3. As shown in Fig. 3, when the light source 15 is turned on, the light from the light source 15 passes through the display section 22 of the decorative display component 20. This allows the display section 22 to be displayed brighter than in the state of Fig. 2 in which the light source 15 is turned off.

[0096] The decorative display system 10 can be installed while ensuring harmony and uniformity with the surrounding environment by the design expression of the decorative film 40 using the design layer 60. Recently, the range of application of the decorative display system 10 has been expanding rapidly, and by using the decorative display component 20, the decorative display system 10 can be applied to the interior of automobiles, the interior of buildings, furniture, home appliances, etc., where design is important.

[0097] Incidentally, conventional decorative display parts have been manufactured by using a decorative film having a printed decorative portion and a non-decorated portion not printed for insert molding. In this conventional example, it is necessary to position the decorative film having the decorative portion and the non-decorated portion relative to a mold used for insert molding. When premolding is performed before insert molding, it is necessary to position the decorative film having the decorative portion and the non-decorated portion relative to an apparatus used for premolding. As another conventional manufacturing method, a decorative display part can be manufactured by attaching a decorative film having a decorative portion and a non-decorated portion to a resin part that has been molded in advance. In this conventional example, it is necessary to position the decorative film relative to the resin part. It is not easy to position a flat decorative film relative to the apparatus or the resin part while checking the position of the non-decorated portion of the decorative film. If the positioning is insufficient, the position of the display part in the obtained decorative display part will be shifted. As a result, the design expression by the design part becomes insufficient, and the design of the decorative display part is impaired. It is also possible that the relative positions of the display part of the decorative display component and the light source become inappropriate, in which case the pattern of the display part cannot be displayed properly by effectively using the light from the light source, resulting in a deterioration in the design of the decorative display component.

[0098] In response to such conventional problems, according to the present embodiment, the decorative film 40 before the holes 43 and the non-forming portion 42 are formed is used for preforming and insert molding. The holes 43 and the non-forming portion 42 are formed in the decorative film 40 bonded to the resin portion 32. Therefore, it is not necessary to check the pattern of the decorative film 40 and position the flat decorative film 40 in the vacuum forming device 85 or the injection molding device 90. Although it is necessary to position the decorative molded product 30 when laser etching it, since the decorative molded product 30 has undergone molding processing, the decorative molded product 30 having a three-dimensional shape can be easily and accurately positioned in the laser irradiation device 80. Therefore, the first top layer 50 and the design layer 60 can be removed from the desired area of ​​the decorative molded product 30 with high accuracy. As a result, the display portion 22, which is the non-forming portion of the first top layer 50 and the design layer 60, can be formed in an appropriate position of the decorative molded product 30. As a result, the expected design can be stably and easily imparted to the decorative display component 20, and the design of the decorative display component 20 can be improved.

[0099] Furthermore, the conventional technology has the following problems. In conventional manufacturing methods, a decorative film having a decorated portion and a non-decorated portion stretches during insert molding or attachment to a resin portion. The stretching depends on the final shape of the decorative display part and is usually non-uniform. Depending on the non-uniformity and magnitude of the stretching, the shape of the non-decorated portion of the decorative film is deformed. Therefore, with conventional decorative display parts, it is difficult to display a desired pattern when the resin portion has a complex three-dimensional shape.

[0100] On the other hand, according to this embodiment, the holes 43 and the non-formed portions 42 are formed by laser etching in the decorative film 40 that is joined to the resin portion 32 and spreads along the outer surface of the resin portion 32. Therefore, unlike conventional decorative display components, the present embodiment does not suffer from the problem of stretching. The holes 43 and the non-formed portions 42 can be formed in the desired shape, and thus can be displayed in the desired pattern.

[0101] Furthermore, the conventional technology has the following drawbacks: The edges of the decorative portion formed by printing in the conventional decorative display components meander minutely and become unclear. Therefore, in the conventional decorative display components, the display observed when the light source is turned on may also become unclear.

[0102] On the other hand, according to the present embodiment, the holes 43 and the non-formed portions 42 are formed by laser etching. Therefore, the edges of the first top layer 50 and the design layer 60 connected to the non-formed portions 42 can be made clear. This makes the display observed when the light source 15 is turned on clearer.

[0103] Furthermore, the conventional technology has the following problems. In the conventional decorative display parts, the decorative film can be produced by printing using a roll plate. The conventional decorative film obtained has non-decorated parts at regular intervals in a long state before cutting. Therefore, depending on the dimensions of the decorative display parts actually produced, the yield of the conventional decorative film can be significantly reduced.

[0104] On the other hand, according to the present embodiment, the holes 43 and the non-formed portions 42 can be formed in desired regions of the decorative film 40 bonded to the resin portion 32. Therefore, regardless of the dimensions of the decorative display component 20, the yield of the decorative film 40 can be significantly improved.

[0105] As shown in FIG. 4, in the decorative display system 10, the first top layer 50 forms the surface of the decorative display component 20 in the design part 21. The first top layer 50 is a layer containing a cured product of an ionizing radiation curable resin, and has physical properties required as a surface layer. In the illustrated decorative display system 10, the second top layer 55 is exposed in the display part 22 and forms the surface of the decorative display component 20. Therefore, the second top layer 55 may be made using a material having physical properties required as a surface layer of the decorative display component 20. The second top layer 55 may have a base layer 55a and a coating layer 55b, and the coating layer 55b may have physical properties required as a surface layer of the decorative display component 20. According to these examples, it is possible to eliminate the need to provide a protective layer such as a coating film on the decorative display component 20 after laser etching.

[0106] As an example, the second top layer 55 and the covering layer 55b may be formed of an acrylic resin, more specifically, polymethyl methacrylate. Acrylic resins such as polymethyl methacrylate have a long track record of being used as surface layers of interior materials, for example, surface layers of interior materials used in automobiles, and have the physical properties required for interior materials.

[0107] In addition, if a protective layer such as a coating film is provided on the decorative display component 20 after laser etching, the surface of the decorative display component 20 will be flattened. Since it is not necessary to provide a protective layer after laser etching, the surface of the decorative display component 20 can be made uneven by the first top layer 50. Accordingly, further ingenuity for improving the design can be applied to the decorative display component 20.

[0108] As an example, as shown in FIG. 18, the first top layer 50 may have a first layer 51 laminated with the design layer 60 and a second layer 52 laminated with a part of the first layer 51. In this example, the second layer 52 is disposed on a part of the first layer 51. The first layer 51 and the second layer 52 are laminated on the design layer 60 in this order. At least a part of the first layer 51 is not covered by the second layer 52 and can form the surface of the decorative display component 20. The first layer 51 and the second layer 52 are layers having different glossiness. Both the first layer 51 and the second layer 52 contain a cured product of an ionizing radiation curable resin. The glossiness of the first layer 51 and the glossiness of the second layer 52 may be different. For example, the first layer 51 and the second layer 52 contain different amounts of the above-mentioned matting agent such as inorganic particles or resin particles, so that the glossiness of the first layer 51 and the glossiness of the second layer 52 can be different values. By including different types of particles, the glossiness of the first layer 51 and the glossiness of the second layer 52 can be different. The first layer 51 may include inorganic particles, and the second layer 52 may include resin particles. By including matting agents with different average particle sizes in the first layer 51 and the second layer 52, the glossiness of the first layer 51 and the glossiness of the second layer 52 can be different. Two or more of the above-mentioned methods for making the glossiness of the first layer 51 and the glossiness of the second layer 52 different may be adopted. The glossiness of the first layer 51 may be higher than that of the second layer 52. The glossiness of the second layer 52 may be higher than that of the first layer 51. The glossiness is a value measured using a gloss meter (VG7000) manufactured by Nippon Denshoku Industries Co., Ltd. at an incident angle of 20° in accordance with JISZ8741. For example, when the design layer 60 displays a wood grain pattern, the first layer 51 having a low glossiness may be exposed due to the vessel portion of the wood grain pattern, and the second layer 52 having a high glossiness may be provided on the portion other than the vessel portion of the wood grain pattern. According to this example, by arranging the second layer 52 according to the design displayed by the design layer 60, the design such as the wood grain pattern can be further improved.

[0109] The ten-point mean roughness RzJIS of the first layer 51 may be 0.7 μm or more and 5 μm or less. The ten-point mean roughness RzJIS of the second layer 52 may be 2 μm or more and 7 μm or less. The ten-point mean roughness RzJIS of the second layer 52 may be larger than the ten-point mean roughness RzJIS of the first layer 51. The ten-point mean roughness RzJIS of the second layer 52 may be larger than the ten-point mean roughness RzJIS of the first layer 51, and the difference between the ten-point mean roughness RzJIS of the second layer 52 and the ten-point mean roughness RzJIS of the first layer 51 may be 0.7 μm or more. By setting the ten-point mean roughness RzJIS of the first layer 51 and the ten-point mean roughness RzJIS of the second layer 52 as described above, the design can be improved. For example, in combination with a design layer such as a wood grain pattern, the artificial impression can be weakened and a natural texture can be created. The ten-point average roughness RzJIS is the ten-point average roughness specified in JIS B 0601:2001.

[0110] Furthermore, as shown in FIG. 19, the decorative film 40 may further include a protruding layer 53 laminated on the second layer 52. The protruding layer 53 has a plurality of protruding portions 53a arranged at intervals. In the illustrated example, the second layer 52 is located between the protruding layer 53 and the design layer 60. The protruding layer 53 provides an excellent tactile sensation. From the viewpoint of providing an excellent tactile sensation, the thickness of the protruding portions 53a along the third direction D3 may be 5 μm or more, 10 μm or more, or 20 μm or more. From the viewpoint of providing an excellent tactile sensation, the thickness of the protruding layer 53 along the third direction D3 may be 50 μm or less.

[0111] In the example shown in Fig. 19, the protruding layer 53 is located on the outermost surface side in the third direction D3, but this is not limited to this example. The protruding layer 53 may be located between the first layer 51 and the second layer 52. The protruding layer 53 may be located between the first layer 51 and the design layer 60. In the example shown in Fig. 19, the protruding layer 53 is used in combination with the first top layer 50 including the first layer 51 and the second layer 52, but this is merely one example. The protruding layer 53 may be used in combination with the first top layer 50 consisting of a single layer.

[0112] The raised layer 53 may be produced by forming the protruding portions 53a by printing a coating liquid containing inorganic particles. The raised layer 53 may be produced by forming the protruding portions 53a by embossing. When the protruding portions 53a are formed by embossing, the protruding portions 53a may be formed integrally with the first layer 51.

[0113] In the embodiment described above, the decorative film 40 is a decorative film to be laser etched, and has a first top layer 50 containing a cured product of an ionizing radiation curable resin, a transparent second top layer 55 laminated with the first top layer 50, and a design layer 60 located between the first top layer 50 and the second top layer 55. The decorative molded product 30 has a decorative film 40 and a resin part 32 laminated with the decorative film 40. The decorative display part 20 has a decorative molded product 30 or a decorative film 40, and the second top layer 55 is exposed in a hole 43 constituting a non-formed part 42 of the first top layer 50 and the design layer 60 to form a surface of the decorative display part 20. The decorative display system 10 has a decorative display part 20 and a light source 15 that projects light onto the decorative display part 20 from the side opposite to the first top layer 50. In addition, in the embodiment described above, the manufacturing method for the decorative display part 20 includes a step of producing the decorative display part 20 by joining the decorative film 40 and the resin part 32 formed by injection molding, and a step of partially removing the first top layer 50 and the design layer 60 by laser etching and forming a part of the surface with the second top layer 55.

[0114] According to this embodiment, the decorative molded product 30 can be produced by joining the decorative film 40 to the resin part 32. Furthermore, the decorative display part 20 can be manufactured by performing laser etching on the decorative molded product 30. For example, the decorative molded product 30 having a three-dimensional shape can be stably and easily positioned in a laser etching device. Therefore, the first top layer 50 and the design layer 60 can be removed with high precision from the desired area of ​​the decorative molded product 30. This allows the display part 22, which is the hole 43 and the non-formed part 42 of the first top layer 50 and the design layer 60, to be formed at an appropriate position of the decorative molded product 30. As a result, the expected design can be stably and easily imparted to the decorative display part 20, and the design of the decorative display part 20 can be improved.

[0115] Although one embodiment has been described with reference to a specific example, the above-mentioned specific example does not limit the embodiment. The above-mentioned embodiment can be embodied in various other specific examples, and various omissions, substitutions, changes, additions, etc. can be made without departing from the spirit of the embodiment.

[0116] An example of the modification will be described below with reference to the drawings. In the following description and the drawings used in the following description, parts that can be configured similarly to the above-mentioned specific example are designated by the same reference numerals as those used for the corresponding parts in the above-mentioned specific example, and duplicated descriptions will be omitted.

[0117] As shown in FIG. 20, the decorative film 40 may further have a second design layer 65 laminated on the second top layer 55. The second top layer 55 is located between the design layer 60 and the second design layer 65 in the third direction D3. The second design layer 65 may display a design similar to that of the design layer 60. However, the second design layer 65 is transparent so as to impart visible light transparency to the display portion 22 of the decorative display component 20. The second design layer 65 may be formed by printing or transfer using the same material as the design layer 60. The second design layer 65 may display a wood grain or marble pattern, a metallic texture, or a geometric pattern.

[0118] In the above-mentioned specific example, insert molding using the decorative film 40 was performed after preforming the decorative film 40. Alternatively, preforming may be omitted. In this example, the flat decorative film 40 may be accommodated in the cavity 92, and the molten injected resin 33 may be supplied into the cavity 92 to form the resin part 32 bonded to the decorative film 40. Such injection molding may also be called thermoject molding. During this injection molding, the decorative film 40 may be deformed according to the shape of the cavity 92.

[0119] When insert molding the decorative film 40 having the protruding layer 53, a masking layer having holes or recesses formed therein for accommodating the protruding portions 53a may be used. By accommodating the decorative film 40 in the cavity 92 with the masking layer overlapping the protruding layer 53, it is possible to prevent the protruding portions 53a from being flattened.

[0120] The thermoplastic resin layer 70 may be omitted from the decorative film 40. For example, when the above-mentioned preforming is omitted, it is not necessary to provide the thermoplastic resin layer 70 in order to maintain the shape after the preforming. Therefore, when the preforming is omitted, the thermoplastic resin layer 70 may be omitted. However, in order to improve the adhesion between the decorative film 40 and the resin part 32, as shown in FIG. 21, the decorative film 40 may have a heat seal layer 77 instead of the thermoplastic resin layer 70. The heat seal layer 77 preferably contains a thermoplastic resin, and more preferably is made of a thermoplastic resin. For example, the heat seal layer 77 may be welded to the second top layer 55 by heating and pressurizing a thermoplastic resin film to the second top layer 55. The heat seal layer 77 is preferably a layer having a lower glass transition temperature than the second top layer 55. Examples of materials for the heat seal layer 77 include polyolefin resins such as polypropylene and polyethylene, vinyl chloride resins, and ABS resins.

[0121] As shown in FIG. 22, the decorative film 40 may further include a concealing layer 67 located between the second top layer 55 and the design layer 60 in the third direction D3. The concealing layer 67 is a layer containing a binder resin and a dark color pigment such as carbon black dispersed in the binder resin. The visible light transmittance of the concealing layer 67 may be lower than that of the design layer 60. The concealing layer 67 may have a visible light blocking property. The concealing layer 67 can absorb the laser light irradiated in the laser etching process with a high absorption rate. This allows the first top layer 50, the design layer 60, and the concealing layer 67 to be stably removed in the area irradiated with the laser light. The formed hole 43 stably penetrates the first top layer 50, the design layer 60, and the concealing layer 67. By increasing the absorption rate of the laser light in the concealing layer 67, it is possible to suppress the residue from remaining in the hole 43. As a result, when the light source 15 is turned on, an image corresponding to the shape of the non-formed portion 42 can be clearly observed. Also, the concealing layer 67 remains in the design portion 21, and when the light source 15 is turned on, the remaining concealing layer 67 absorbs light from the light source. When the light source 15 is turned on, the emission of light from areas other than the non-formed portion 42 is suppressed, so that the contour of the non-formed portion 42 can be clearly displayed.

[0122] The concealing layer 67 may contain light absorbing particles. An example of the light absorbing particles is carbon black. The content of carbon black in the concealing layer 67 may be 0.05 g / m2 or more and 2 g / m2 or less, or 0.05 g / m2 or more and 1.5 g / m2 or less. By making the content of carbon black in the concealing layer 67 0.05 g / m2 or more, the laser light can be stably absorbed by the concealing layer 67. This allows the first top layer 50, the design layer 60, and the concealing layer 67 to be stably removed. The residue remaining in the formed hole 43 can be suppressed. By making the content of carbon black in the concealing layer 67 2 g / m2 or less, the size of the formed hole 43 can be suppressed from becoming too large, and the non-formed portion 42 can be formed with high accuracy in the desired area.

[0123] In the above example, during the laser etching process, the laser light passes through the first top layer 50 and enters the design layer 60. However, the present invention is not limited to this example, and the laser light may pass through the second top layer 55 and enter the design layer 60 or the concealing layer 67. [Explanation of symbols]

[0124] D1: first direction, D2: second direction, D3: third direction, 10: decorative display system, 15: light source, 20: decorative display part, 21: design part, 22: display part, 30: decorative molded product, 32: resin part, 33: injected resin, 35: laminate, 40: decorative film, 42: non-formed part, 43: hole, 50: first top layer, 51: first layer, 52: second layer, 53: raised layer, 55: second top layer, 55a: base layer, 55b: covering layer, 60: design layer, 65: second design layer, 67: concealing layer, 70: thermoplastic resin layer, 70a: main body, 70b: adhesive layer, 77: heat seal layer, 80: laser irradiation device, 81: first roll, 82: second roll, 85: vacuum forming device, 86: heater, 87: mold, 90: injection molding device, 91: molding die, 91A: first die, 91B: second die, 92: cavity, 93: gate

Claims

1. A decorative film to be laser etched, a first top layer including a cured product of an ionizing radiation curable resin; a transparent second top layer laminated to the first top layer; a design layer located between the first top layer and the second top layer; a concealing layer located between the second top layer and the design layer, A decorative film, wherein the visible light transmittance of the concealing layer is lower than the visible light transmittance of the design layer.

2. A decorative film as described in claim 1, wherein the second top layer forms a surface together with the first top layer after the first top layer and the design layer are partially removed by laser etching.

3. Further comprising a thermoplastic resin layer laminated with the second top layer and containing a thermoplastic resin; The decorative film according to claim 1 or 2, wherein the second top layer is located between the design layer and the thermoplastic resin layer.

4. Further comprising a heat seal layer laminated with the second top layer and comprising a thermoplastic resin; the second top layer is located between the design layer and the heat seal layer; the second top layer comprises a thermoplastic resin; The decorative film according to claim 1 or 2, wherein the heat seal layer has a glass transition temperature lower than the glass transition temperature of the second top layer.

5. A first top layer comprising a cured product of an ionizing radiation curable resin; a transparent second top layer laminated to the first top layer; a design layer located between the first top layer and the second top layer; a concealing layer positioned between the second top layer and the design layer; a thermoplastic resin layer laminated with the second top layer and containing a thermoplastic resin, the second top layer is located between the design layer and the thermoplastic resin layer; A decorative film, wherein the visible light transmittance of the concealing layer is lower than the visible light transmittance of the design layer.

6. A decorative film as described in Claim 5, wherein the thickness of the thermoplastic resin layer is 100 μm or more and 1000 μm or less.

7. A decorative film as described in claim 1 or 5, wherein the second top layer comprises an acrylic resin.

8. The design layer forms a design, The design is any one of a figure, pattern, picture, photograph, character, mark, pictogram, letter, number, design, and geometric pattern, The decorative film according to claim 1 or 5, wherein the pattern is any one of a wood grain pattern, a marble pattern, and a metallic pattern.

9. The first top layer has a first layer and a second layer laminated with a portion of the first layer, The first layer and the second layer are laminated with the design layer in this order, The decorative film according to claim 1 or 5, wherein the first layer has a glossiness different from that of the second layer.

10. The first top layer further has a raised layer having a plurality of convex portions, The plurality of protrusions are arranged at intervals, The decorative film according to claim 9 , wherein the thickness of the convex portions is 5 μm or more and 50 μm or less.

11. A decorative film as described in claim 1 or 5, wherein the surface formed by the first top layer has unevenness.

12. Further comprising a second design layer laminated on the second top layer, The decorative film according to claim 1 or 5, wherein the second top layer is located between the design layer and the second design layer.

13. A decorative film according to claim 1 or 5, A decorated molded product comprising: a resin portion laminated with the decorative film and containing a thermoplastic resin.

14. A decorative molded product according to claim 13, The second top layer is a decorative display component exposed from a hole penetrating the first top layer and the design layer.

15. A decorative film; a resin portion laminated with the decorative film and containing a thermoplastic resin, The decorative film is a first top layer including a cured product of an ionizing radiation curable resin; a transparent second top layer laminated to the first top layer; a design layer positioned between the first top layer and the second top layer; a concealing layer located between the second top layer and the design layer, the second top layer is located between the concealing layer and the resin portion, the second top layer is exposed from a hole penetrating the first top layer and the design layer; The decorative display component, wherein the visible light transmittance of the concealing layer is lower than the visible light transmittance of the design layer.

16. A decorative display component as described in Claim 14, wherein the second top layer is exposed through holes provided in the first top layer and the design layer to form the surface of the decorative display component.

17. A decorative display component as described in Claim 15, wherein the thickness of the resin portion is greater than the thickness of the second top layer.

18. The design layer forms a design, The design is any one of a figure, pattern, picture, photograph, character, mark, pictogram, letter, and number, The decorative display component according to claim 15, wherein the pattern is one of a wood grain pattern, a marble pattern, and a metallic pattern.

19. A decorative display component according to claim 15; A decorative display system comprising: a light source that irradiates the decorative display component with light.

20. A process of joining the decorative film according to claim 1 or 5 with a resin part formed by injection molding to produce a decorated molded product; a step of partially removing the first top layer and the design layer by laser etching, and forming a portion of the surface with the second top layer.

21. A method for manufacturing a decorative display part as described in Claim 20, wherein in the process of producing the decorated molded product, heated thermoplastic resin is supplied into a cavity containing the decorative film to produce the decorated molded product.

22. The method further comprises the step of preforming and deforming the decorative film, The method for manufacturing a decorative display component according to claim 21 , wherein the preformed decorative film is housed in the cavity.

23. The method further comprises the step of producing the decorative film, 21. The method for manufacturing a decorative display component according to claim 20, wherein the process for producing the decorative film includes the steps of forming the design layer on the second top layer by printing, and applying and curing a composition containing an ionizing radiation curable resin onto the design layer.

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