Decorative film, method for manufacturing decorative film, and method for manufacturing decorated molded body

Abstract

To provide a decorative film capable of improving workability when being stuck on a compact; and to provide a manufacturing method of the decorative film, a decorative compact manufactured by using the same, and a manufacturing method of the decorative compact.SOLUTION: A decorative film 10 contains, in this order, an epidermal layer 12, a substrate layer 14, an adhesion layer 18, an adhesion layer protective sheet 20, and a shape holding layer 22 having a perforated line containing a cut part 28A, and is used for decoration of a compact. A manufacturing method of the decorative film 10, a decorative compact, and a manufacturing method of the decorative compact are also provided.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a decorative film, a method for manufacturing a decorative film, a decorated molded body, and a method for manufacturing a decorated molded body.

Background Art

[0002] Decorative films are known for changing the appearance of vehicles such as automobiles or imparting a desired design to the vehicles. By attaching a decorative film to the roof, body side, etc. of an automobile, a design can be easily imparted without applying painting or the like, and the appearance of the vehicle can be easily changed, which has attracted attention. Various decorative films for vehicle exterior have been proposed and there are also commercially available products. However, most of the decorative films for vehicle exterior are films that attach a flexible decorative film while following the shape of the vehicle, and it has required skill to conform such a film to the shape of the vehicle and attach it without impairing the appearance.

[0003] Therefore, for the purpose of improving the workability of attaching to the vehicle exterior, a decorative film having a release layer, an adhesive layer, and a skin layer, and the release layer including a shape-retaining layer has been proposed (see Patent Document 1 and Patent Document 2). By providing the release layer of the decorative film with a shape-retaining layer, the decorative film can be preformed in advance according to the shape of the adherend, and the preformed decorative film is said to be easier to align with the unevenness on the surface of the adherend compared to a flat decorative film.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] When the pre - formable decorative film is attached to an adherend such as a vehicle exterior, pre - forming and trimming are performed. After exposing the entire adhesive layer surface of the decorative laminate obtained by peeling the release layer from the pre - formed decorative film, the adhesive layer is pressed against the adherend and attached. At this time, since the entire adhesive layer is exposed, it becomes difficult to position the attachment position. If the attachment position is corrected after the decorative laminate is once attached to the adherend, slight wrinkles are generated due to the stress applied to the decorative laminate, and uneven gloss due to the fine wrinkles of the decorative laminate appears on the surface of the adherend, resulting in a poor appearance.

[0006] Therefore, it is conceivable to form a dividing line on the release layer after pre - forming, peel the release layer along this dividing line to partially expose the adhesive layer, and attach it to the adherend step by step. However, since the pre - formed decorative film has a three - dimensional shape, it is difficult to accurately form the dividing line.

[0007] An object of the present disclosure is to provide a decorative film and a method for manufacturing the decorative film that improve workability when attaching to a molded body, a decorative molded body manufactured using the same, and a method for manufacturing the decorative molded body.

Means for Solving the Problems

[0008] The means for solving the problems include the following embodiments. <1> An epidermal layer, A base material layer, An adhesive layer, An adhesive layer protection sheet, A shape - holding layer having a cut - off line including a cut portion, In this order, A decorative film used for decorating a molded body. <2> The depth of the cut portion is 150 μm to 300 μm, The decorative film according to <1>. <3> The cut - off line is formed by alternately arranging the cut portion and the non - cut portion, The length of the non - cut portion is 1.5 mm or less. The decorative film described in <1> or <2>. <4> The cut lines are arranged such that the cut portions and the non-cut portions are alternately disposed, wherein the length of the cut portion is 0.5 mm to 2.5 mm, The decorative film according to any one of <1> to <3>. <5> The base material layer contains at least one resin selected from the group consisting of vinyl chloride resin, acrylic resin, and ABS resin, the skin layer contains at least one resin selected from the group consisting of fluororesin, acrylic resin, and vinyl chloride resin, the shape-retaining layer contains at least one resin selected from the group consisting of ABS resin and vinyl chloride resin, The decorative film according to any one of <1> to <4>. <6> A step of laminating a skin layer on one surface side of the base material layer, a step of forming an adhesive layer on the other surface side of the base material layer, a step of covering the adhesive layer with an adhesive layer protection sheet, a step of laminating a shape-retaining layer via an adhesive on the side opposite to the adhesive layer side of the adhesive layer protection sheet, a step of forming cut lines including cut portions in the shape-retaining layer, including A method for manufacturing a decorative film used for decorating a molded body. <7> The base material layer contains at least one resin selected from the group consisting of vinyl chloride resin, acrylic resin, and ABS resin, the skin layer contains at least one resin selected from the group consisting of fluororesin, acrylic resin, and vinyl chloride resin, the shape-retaining layer contains at least one resin selected from the group consisting of ABS resin and vinyl chloride resin, The method for manufacturing a decorative film according to <6>. <8> A molded body, A decorated laminate in which the adhesive layer protection sheet and the shape retention layer are peeled off from the decorated film according to any one of <1> to <5>, and the decorated laminate is adhered to the molded body by the adhesive layer. A decorated molded body containing <9> A preliminary forming step of preliminarily forming the decorated film according to any one of <1> to <5> into a shape conforming to the molded body by a vacuum forming method; A partial peeling step of partially peeling the adhesive layer protection sheet and the shape retention layer from the preliminarily formed decorated film with the cut line as a boundary to expose a part of the adhesive layer; A partial adhesion step of partially peeling the shape retention layer and the adhesive layer protection sheet from the preliminarily formed decorated film with the cut line as a boundary and adhering a part of the exposed adhesive layer to the surface of the molded body; Including A method for manufacturing a decorated molded body, in which the decorated laminate from which the shape retention layer and the adhesive layer protection sheet are peeled off is gradually attached to the surface of the molded body by alternately repeating the partial peeling step and the partial adhesion step.

Effect of the Invention

[0009] According to an embodiment of the present invention, it is possible to provide a decorated film and a method for manufacturing a decorated film, the workability during attachment to a molded body is improved, and a decorated molded body manufactured using the same and a method for manufacturing a decorated molded body.

Brief Description of the Drawings

[0010] [Figure 1] It is a schematic cross-sectional view showing one aspect of the decorated film of the present disclosure. [Figure 2] It is a schematic cross-sectional view showing one aspect of the decorated molded body of the present disclosure. [Figure 3] It is a schematic view showing one aspect of the cut line formed in the shape retention layer of the decorated film in Examples 1-4. [Figure 4] It is a schematic view showing the cut line formed in the shape retention layer of the decorated film in Examples 5-8. [Figure 5] FIG. 10 is a schematic diagram showing the cutting lines formed on the shape-retaining layer of the decorative film in Examples 9-12. [Figure 6] FIG. 10 is a schematic diagram showing the cutting lines formed on the shape-retaining layer of the decorative film in Examples 13-16. [Figure 7] FIG. 1 is a schematic diagram showing the cutting lines formed on the shape-retaining layer of the decorative film in Examples 17-20. [Figure 8] 1 is a schematic diagram showing a decorative film (without cut lines) in Comparative Example 1. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0011] The decorative film, the method for manufacturing the decorative film, the method for manufacturing the decorated molded article, and the decorated molded article according to the present disclosure will be described in detail below. The following description of the components may be based on representative embodiments of the present disclosure, but the present disclosure is not limited to the following embodiments. In the present disclosure, the use of "to" to indicate a range of values means that the values before and after it are included as the lower limit and upper limit. In the numerical ranges described in stages in this disclosure, the upper limit value described in one numerical range may be replaced by the upper limit value of another numerical range described in stages, or the lower limit value described in one numerical range may be replaced by the lower limit value of another numerical range described in stages. Furthermore, in the numerical ranges described in the present disclosure, the upper or lower limit of the numerical range may be replaced with values shown in the examples. In the present disclosure, combinations of preferred aspects are more preferred aspects. In the present disclosure, when a plurality of substances corresponding to each component are present in the composition, the amount of each component in the composition means the total amount of the plurality of substances present in the composition, unless otherwise specified. In the present disclosure, the term "process" includes not only an independent process but also a process that cannot be clearly distinguished from other processes as long as the intended purpose of the process is achieved.

[0012] In the present disclosure, the term "layer containing a resin" refers to a "layer formed containing a resin that is the main component of the layer." That is, in the present disclosure, the term "layer containing a resin" is used to encompass both a resin layer containing only a resin, and a layer formed from a resin composition that contains, in addition to the resin that is the main component, optional components such as a plasticizer, a colorant, and an ultraviolet absorber. In the present disclosure, the term "resin that is the main component" refers to a resin that is contained in an amount of 60 mass % or more relative to the total amount of the resin composition containing that component. In this disclosure, vinyl chloride resin may be referred to as PVC resin, and acrylonitrile / butadiene / styrene copolymer may be referred to as ABS resin. In the present disclosure, a "molded body having a three-dimensional shape" or a "molded body" refers to a molded body before decoration, and a "decorated molded body" refers to a molded body decorated with the decorative film of the present disclosure. In addition, the "three-dimensional shape" of the molded body means that the surface of the molded body to which the decorative film is attached is not flat. The laminate comprising the surface layer, base layer and adhesive layer, which is used for attachment to an adherend after the adhesive layer protective sheet and shape-retaining layer have been peeled off from the decorative film, is referred to as the decorative laminate.

[0013] In the decorative film of the present disclosure, when the decorative film is used to decorate a molded body, the shape-retaining layer provided on the side opposite the adhesive layer of the adhesive layer protective sheet suppresses shrinkage of the adhesive layer protective sheet during preforming by vacuum forming or the like, contributing to achieving preforming as designed. Furthermore, the decorative film is likely to maintain its preformed shape due to the function of the shape-retaining layer even after the pressure applied during preforming is removed.

[0014] When the decorative laminate is to be attached to a molded body as an adherend, the decorative laminate is preformed into a shape that fits the molded body as an adherend, and positioning is easy. By using the decorative film of the present disclosure, the pasting workability is improved. For example, the appearance of vehicles such as automobiles can be easily changed, various designs can be applied to the surfaces of various molded bodies, and a decorative molded body with excellent appearance can be easily manufactured.

[0015] Hereinafter, the decorative film of the present disclosure, the manufacturing method of the decorative film, the manufacturing method of the decorative molded body, and the preferred embodiments of the decorative molded body will be described in detail. However, the present disclosure is not limited to the following embodiments at all.

[0016] <Decorative film> The decorative film of the present disclosure includes an epidermal layer, a base material layer, an adhesive layer, an adhesive layer protective sheet, and a shape-retaining layer having a cut line including a cut portion, in this order, and is a decorative film used for decorating a molded body.

[0017] The decorative film of the present disclosure will be described with reference to the drawings. FIG. 1 is a schematic cross-sectional view showing a preferred aspect of the layer structure of the decorative film 10 of the present disclosure. FIG. 2 is a schematic cross-sectional view showing an aspect of a decorative molded body 30 in which a decorative laminate 24 obtained by peeling an adhesive layer protective sheet 20 and a shape-retaining layer 22 from the decorative film 10 of the present disclosure is pasted on a molded body 26. The decorative film 10 is arranged in this order with an epidermal layer 12, a base material layer 14, an adhesive layer 18, an adhesive layer protective sheet 20 covering the adhesive layer 18, and a shape-retaining layer 22. A cut line 28 including a cut portion 28A is provided in the shape-retaining layer 22. That each layer is "arranged in this order" means that each layer is arranged in the described order in the thickness direction of the decorative film 10, and does not exclude any optional layer that may be further provided as necessary. For example, a primer layer, which is a resin layer for improving the adhesiveness between the two, may be arranged between the base material layer 14 and the adhesive layer 18.

[0018] In one embodiment of the decorative film 10 shown in FIG. 1, a laminated structure including an adhesive layer protective sheet 20 and a shape retention layer 22 is provided for a laminate (decorative laminate 24 in FIG. 2) having a skin layer 12, a base material layer 14, and an adhesive layer 18 in this order. The surface of the skin layer 12 opposite to the side of the base material layer 14 may have an uneven pattern also referred to as a matte pattern. The side having the uneven pattern of the skin layer is located on the outermost surface when the decorative laminate 24 obtained by peeling the adhesive layer protective sheet 20 and the shape retention layer 22 from the decorative film 10 is disposed on a molded body described later to form a decorative molded body. Therefore, it may be hereinafter referred to as the surface. The uneven pattern is a pattern that characterizes the appearance of the surface of the molded body by the decorative film, typified by the uneven pattern of natural leather, and is provided as necessary. Further, the base material layer 14 can impart an arbitrary hue to the decorative film 10, for example, by containing a colorant. Therefore, a desired hue can be easily imparted to the decorative molded body to which the decorative film 10 of the present disclosure is applied. In addition, in FIGS. 1 and 2, components denoted by the same reference numerals mean the same components.

[0019] Hereinafter, the decorative film will be sequentially described together with the materials constituting it and its manufacturing method.

[0020] (1. Skin layer) The skin layer of the decorative film is formed by including a resin. From the viewpoint of durability, the skin layer preferably contains at least one resin selected from the group consisting of fluororesins, acrylic resins, and vinyl chloride resins. By the skin layer containing at least one resin selected from the group consisting of fluororesins, acrylic resins, and vinyl chloride resins, the durability of the decorative film and further the durability of the decorative laminate attached to the molded body are improved.

[0021] The fluororesin that can be used for the skin layer is not particularly limited as long as it is a resin obtained by polymerizing at least one monomer containing a fluorine atom as a polymerization component, but a resin obtained by polymerizing an olefin containing a fluorine atom is preferred. Examples of the fluororesin include resins composed of polymerization components selected from, for example, ethylene tetrafluoride, vinylidene chloride, vinyl fluoride, and vinylidene fluoride. More specifically, homopolymers of polymerization components containing fluorine atoms such as ethylene tetrafluoride resin, vinyl fluoride resin, and vinylidene fluoride resin, and copolymers containing the polymerization components, such as vinylidene chloride-vinylidene fluoride copolymer, vinylidene fluoride-hexafluoropropylene copolymer, and vinylidene fluoride-hexafluoropropylene-ethylene tetrafluoride copolymer, can be mentioned. Among them, it is preferable to contain at least one fluororesin selected from the group consisting of vinylidene chloride-vinylidene fluoride copolymer, vinylidene fluoride-hexafluoropropylene copolymer, and vinylidene fluoride-hexafluoropropylene-ethylene tetrafluoride copolymer.

[0022] When the skin layer contains a fluororesin, it may contain only one type of fluororesin, or two or more types may be used in combination. When the skin layer contains two or more types of fluororesins, for example, a mixture of two or more resins selected from the group consisting of vinylidene fluoride resin, vinylidene chloride-vinylidene fluoride copolymer, vinylidene fluoride-hexafluoropropylene copolymer, and vinylidene fluoride-hexafluoropropylene-ethylene tetrafluoride copolymer can also be preferably used.

[0023] When the skin layer contains two or more types of resins, in addition to the mode of being a mixture of two or more types of resins as described above, a mode of a laminated structure of two or more types of resins can also be adopted. For example, as the skin layer, when a decorative laminate is disposed on the outermost surface, that is, the surface corresponding to the outside when the decorative laminate is disposed on the molded body, the surface is a layer containing a fluororesin, and for the purpose of further improving the adhesiveness between the skin layer and the base material layer, the skin layer can be a two-layer structure of a layer containing a fluororesin and a layer containing an acrylic resin, and the layer containing the acrylic resin can be positioned on the surface in contact with the base material layer.

[0024] The skin layer may be formed by known sheet forming methods, such as an extrusion method of extrusion molding with a T-die or the like, a calendar method, a casting method, etc., or may be formed by applying a commercially available film.

[0025] The skin layer may have a concavo-convex pattern on the surface side that becomes the appearance (i.e., the side opposite to the base material layer). From the viewpoints of strength and the retention of the concavo-convex pattern when forming the concavo-convex pattern, the thickness of the skin layer is preferably in the range of 5 μm to 100 μm, and more preferably in the range of 10 μm to 60 μm. Here, the thickness of the skin layer, when a concavo-convex pattern is provided, refers to the distance from the top of the convex portion to the bottom surface of the skin layer. From the viewpoint of the retention of the concavo-convex pattern formed on the side opposite to the surface of the skin layer on the base material layer side, the thickness of the skin layer is preferably greater than the distance between the bottom of the deepest part of the concave portion and the top of the convex portion of the concavo-convex pattern. For example, when forming a concavo-convex pattern where the depth of the concave portion is 1 μm or less, the thickness of the skin layer can be about 5 μm. When there are shallow concave portions and deep concave portions, such as a natural leather-like pattern, and the depth of the deep concave portion is 2 μm to 5 μm, the thickness of the skin layer is preferably 10 μm or more. In addition, when the skin layer has a laminated structure of two or more layers as described above, the thickness of the skin layer refers to the total thickness of the plurality of layers. The thickness of each layer in the decorative film of the present disclosure can be measured by observing a cross-section obtained by cutting the decorative film perpendicularly to the plane direction. Therefore, the film thickness of each layer in the decorative film in the present disclosure refers to the film thickness after drying.

[0026] The method of forming the skin layer on the surface of the base material layer opposite to the surface on the shape-retaining layer side is arbitrary. For example, a pre-formed skin layer and a base material layer may be adhered, or after forming the skin layer, the base material layer may be formed on one surface of the skin layer.

[0027] The method for forming the textured pattern on the surface of the skin layer opposite to the surface on the base layer side is not particularly limited, and any known method can be used. Known methods include a method of forming a skin layer on a release paper having a textured pattern, and a method of first forming a skin layer with a smooth surface and then embossing it using a squeeze roll.

[0028] (2. Base material layer) The substrate layer is formed containing a resin, and preferably contains at least one resin selected from the group consisting of PVC resin, acrylic resin, and ABS resin. When the base layer contains at least one resin selected from the group consisting of PVC resin, acrylic resin, and ABS resin, the thermal stress on the surface layer is alleviated, and the desired textured pattern formed on the surface layer is better retained. There are no particular limitations on the PVC resin, acrylic resin, and ABS resin, and any known film-forming PVC resin, acrylic resin, or ABS resin can be appropriately selected and used.

[0029] The substrate layer may contain other components in addition to the resin. Examples of other components that the substrate layer may contain include colorants, plasticizers, fillers, lubricants, processing aids, etc. The other components can be used within a range that does not impair the thermal processability of the substrate layer.

[0030] The substrate layer may include a colorant. By including a colorant in the base layer, when manufacturing a decorated molded body, the hue, design, etc. inherent to the molded body to be adhered is prevented from affecting the appearance of the decorated molded body in the area where the decorative laminate is attached, and any hue can be imparted to the decorated molded body to which the decorative laminate is attached. When the skin layer has good transparency, the color of the base layer can characterize the appearance of the decorative film by including a colorant in the base layer. For example, by attaching and decorating a decorative laminate using a decorative film having a base material layer containing a silver colorant only to the roof portion of a red vehicle as a molded body, the vehicle body is red and only the roof with the decorative laminate attached is silver, and the red color, which is the original hue of the molded body, is concealed at the location where the decorative laminate is attached. When the base material layer contains a colorant, there are no particular restrictions on the colorant, and dyes, pigments, etc. can be appropriately selected and used. In addition, the base material layer may contain extender pigments (fillers) such as calcium carbonate, silica (silicon dioxide), alumina (aluminum oxide), and barium sulfate, as necessary.

[0031] The thickness of the base material layer is preferably in the range of 50 μm to 400 μm, and more preferably in the range of 100 μm to 350 μm. When the thickness is within the above range, breakage due to melting of the decorative film during pre-forming the decorative film by a vacuum forming method or the like is effectively suppressed, and furthermore, the concealability of the molded body as the adherend becomes better.

[0032] There are no particular restrictions on the method for forming the base material layer, and known sheet forming methods such as an extrusion method of extrusion molding with a T-die or the like, a calendering method, a casting method, etc. can be applied. Among them, the calendering method is preferable in terms of simplicity of production and ease of equipment maintenance. In particular, when the base material layer contains a colorant, since the softened resin and the solid colorant can be supplied to the calender roll and formed into a sheet or film shape, a base material layer containing various colorants can be easily produced. In addition, by applying the calendering method, compared with a molding method such as the extrusion method, cleaning inside the apparatus required when changing the type or addition amount of the colorant can be performed more easily. Therefore, by applying the calendering method when forming a layer containing a colorant as the base material layer, various base material layers having a desired hue can be easily produced, which is also suitable for small-lot production of decorative films.

[0033] (3. Adhesive layer) The decorative film has an adhesive layer on the surface of the substrate layer opposite to the surface layer side, for improving adhesion to the molded article. The adhesive layer can be formed by applying at least one of a known adhesive and a known pressure-sensitive adhesive to the surface of the substrate layer opposite to the surface layer side. The adhesive used to form the adhesive layer is not particularly limited and may be appropriately selected depending on the type of molded article. Suitable adhesives include, for example, (1) polyester adhesives or pressure-sensitive adhesives, (2) urethane adhesives or pressure-sensitive adhesives, and (3) acrylic adhesives or pressure-sensitive adhesives. The thickness of the adhesive layer is preferably in the range of 20 μm to 80 μm, and more preferably in the range of 30 μm to 60 μm.

[0034] When forming an adhesive layer on the surface of a base layer, a primer layer, as described below, can be formed between the base layer and the adhesive layer in order to improve adhesion, and the adhesive layer can be formed by applying at least one of an adhesive and a pressure-sensitive adhesive to the surface of the formed primer layer. The adhesive layer can be applied to the substrate layer or the primer layer by any known method such as a transfer method or a coating method. From the viewpoint of easily forming an adhesive layer of uniform thickness, the transfer method is preferably used.

[0035] (4. Adhesive layer protective sheet) After the adhesive layer is formed, the surface of the adhesive layer is covered with an adhesive layer protective sheet for the purpose of protecting the surface of the adhesive layer. As the material for the adhesive layer protective sheet, from the viewpoint of preformability, resin film, resin-laminated paper, etc. are preferred, and from the viewpoint of better preformability, resin film is more preferred. Examples of the resin film include a PP film and a PET film, with a PP film being preferred. There are no particular restrictions on the thickness of the adhesive layer protective sheet, but from the viewpoint of good 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 even more preferably in the range of 45 μm to 60 μm. The subsequent layer protection sheet is peeled off when applied to the molded body after the pre-forming of the decorative film described later.

[0036] (5. Shape retention layer) A shape retention layer is disposed on the surface of the adhesive layer protection sheet opposite to the adhesive layer side. The shape retention layer is provided with a cutting line including a cut portion on the surface opposite to the adhesive layer protection sheet. In the present disclosure, a layer that gives the function of holding the shape pre-formed of the decorative film after pre-forming with heating is referred to as the shape retention layer. That is, the shape retention layer has the function as a layer that holds the shape of the decorative film during pre-forming. By having the shape retention layer in the decorative film, even when the decorative film is pre-formed by means such as the vacuum forming method under temperature conditions of 80°C to 150°C and then cooled to room temperature (25°C), the entire decorative film retains the shape pre-formed due to the function of the shape retention layer. Here, "the shape is retained" means that when a pre-formed decorative film of 50 cm square is fixed at one point of the square corner, the unfixed part does not deform, such as being deformed and hanging down from the fixed point due to gravity.

[0037] The shape retention layer is formed of resin. From the viewpoint of good shape retention by pre-forming, the shape retention layer preferably contains at least one resin selected from ABS resin and PVC resin. By including at least one resin selected from ABS resin and PVC resin in the shape retention layer, when the decorative film is pre-formed by the vacuum forming method or the like, the shrinkage of the laminated adhesive layer protection sheet is suppressed, and the maintainability of the pre-formed shape is good. Furthermore, breakage due to stretching or the like of local stretched portions during pre-forming is effectively suppressed. ABS resin and PVC resin may be used alone, respectively, or may be used in mixture with AS resin, polycarbonate (PC), polypropylene (PP), etc. Also, ABS resin and PVC resin may be used in combination. Among them, as the resin, it is preferable to use ABS resin or PVC resin alone, or a mixture of PC and ABS resin (PC / ABS), and it is more preferable to use ABS resin or PVC resin alone as the resin. As for the ABS resin, only one type may be used, or two or more types of ABS resins having different copolymerization ratios may be used in combination. There is no particular limitation on the PVC resin, and known film-forming PVC resins can be appropriately selected and used.

[0038] In addition to at least one resin selected from ABS resin and PVC resin, the shape-retaining layer may contain other components as necessary as long as the effects are not impaired. Examples of other components that the shape-retaining layer may contain include plasticizers, fillers, lubricants, processing aids, and the like. Also, from the viewpoint of exhibiting good shape retention, the thickness of the shape-retaining layer is preferably in the range of 100 μm to 800 μm, and more preferably in the range of 200 μm to 600 μm. When the thickness is within the above range, the shape retention is better when the decorative film is preformed.

[0039] Note that by selecting the resin contained in the base material layer, the thickness of the base material layer, etc., it is possible to give the base material layer a shape-retaining function. However, when giving the base material layer a shape-retaining function, it is necessary to maintain the thickness and rigidity of the base material layer within a predetermined range. However, in order to increase the thickness or impart rigidity, there are limitations in the composition of the base material layer, which may affect the appearance quality and the like due to the dispersibility of the pigment. On the other hand, the decorative film of the present disclosure can provide a shape-retaining function to the decorative film while mainly ensuring the appearance quality by the base material layer by providing a shape-retaining layer on the side opposite to the skin layer side of the base material layer separately from the base material layer. Therefore, the decorative film of the present disclosure is provided with a shape-retaining layer as a separate layer from the base material layer. Therefore, the decorative film of the present disclosure is heat-moldable and has excellent preformability.

[0040] Moreover, the decorative film of the present disclosure is provided with a cutting line including a cut portion in the shape-retaining layer. The cut portion is a portion cut in the thickness direction of the shape-retaining layer, and the cut portions are formed intermittently or continuously in the in-plane direction along the cutting line. By providing the cutting line including the cut portion in the shape-retaining layer, as will be described later, the workability in manufacturing the decorated molded body by attaching it to the molded body can be greatly improved. All the cutting lines may be composed of only cut portions, but it is preferable that the cut portions and non-cut portions are alternately arranged to form the cutting line. From the viewpoint of workability, the pattern shape of the cutting line (defined by "the length of the cut portion" and "the length of the non-cut portion") is preferably such that the length of the non-cut portion is 1.5 mm or less, and more preferably 1.0 mm or less. On the other hand, the length of the cut portion is preferably 0.5 mm to 2.5 mm. Also, the depth of the cut portion of the cutting line depends on the thickness of the shape-retaining layer. When the thickness of the shape-retaining layer is in the range of 100 μm to 800 μm described above, the depth of the cut portion of the cutting line is preferably 150 μm to 300 μm from the viewpoint of pasting workability.

[0041] (6. Other Layers) In addition to the aforementioned skin layer, base material layer, adhesive layer, adhesive layer protective sheet, and shape-retaining layer, the decorative film may further have other layers as long as the effects are not impaired. Examples of other layers include a primer layer and a design layer.

[0042] (6-1. Primer Layer) The decorative film may further have a resin layer as a primer layer between the base material layer and the adhesive layer for the purpose of improving the adhesion between the adhesive layer provided adjacent to the base material layer and the base material layer. The primer layer can be formed by a coating method. That is, the resin for forming the primer layer is dissolved in an appropriate solvent, applied to the surface of the base material layer opposite to the skin side, and dried to form the primer layer. The resin contained in the primer layer is preferably formed using a resin such as a polyester resin, from the viewpoint of having good affinity with the thermoplastic resin contained in the base material layer and the adhesive contained in the adhesive layer provided adjacent thereto. There is no particular limitation on the amount of resin layer applied as a primer layer, and it can be selected appropriately depending on the purpose. Generally, from the viewpoint of improving adhesion, it is 1 g / m 2 ~5g / m 2 It is preferable that the range is 2 g / m 2 ~3g / m 2 It is more preferable that the range is:

[0043] (6-2. Design layer) The decorative film of the present disclosure may further include a design layer between the skin layer and the base layer. The design layer is a layer that imparts a design to the decorative film, and may be a printed layer formed by printing, a colored layer containing a colorant, or a layer that combines these. By providing a design layer on the decorative film of the present disclosure, various designs can be imparted to the molded article as desired depending on the intended use of the decorative film, and an appearance with excellent design can be imparted to the molded article.

[0044] The design layer may be, for example, a printed layer formed by a printing method on the surface of the surface layer or the base layer. Examples of the printed layer include a layer formed by a known printing method using a printing ink containing a resin. As the printing ink containing a resin, a printing ink containing an acrylic resin, a vinyl chloride-vinyl acetate copolymer, or the like is preferred from the viewpoint of being able to form a clear printed image. There are no particular limitations on the printing method, and any printing method can be applied, such as gravure printing (intaglio printing), letterpress printing, offset printing, inkjet printing, and screen printing. The design layer is preferably a printing ink layer containing at least one selected from acrylic resins and vinyl chloride-vinyl acetate copolymers.

[0045] The design layer may be a colored layer. Examples of the colored layer include layers formed from a resin composition containing an arbitrary colorant. For example, a resin composition obtained by incorporating a colorant selected from those exemplified as colorants that can be used for the aforementioned base material layer into an acrylic resin, and formed into a film shape by a calendar method, an extrusion method, a casting method, etc., such as a design layer, can be mentioned.

[0046] Specific examples of the acrylic resin that can be used for forming the design layer include polymers or copolymers of methacrylic acid or methacrylic acid esters typified by polymethyl methacrylate (PMMA), copolymers of alkyl methacrylate, alkyl acrylate, and styrene, etc. From the viewpoint of moldability, a mixture of a copolymer of alkyl methacrylate, alkyl acrylate, and styrene and a copolymer of methyl methacrylate and methyl acrylate is preferable.

[0047] The acrylic resin is excellent in weather resistance and stretchability, and has good adhesion to other resin layers provided adjacent thereto. In addition, since the acrylic resin has good transparency, by adding a colorant or the like to the acrylic resin, or adding a light-scattering colorant such as a pigment having a metallic luster or a pearl pigment, a desired good hue and a design excellent in gloss can be arbitrarily imparted to the decorative film. Also, when forming a printing ink layer using a printing ink containing an acrylic resin, by printing characters, images, etc., a more complex arbitrary design can be imparted to the decorative film.

[0048] When the decorative film of the present disclosure has a design layer, the thickness of the design layer 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. When the thickness is within the above range, a desired design can be imparted to the decorative film, and a good correlation between the skin layer and the base material layer is maintained when preforming the decorative film, and the retention of the uneven pattern of the skin layer becomes better.

[0049] A preferred embodiment of the decorative film of the present disclosure includes a surface layer having a textured pattern on one side and a heat-resistant layer containing a fluororesin. In a surface layer containing a fluororesin, the textured pattern optionally formed on one side is less likely to deform when heated. Furthermore, the surface layer is preferably laminated with a substrate layer containing a PVC resin. The adhesive layer protection sheet contains at least one resin selected from PP, PET, PEN, and PE, which are suitable for preforming, and a shape-retaining layer adjacent to the adhesive layer protection sheet preferably contains at least one resin selected from ABS resin and PVC resin. Decorative films having these layers exhibit better shape retention when preformed by vacuum forming or the like. In a preferred embodiment, the surface layer and the adjacent base layer containing PVC resin are both flexible and easily deformable, and further, a shape-retaining layer containing at least one resin selected from ABS resin and PVC resin is formed adjacent to the adhesive layer protection sheet. These layers suppress shrinkage of the adhesive layer protection sheet during vacuum forming, allowing preforming to be performed as designed. Therefore, even after vacuum forming, when the adhesive layer protective sheet is peeled off to form the decorative laminate, the decorative laminate having the skin layer, base layer, and adhesive layer maintains a shape that better matches the molded body to which it is to be attached, and can be easily attached to the molded body.

[0050] The decorative film of the present disclosure has, on its outermost surface, a surface layer that is excellent in transparency and durability and that maintains its textured pattern well when heated, and also has a base layer that is excellent in thermal processability, an adhesive layer protective sheet, and a shape-retaining layer that is excellent in shape retention during preforming. Therefore, the decorative film is preformed into a shape that fits a molded body, and then the adhesive layer protective sheet and the shape-retaining layer are peeled off to obtain a decorative laminate that has a certain degree of flexibility while maintaining the preformed shape well. Therefore, for example, when the preformed decorative laminate is attached to the surface of a molded body having a three-dimensional shape, positioning is easy, and any design can be easily formed on the molded body using the decorative laminate. The decorated molded body obtained by attaching the decorative laminate to the surface has excellent appearance reflecting the design property of the decorative film and also excellent durability such as solvent resistance. Therefore, the decorative film of the present disclosure can be applied to various uses as a decorative film for imparting design property to the surface of a molded body.

[0051] <Method for manufacturing a decorative film> The method for manufacturing the decorative film of the present disclosure described above is not particularly limited, and known manufacturing methods can be appropriately adopted. Among them, it is preferably manufactured by the method for manufacturing the decorative film of the present disclosure described later. That is, the method for manufacturing the decorative film of the present disclosure is a step of laminating an epidermal layer on one surface side of a base material layer; a step of forming an adhesive layer on the other surface side of the base material layer; a step of covering the adhesive layer with an adhesive layer protection sheet; a step of laminating a shape retention layer via an adhesive on the side opposite to the adhesive layer side of the adhesive layer protection sheet; a step of forming a cut line including a cut portion in the shape retention layer; and includes.

[0052] Furthermore, as a specific example of the method for manufacturing the decorative film of the present disclosure, a method including the following steps (I) to (X) can be mentioned. Step (I) A step of preparing an epidermal layer containing at least one resin selected from the group consisting of a fluororesin, an acrylic resin, and a vinyl chloride resin Step (II) A step of preparing a base material layer containing at least one resin selected from the group consisting of a vinyl chloride resin, an acrylic resin, and an ABS resin Step (III) A step of laminating the epidermal layer on one surface side of the base material layer Step (IV) A step of forming an adhesive layer on the other surface side of the base material layer Step (V) A step of preparing an adhesive layer protection sheet Step (VI) A step of covering the adhesive layer with the adhesive layer protection sheet Step (VII): Preparing a shape-retaining layer containing at least one resin selected from the group consisting of an ABS resin and a vinyl chloride resin Step (VIII): Laminating the shape-retaining layer on the side opposite to the adhesive layer side of the adhesive layer protection sheet via an adhesive to form a decorative film Step (IX): Cutting the decorative film into a desired shape Step (X): Forming a cutting line including a cut portion in the shape-retaining layer In addition to the above steps (I) to (X), other steps can be included. For example, in step (III), when laminating the base material layer and the skin layer, a laminating embossing process can be further included by bringing a squeezing roll into contact with the skin layer side to form an uneven pattern on the surface of the skin layer on the side opposite to the base material layer side (step (III-2)). Also, for example, a step of forming a primer layer (step (XI)) between the base material layer and the adhesive layer, and a step of forming a design layer (step (XII)) between the skin layer and the base material layer can be included.

[0053] Step (I) In step (I), a skin layer containing at least one resin selected from the group consisting of a fluororesin, an acrylic resin, and a vinyl chloride resin is prepared. The preparation of the skin layer may involve forming the skin layer or procuring a commercially available skin layer. The skin layer can be formed by a calendar method, an extrusion method, a casting method, or the like. When forming a skin layer having a laminated structure, a laminated film can be formed by co-extrusion of two or more resins or the like.

[0054] Step (II) In step (II), a base material layer containing at least one resin selected from the group consisting of a vinyl chloride resin, an acrylic resin, and an ABS resin is prepared. For example, a resin composition containing at least one resin selected from the group consisting of vinyl chloride resin, acrylic resin, and ABS resin is used to form a substrate layer by a known method such as a calendaring method, an extrusion method, or a casting method. Among these, from the viewpoint of processability, it is preferable to form the substrate layer by a calendaring method. Forming the substrate layer by a calendaring method allows a substrate layer with a uniform thickness to be formed more easily than, for example, an extrusion method. Furthermore, when a colorant is incorporated into the substrate layer, the application of the calendaring method also facilitates cleaning of the inside of the device, which is necessary when changing the type or amount of colorant used in the substrate layer. For example, one example of a method for forming a base layer using PVC resin and a pigment as a colorant includes adding a predetermined amount of pigment to PVC resin, heating and mixing the PVC resin with a hot mixing roll to obtain a colored PVC resin, and forming a base layer using the obtained colored PVC resin by a calendar method. When a colorant is not used, the same method can be used, omitting the step of adding the pigment. Either step (I) or step (II) may be carried out first, and the steps may be carried out in parallel.

[0055] (Process (III)) In step (III), the skin layer prepared in step (I) is laminated on one side of the substrate layer obtained in step (II). In step (III), a base layer is laminated on one side of the skin layer, and then the laminate is laminated using a pair of rolls to bond the skin layer and the base layer together under heat and pressure. The heating temperature in the laminating process is preferably 100° C. to 190° C. In the present disclosure, the heating temperature in the laminating process refers to the surface temperature of the roll. The term "laminating" as used herein refers to a process in which a laminate of multiple layers is heated and compressed using a pair of rolls to bond multiple resin-containing films together by thermocompression. In step (III), in addition to laminating the surface layer and the base layer, a step (step (III-2)) can also be performed in which the surface layer is laminated and embossed using a squeeze roll to form a textured pattern on the surface of the surface layer opposite the base layer. By carrying out step (III-2), it is possible to simultaneously laminate the surface layer and the base layer and form a textured pattern on one surface of the surface layer. That is, the base layer is laminated on one surface of the surface layer, and then the laminate is embossed using a squeeze roll, thereby simultaneously bonding the layers under heat and pressure and forming a desired textured pattern on the surface of the surface layer. The laminate embossing in step (III-2) of the present disclosure refers to embossing using a squeeze roll on one of a pair of embossing rolls used for thermocompression bonding, bonding multiple resin-containing films together by thermocompression bonding, and squeezing the surface of the resin-containing film that contacts the squeeze roll to form irregularities on the surface. In step (III-2), laminate embossing is performed in an arrangement where the squeeze roll is located on the skin layer side and the smooth roll is located on the base layer side. This method allows the lamination of the two layers and the formation of an irregular pattern on the skin layer to be performed sequentially or simultaneously in a single step.

[0056] By laminating and embossing the surface of the skin layer using a squeezing roll on which any desired uneven pattern, such as a natural leather-like uneven pattern, has been formed in advance, the bonding to the base layer and squeezing (forming the uneven pattern) of the skin layer are carried out in one step, and the uneven pattern of any desired design, such as a natural leather-like uneven pattern, is transferred to the top surface of the skin layer in the formed decorative film. By selecting the shape of the uneven pattern to be formed on the squeezing roll, it is possible to form not only a natural leather-like pattern but also a pattern having any uneven shape on the surface of the decorative film. The heating temperature in the laminate embossing is preferably 100°C to 190°C.

[0057] The method of forming unevenness on one surface of the skin layer is not limited to this. For example, when the skin layer is formed by a coating method, a composition for forming the skin layer can be applied onto a release paper on which unevenness has been previously formed, and the unevenness on the release paper can be transferred to the skin layer to form it.

[0058] (Step (IV)) In step (IV), an adhesive layer is formed on the surface of the base material layer formed in step (II) on the side opposite to the side having the skin layer. The adhesive layer can be formed by applying at least one of a known adhesive and an adhesive agent to the surface of the base material layer on the side opposite to the side having the skin layer. There is no particular limitation on the adhesive used for forming the adhesive layer, and it is appropriately selected according to the type of the molded body. As the adhesive, for example, (1) a polyester-based adhesive or adhesive agent, (2) a urethane-based adhesive or adhesive agent, (3) an acrylic-based adhesive or adhesive agent, etc. are preferably used. The thickness of the adhesive layer is preferably in the range of 20 μm to 80 μm.

[0059] (Step (V)) In step (V), an adhesive layer protection sheet for protecting the adhesive layer is prepared. As the adhesive layer protection sheet, a resin film is preferably used. Examples of the resin film include a PP film, a PET film, etc., and a PP film is preferred. There is no particular limitation on the thickness of the adhesive layer protection sheet, but from the viewpoint of good preformability, it is preferably in the range of 5 μm to 100 μm, and more preferably in the range of 40 μm to 70 μm.

[0060] When the adhesive layer protection sheet is applied to the molded body after the preforming of the decorative film described later, it is partially peeled off together with the adjacent shape retention layer with the cut-off line of the shape retention layer as the boundary, and the whole is peeled off step by step.

[0061] (Step (VI)) In step (VI), the adhesive layer protection sheet prepared in step (V) is brought into contact with the adhesive layer formed in step (IV), and the adhesive layer is covered with the adhesive layer protection sheet. As the adhesive layer protection sheet, as described above, a peelable resin film, for example, a PP film, is more preferable. Step (VI) can include forming an adhesive layer by applying an adhesive, preferably, on the base material layer (step (IV)), and applying and covering the adhesive layer protection sheet on the surface of the adhesive layer while the adhesive layer is in an uncured state.

[0062] (Step (VII)) In step (VII), a shape-retaining layer containing at least one resin selected from the group consisting of an ABS resin and a vinyl chloride resin is prepared. For example, a shape-retaining layer is formed using a resin composition containing at least one resin selected from the group consisting of an ABS resin and a vinyl chloride resin. Examples of the method for forming the shape-retaining layer include known methods such as a calendering method, an extrusion method, and a casting method. Among them, from the viewpoint of processability, it is preferable to form the shape-retaining layer by the calendering method. The method for forming the shape-retaining layer by the calendering method can be carried out in the same manner as the method for forming the base material layer in step (II), except that the resin used is different.

[0063] (Step (VIII)) In step (VIII), the shape-retaining layer obtained in step (VII) is bonded via an adhesive to the surface of the adhesive layer protection sheet on the side opposite to the adhesive layer side. As the adhesive, a silicone resin-based adhesive is preferable. Also, the adhesive used for forming the adhesive layer can be used in the same manner. The coating amount of the adhesive is preferably in the range of 20 g / m 2 ~70 g / m 2 of the range.

[0064] Through the above steps, a decorative film having an epidermal layer, a base material layer, an adhesive layer, an adhesive layer protection sheet, and a shape-retaining layer in this order is obtained.

[0065] (Step (IX)) In the step (IX), the decorative film is cut into a desired shape. The decorative film obtained in step (VIII) is cut using a cutter into a shape that fits the molded article that is the adherend. The cut shape may be selected depending on the shape of the adherend to be used.

[0066] (Process (X)) In the step (X), a cutting line including a cut portion is formed in the shape-retaining layer. The method for forming the cutting lines including the cut portions in the shape-retaining layer is not particularly limited, and for example, the cutting lines can be formed using a cutting device. There are no limitations on the cutting device that can be used as long as it is capable of forming a cutting line in the shape-retaining layer. For example, a commercially available cutting device can be used to form a cutting line including a cut portion on the side of the shape-retaining layer of the decorative film opposite the adhesive layer protective sheet side. The blade type used in the cutting device is preferably an eccentric cutter. For example, while the eccentric cutter held by the cutter head is pressed against the decorative film so that it can be moved up and down, the cutter head is moved in the X and Y directions, and the pressure of the eccentric cutter that is pressing against the decorative film is reduced at regular intervals. This cuts the shape-retaining layer in the in-plane direction in dotted lines (i.e., intermittently) to the desired depth, forming a cutting line consisting of cut and non-cut parts in the decorative film.

[0067] When attaching the decorative laminate to a molded body using a decorative film, the adhesive layer protective sheet and the shape-retaining layer are partially peeled off from the decorative film along the cutting line of the shape-retaining layer, and part of the exposed adhesive layer is brought into contact with the molded body.The adhesive layer protective sheet and the remaining part of the shape-retaining layer are then peeled off and the exposed adhesive layer is attached to the molded body.

[0068] The method for producing a decorative film of the present disclosure may further include other steps. For example, the method for manufacturing a decorative film may further include a step (step (XI)) of forming a primer layer between the substrate layer and the adhesive layer, and a step (step (XII)) of forming a design layer between the skin layer and the substrate layer.

[0069] (Process (XI)) In step (XI), the primer layer can be formed by a coating method, in which a resin for forming the primer layer is dissolved in an appropriate solvent, and the solution is applied to the surface of the substrate layer opposite to the surface of the skin layer, followed by drying. When a primer layer is formed, the above-mentioned step (IV) may be carried out after the step (XI) to form an adhesive layer on the primer layer.

[0070] (Process (XII)) Step (XII) is an optional step in which a design layer is further formed in the method for producing a decorative film. In step (XII), a design layer can be formed on one side of the skin layer prepared in step (I) or the substrate layer prepared in step (II). Methods for forming a design layer include, for example, a method in which a pre-formed design layer is adhered to one side of the surface layer or base layer, and a method in which one side of the surface layer or base layer is printed using a printing ink containing acrylic resin or vinyl chloride-vinyl acetate copolymer. Among these, forming the design layer by printing is preferred because it allows for a high degree of freedom in design. As a method for forming the design layer, a printing method can be applied for a design layer including a pattern, and for a design layer as a colored layer, a method can be applied in which a resin composition containing a colorant is formed into a film by a known method to form the design layer.

[0071] The printing method is a method of printing a known design using printing ink containing a resin, and examples of such methods include printing a resin-containing printing ink, such as a printing ink containing an acrylic resin, a vinyl chloride-vinyl acetate copolymer, or the like, using a known printing method, such as gravure printing (intaglio printing), letterpress printing, offset printing, inkjet printing, or screen printing. Specifically, the printing method may involve printing one side of the skin layer by gravure printing using a printing ink containing an acrylic resin. By adjusting the size of the engraving on the print roll used for gravure printing, it is possible to adjust the amount of printing ink applied during printing, and various designs can be formed. The design layer, which is an optional layer, can be formed independently on one side of the skin layer or the base layer as desired, so that a layer having a desired design can be formed with any color and any design. Therefore, by providing the design layer, various designs can be imparted to the decorative film.

[0072] <Decorative molding> The decorated molded body of the present disclosure includes a molded body and a decorative laminate in which the adhesive layer protective sheet and the shape-retaining layer have been peeled off from the decorative film of the present disclosure as described above, and the decorative laminate is adhered to the molded body by the adhesive layer. As shown in Fig. 2, the decorated molded body 30 includes a molded body 26 to be decorated and a decorative laminate 24, which is disposed on the surface of the molded body and is formed by peeling off the adhesive layer protective sheet and shape-retaining layer from the decorative film of the present disclosure. The decorative laminate 24 has the same layer structure as the decorative film of the present disclosure, except that it does not include the adhesive layer protective sheet or shape-retaining layer. That is, as shown in Fig. 2, the decorative laminate 24 includes a skin layer 12, a substrate layer 14, and an adhesive layer 18. In Fig. 2, an optional primer layer may be provided to improve adhesion between the substrate layer 14 and the adhesive layer 18.

[0073] <Method of manufacturing decorated molded body> The decorative film of the present disclosure described above is suitably used for the purpose of imparting a design to the surface of a molded article when the article is produced by heat molding. The method for manufacturing the decorated molded body of the present disclosure includes a preliminary molding step (A) of preliminarily molding the above-described decorative film of the present disclosure into a shape conforming to the molded body by a vacuum molding method, a partial peeling step (B) of partially peeling the adhesive layer protection sheet and the shape retention layer from the preliminarily molded decorative film with the cut line as a boundary to expose a part of the adhesive layer, and a partial adhesion step (C) of adhering a part of the adhesive layer exposed by partially peeling the shape retention layer and the adhesive layer protection sheet from the preliminarily molded decorative film with the cut line as a boundary to the surface of the molded body. The partial peeling step (B) and the partial adhesion step (C) are alternately repeated to gradually attach the decorative laminate from which the shape retention layer and the adhesive layer protection sheet have been peeled to the surface of the molded body.

[0074] In step (A), the decorative film of the present disclosure is preliminarily molded by a vacuum molding method using a mold conforming to the shape of the molded body as the adherend. As a method of preliminary molding, from the viewpoint of the shape retention of the preliminarily molded decorative film (preliminary molded body of the decorative film), a vacuum molding method is applied. A known method can be applied as the vacuum molding method. The heating conditions when preliminarily molding the decorative film by vacuum molding are preferably in the temperature range of 80°C to 150°C as described above. In step (A), the decorative film 10 is placed on the surface of the molding die having a shape conforming to the molded body, and vacuum suction is performed by a conventional method to preliminarily mold it along the molding die to obtain a preliminary molded body of the decorative film. Since the decorative film of the present disclosure has the above-described layer configuration, it can be quickly preliminarily molded by the vacuum molding method, and the obtained preliminary molded body has good shape retention.

[0075] In step (B), the adhesive layer protection sheet and the shape retention layer are partially peeled from the preliminarily molded decorative film with the cut line as a boundary to expose a part of the adhesive layer. In step (C), a part of the adhesive layer exposed by partially peeling the shape retention layer and the adhesive layer protection sheet from the preliminarily molded decorative film with the cut line as a boundary is adhered to the surface of the molded body. Then, steps (B) and (C) are alternately performed manually by an operator. For example, as shown in FIG. 3, when the rectangular decorative film 10 is cut into a shape 32 that conforms to the molded body, and in the case of the decorative film 32 with a single straight cut line 28 formed linearly, the area is divided with the cut line 28 as a boundary, and the peeling of the adhesive layer protection sheet and the shape retention layer and the pasting with the adhesive layer are performed step by step. Specifically, the pasting operation is performed as follows in (1) to (4) below. (1) Step (B) Peel off the adhesive layer protection sheet and the shape retention layer of the "A part" where the area of the decorative film is small to partially form a decorative laminate, and partially expose the adhesive layer of the decorative laminate. Here, since the shape retention layer is provided with a cut line cut in a dotted line shape in the in-plane direction, the "A part" can be easily cut along the cut line and the adhesive layer protection sheet can be easily peeled off. (2) Step (C) Face the adhesive layer of the "A part" of the decorative laminate exposed in (1) to the surface of the molded body, press the decorative laminate, and paste it to the surface of the molded body with the adhesive layer. (3) Step (B) Peel off the adhesive layer protection sheet and the shape retention layer of the remaining "B part" with a large area to form the whole into a decorative laminate, and expose the remaining adhesive layer of the decorative laminate. (4) Step (C) Face the adhesive layer of the decorative laminate exposed in (3) to the surface of the molded body, press the decorative laminate, and paste it to the surface of the molded body with the adhesive layer. This enables the step-by-step pasting of the decorative laminate and improves the workability of the pasting operation. Note that the manufacturing method of the decorative laminate molded body of the present disclosure is not limited to the above order of steps. For example, after providing the cut line 28 in the shape retention layer of the decorative film 10 before cutting, it may be cut into a shape that conforms to the molded body to be applied. Also, although it is more workable to first peel off the small A part with the cut line 28 as a boundary and paste it to the molded body, it is also possible to first peel off and paste the large B part.

[0076] As described above, the decorated molded article of the present disclosure is easy to attach the decorative laminate to the molded article and can be manufactured by a simple method. Since different hues, designs, etc. can be easily imparted to the same molded article, it can be applied to various uses. Further, the decorative laminate obtained by pre-molding and peeling the adhesive layer protective sheet and the shape-retaining layer is flexible, and a decorated molded article with good appearance in various designs can be obtained by a simple method. Therefore, the manufacturing method of the decorated molded article of the present disclosure is also suitable for small-lot production of decorated molded articles with different designs. And since the shape-retaining layer is provided with a cutting line including a cut portion, the workability of attaching to the molded article is improved, and losses due to attachment mistakes, appearance defects due to reattachment, etc. can be effectively suppressed. The field of the molded article to which the decorative laminate of the present disclosure can be applied is not particularly limited, and examples include vehicles such as automobiles and railways, furniture, airplanes, ships, building finishes, wall finishes, etc. The decorative film and the decorative laminate of the present disclosure can be suitably used for decorating various molded articles.

Example

[0077] Hereinafter, the decorative film of the present disclosure will be specifically described with reference to examples, but the present disclosure is not limited thereto.

[0078] <Manufacture of Decorative Film> Step (I) Preparation of Skin Layer As the skin layer, KFC film FT-50Y (trade name), a laminate of a polyvinylidene fluoride-containing layer (fluororesin) and a polymethyl methacrylate-containing layer (acrylic resin) manufactured by Kureha Extec Co., Ltd., with a thickness of 50 μm, was prepared.

[0079] Step (II) Substrate Layer Formation 2 kg of a pigment [PV MAF 725 (trade name), manufactured by Dainichi Seika Kogyo Co., Ltd.] was added to 100 kg of PVC resin [TH800 (trade name), manufactured by Taiyo Vinyl Co., Ltd.], and the mixture was formed into a sheet shape by a calendar method so that the thickness after drying would be 150 μm to obtain a substrate layer.

[0080] Process (III) Lamination of the Substrate Layer and the Skin Layer The substrate layer was laminated on the side of the polymethyl methacrylate-containing layer in the skin layer, passed between a pair of rolls, and laminated at a lamination temperature of 150 °C to obtain a laminate.

[0081] Process (XI) Formation of the Primer Layer A urethane-based resin [Resaloid (trade name), Dainichi Seika Kogyo Co., Ltd.] was applied to the surface of the substrate layer of the laminate opposite to the skin layer side, and a primer layer with a dry film thickness of 3 μm was formed.

[0082] Process (IV) Formation of the Adhesive Layer An acrylic-based adhesive [Olivine BPS (trade name), Toyochem Co., Ltd.] was applied onto the primer layer in an amount such that the film thickness after drying would be 55 μm, and dried to form an adhesive layer with a thickness of 55 μm.

[0083] Process (V) Preparation of the Adhesive Layer Protection Sheet As the substrate of the adhesive layer protection sheet, a flat resin sheet (PP [Fujicol Co., Ltd., BK0A (trade name), thickness: 60 μm]) was prepared.

[0084] Process (VI) Coating the Adhesive Layer with the Adhesive Layer Protection Sheet The surface of the adhesive layer formed in Process (VI) was coated with the adhesive layer protection sheet prepared in Process (V).

[0085] Process (VII) Formation of the Shape Retaining Layer 100 kg of an ABS resin [TM-30G6 (trade name), UMG-ABS Co., Ltd.] was formed into a sheet shape by the calendar method so that the thickness after drying would be 500 μm to form a shape retaining layer.

[0086] Process (VIII) Lamination of the Shape Retaining Layer and the Adhesive Layer Protection Sheet The adhesive layer protection sheet that coated the adhesive layer in Process (VI) and the shape retaining layer obtained in Process (VII) were bonded together through a silicone resin-based adhesive [Semidain PM165-R (trade name), Semidain Co., Ltd., coating amount 5 g / m 2 to obtain a decorative film.

[0087] Process (IX): Cutting of the decorative film The decorative film was cut to a size of 1260 mm (L direction) × 810 mm (W direction). Using this decorative film, the shape holding layer was modified in terms of the shape of the cut lines (cut length, non - cut length) and the depth of the cut portion as follows to produce the decorative films of Examples 1 - 20.

[0088] 〔Example 1〕 Process (X): Forming cut lines in the shape holding layer Using a cutting device (manufactured by Kongsberg, blade type: eccentric cutter), the decorative film was placed at a predetermined position of the cutting device such that the shape holding layer side of the decorative film faced the cut portion of the cutting device. Cut lines (cut depth: 150 μm) having the shape shown in Fig. 3 (cut length: 0.5 mm, non - cut length: 0.5 mm) were formed. Thereby, the decorative film of Example 1 was obtained.

[0089] 〔Example 2〕 The decorative film of Example 2 was obtained in the same manner as Example 1, except that the cut depth of the cut lines formed in Process (X) in Example 1 was changed to 200 μm.

[0090] 〔Example 3〕 The decorative film of Example 3 was obtained in the same manner as Example 1, except that the cut depth of the cut lines formed in Process (X) in Example 1 was changed to 250 μm.

[0091] 〔Example 4〕 The decorative film of Example 4 was obtained in the same manner as Example 1, except that the cut depth of the cut lines formed in Process (X) in Example 1 was changed to 300 μm.

[0092] 〔Example 5〕 The decorative film of Example 5 was obtained in the same manner as in Example 1, except that the cut line formed in step (X) in Example 1 was changed to a cut line having the shape shown in Fig. 4 (cut length: 2.5 mm, non-cut length: 0.5 mm) (cut portion depth: 150 μm).

[0093] [Example 6] The decorative film of Example 6 was obtained in the same manner as in Example 5, except that the depth of the cut portion of the cut line formed in step (X) in Example 5 was changed to 200 μm.

[0094] [Example 7] The decorative film of Example 7 was obtained in the same manner as in Example 5, except that the depth of the cut portion of the cut line formed in step (X) in Example 5 was changed to 250 μm.

[0095] [Example 8] The decorative film of Example 8 was obtained in the same manner as in Example 5, except that the depth of the cut portion of the cut line formed in step (X) in Example 5 was changed to 300 μm.

[0096] [Example 9] The decorative film of Example 9 was obtained in the same manner as in Example 1, except that the cut line formed in step (X) in Example 1 was changed to a cut line having the shape shown in Fig. 5 (cut length: 1.5 mm, non-cut length: 1.5 mm) (cut portion depth: 150 μm).

[0097] [Example 10] The decorative film of Example 10 was obtained in the same manner as in Example 9, except that the depth of the cut portion of the cut line formed in step (X) in Example 9 was changed to 200 μm.

[0098] [Example 11] The decorative film of Example 11 was obtained in the same manner as in Example 9, except that the depth of the cut portion of the cut line formed in step (X) in Example 9 was changed to 250 μm.

[0099] [Example 12] A decorative film of Example 12 was obtained in the same manner as in Example 9, except that the depth of the cut portion of the cut line formed in step (X) in Example 9 was changed to 300 μm.

[0100] Example 13 The decorative film of Example 13 was obtained in the same manner as Example 1, except that the cut line formed in step (X) in Example 1 was changed to a cut line (cut depth: 150 μm) with the shape shown in Figure 6 (cut length: 0.5 mm, uncut length: 2.5 mm).

[0101] Example 14 A decorative film of Example 14 was obtained in the same manner as in Example 13, except that the depth of the cut portion of the cut line formed in step (X) in Example 13 was changed to 200 μm.

[0102] Example 15 A decorative film of Example 15 was obtained in the same manner as in Example 13, except that the depth of the cut portion of the cut line formed in step (X) in Example 13 was changed to 250 μm.

[0103] Example 16 A decorative film of Example 16 was obtained in the same manner as in Example 13, except that the depth of the cut portion of the cut line formed in step (X) in Example 13 was changed to 300 μm.

[0104] Example 17 The decorative film of Example 17 was obtained in the same manner as Example 1, except that the cut line formed in step (X) in Example 1 was changed to a cut line (cut depth: 150 μm) with the shape shown in Figure 7 (cut length: 2.5 mm, uncut length: 2.5 mm).

[0105] Example 18 A decorative film of Example 18 was obtained in the same manner as in Example 17, except that the depth of the cut portion of the cut line formed in step (X) in Example 17 was changed to 200 μm.

[0106] Example 19 A decorative film of Example 19 was obtained in the same manner as in Example 17, except that the cut depth of the cut line formed in step (X) in Example 17 was changed to 250 μm.

[0107] [Example 20] A decorative film of Example 20 was obtained in the same manner as in Example 17, except that the cut depth of the cut line formed in step (X) in Example 17 was changed to 300 μm.

[0108] [Comparative Example 1] As shown in FIG. 8, a decorative film of Comparative Example 1 was a decorative film in which no cut line was formed in the shape-retaining layer of the decorative film (cut length: 0 mm, non-cut length: 0 mm).

[0109] [Manufacture of Decorative Molding] Each of the decorative films of the examples and comparative examples was preformed using a vacuum forming apparatus to match the shape of the molded body, which was the adherend. As the molded body, a vehicle side roof was applied. The adhesive layer protective sheet and the shape-retaining layer of the decorative film after preforming were partially peeled off with the cut line of the shape-retaining layer as the boundary ("cut workability" was evaluated), and the adhesive layer side was attached to the molded body ("attachment workability" was evaluated) to manufacture a decorative molded body.

[0110] [Evaluation of Decorative Film] Ten operators as monitors actually performed the work of attaching the decorative film after preforming to the molded body and evaluated the cut workability of the adhesive layer protective sheet and the shape-retaining layer, as well as the attachment workability to the molded body, according to the following criteria. Among the ten operators, the most frequent evaluation was adopted. When the evaluation results were the same, the better result was described.

[0111] [Cut Workability] A: The cutting work of the adhesive layer protective sheet and the shape-retaining layer is extremely easy and there is no problem. B: The cutting work of the adhesive layer protective sheet and the shape-retaining layer is easy and there is no problem. C: It is slightly difficult to cut off the adhesive layer protection sheet and shape-retaining layer, but there is no problem. D: It is impossible to cut off the adhesive layer protection sheet and the shape-retaining layer, and there is a problem. Regarding the ease of cutting, A, B and C are ratings that indicate no practical problems.

[0112] <Ease of application> A: The decorative laminate is easy to attach to the molded product, and there are no problems. B: The decorative laminate is difficult to attach to the molded body, which is problematic. The ease of application was evaluated as A, which means that there was no practical problem.

[0113] The results are shown in Table 1 below.

[0114] [Table 1]

[0115] The decorative films of the Examples were rated higher in both ease of cutting and ease of application than the decorative films of the Comparative Examples. Particularly, the cutting lines having the shapes shown in Figs. 3, 4 and 5, that is, the cutting length being 0.5 mm to 2.5 mm and the uncut length being 1.5 mm or less, are preferable. [Explanation of symbols]

[0116] 10 Decorative film 12 Epidermal layer 14 Base material layer 18 Adhesive layer 20 Adhesive layer protection sheet 22 Shape retention layer 24 Decorative laminate 26 Molded object (adherent) 28 Cut Lines 28A Cut section 28B Uncut part 30 Decorative molding 32 Decorative film (after cutting)

Claims

1. An epidermal layer, a base material layer, an adhesive layer, an adhesive layer protective sheet, a shape-retaining layer having a cut line in which cut portions and non-cut portions are alternately arranged, comprising them in this order, wherein the depth of the cut portion is shorter than the thickness of the shape-retaining layer, After being preformed into a shape adapted to a three-dimensional shaped body, with the cut line as a boundary, peeling of the adhesive layer protective sheet and the shape-retaining layer, and stepwise attachment of the shaped body to the surface of the shaped body by the adhesive layer are possible. A decorative film used for decorating a shaped body.

2. The depth of the cut portion is 150 μm to 300 μm, The decorative film according to claim 1.

3. The length of the non-cut portion is 1.5 mm or less, The decorative film according to claim 1 or claim 2.

4. The length of the cut portion is 0.5 mm to 2.5 mm, The decorative film according to any one of claims 1 to 3.

5. The base material layer contains at least one resin selected from the group consisting of vinyl chloride resin, acrylic resin, and ABS resin, The epidermal layer contains at least one resin selected from the group consisting of fluororesin, acrylic resin, and vinyl chloride resin, The shape-retaining layer contains at least one resin selected from the group consisting of ABS resin and vinyl chloride resin, The decorative film according to any one of claims 1 to 4.

6. The decorative film according to any one of claims 1 to 5, which is a decorative film for vehicle exterior.

7. A method for manufacturing the decorative film according to any one of claims 1 to 6, comprising: A step of laminating an epidermal layer on one surface side of the base material layer, A step of forming an adhesive layer on the other surface side of the base material layer, A step of covering the adhesive layer with an adhesive layer protective sheet, A step of laminating a shape-retaining layer on the side opposite to the adhesive layer side of the adhesive layer protective sheet via an adhesive, A step of forming a cut line in which cut portions and non-cut portions are alternately arranged in the shape-retaining layer, and the depth of the cut portion is shorter than the thickness of the shape-retaining layer, Including, A method for manufacturing a decorative film used for decorating a shaped body.

8. The base material layer contains at least one resin selected from the group consisting of vinyl chloride resin, acrylic resin, and ABS resin, The epidermal layer contains at least one resin selected from the group consisting of fluororesin, acrylic resin, and vinyl chloride resin, The shape-retaining layer contains at least one resin selected from the group consisting of an ABS resin and a vinyl chloride resin. The method for manufacturing a decorative film according to claim 7.

9. A preliminary forming step of preliminarily forming the decorative film according to any one of claims 1 to 6 into a shape that conforms to a molded article having a three-dimensional shape by a vacuum forming method, A partial peeling step of partially peeling the adhesive layer protection sheet and the shape-retaining layer from the preliminarily formed decorative film with the cut line as a boundary to expose a part of the adhesive layer, A partial adhesion step of adhering a part of the adhesive layer exposed by partially peeling the shape-retaining layer and the adhesive layer protection sheet from the preliminarily formed decorative film with the cut line as a boundary to the surface of the molded article, comprising A method for manufacturing a decorated molded article, in which the partial peeling step and the partial adhesion step are alternately repeated to gradually attach a decorative laminate from which the shape-retaining layer and the adhesive layer protection sheet have been peeled to the surface of the molded article.

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