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

Abstract

To provide a decorative film that allows any design pattern to be easily formed on an adherend without using a transfer sheet, a method for producing the decorative film, a decorative molding having the decorative film and a method for producing the decorative molding.SOLUTION: The present invention pertains to a decorative film used for decorating a molding, the decorative film having a decorative layer having a peelable part and a non-peelable part, an adhesive layer, and an adhesive layer protective sheet, in the stated order. The peelable part and the non-peelable part are separated along a tear-off line with its depth being less than 100% of the thickness of the decorative layer from the surface side of the decorative layer. There are also provided applications for the same.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 article, and a method for manufacturing a decorated molded article. [Background technology]

[0002] Synthetic resin decorative films (hereinafter sometimes referred to as decorative films) with various designs are used as exterior materials for automobiles, railway vehicles, aircraft, etc. By performing a decorating method in which the decorative film is attached to an adherend, for example, the exterior surface of an automobile, etc., any design can be easily imparted to the exterior of the automobile, etc. Furthermore, the decorative film can be peeled off without damaging the original exterior material of the automobile, etc., and can also be replaced. Examples of decorative films include decorative sheets used to cover the entire surface of a partial area such as the roof or spoiler of an automobile. As a decorative sheet, a decorative sheet having an adhesive layer with a shape-retaining layer has been proposed to improve workability (see Patent Document 1). The decorative sheet described in Patent Document 1 has a shape-retaining layer, which is said to improve the ease of application by preforming the decorative sheet into a shape that fits the molded body to which it is to be applied.

[0003] Also known is an application sheet (hereinafter referred to as a "transfer sheet") for attaching design patterns such as letters and designs. By attaching only the design pattern such as letters and designs on the transfer sheet to an adherend, any design pattern can be formed in any area. A decorative transfer sheet is formed by transferring a design pattern, such as letters or a design, that is on a decorative sheet, a decorative adhesive sheet, or the like (hereinafter referred to as "decorative sheet, etc.") to a base sheet for forming the transfer sheet to obtain a decorative transfer sheet. The formed decorative transfer sheet is attached to an adherend, and the base sheet of the transfer sheet is then peeled off, thereby decorating the adherend with the design pattern. As a decorative sheet, a decorative sheet has been proposed that includes a decorative film and an application tape, each of which satisfies a specific tensile modulus, so that the decorative surface does not stretch or distort when attached to a three-dimensional molded body (see Patent Document 2). Furthermore, a method has been proposed for producing a transfer sheet in which a decorative adhesive sheet attached to a release body via an adhesive layer is used, the decorative adhesive sheet is cut into a desired shape, and the cut-out design portion is attached to an application tape with specific physical properties and provided with a pressure-sensitive adhesive layer (see Patent Document 3). In this method, the release body is peeled off from the transfer sheet, the design portion is attached to an adherend, and the application tape is peeled off, thereby transferring the design to the adherend. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2016-198900 A [Patent Document 2] Japanese Patent Application Laid-Open No. 2006-248120 [Patent Document 3] Japanese Patent Application Publication No. 06-051702 Summary of the Invention [Problem to be solved by the invention]

[0005] However, the decorative sheet described in Patent Document 1 is preformed into a shape that fits the molded body to which the decorative sheet is to be attached, and then the preform is attached to the molded body as is, making it difficult to apply only the design part, such as letters or figures of a specific shape, to the molded body rather than the entire area. Furthermore, the decorative sheets described in Patent Documents 2 and 3 require a transfer sheet such as an application tape in addition to the decorative layer, and the elastic modulus, thermal properties, etc. of the transfer sheet must be controlled within a predetermined range. Also, in order to stably hold the design part on the transfer sheet until transfer, the design part needs to have a certain degree of adhesion to the transfer sheet.

[0006] An object of one embodiment of the present invention is to provide a decorative film and a method for manufacturing the decorative film, which can easily form any design pattern on an adherend without using a transfer sheet. Another object of another embodiment of the present invention is to provide a decorated molded body with good design properties and a method for manufacturing a decorated molded body, using a decorative film that can easily form any design pattern on an adherend without using a transfer sheet. [Means for solving the problem]

[0007] The means for solving the problems include the following aspects. <1> A decorative film used to decorate a molded body comprises, in this order: a decorative laminate having a decorative layer with a peelable portion and a non-peeling portion, and an adhesive layer; and an adhesive layer protective sheet, wherein the peelable portion and the non-peeling portion are defined by a cutting line whose depth is less than 100% from the surface side of the decorative layer relative to the thickness of the decorative layer. <2> The depth of the cut line in the decorative layer is 25% or more and less than 100% of the thickness of the decorative layer from the surface side of the decorative layer. <1> The decorative film according to claim 1. <3> The peeling unit includes a peeling assisting unit. <1> or <2> The decorative film according to claim 1. <4> A colored sheet having a different hue from that of the decorative layer is further provided on the surface of the decorative layer opposite to the adhesive layer side. <1> ~ <3> 10. The decorative film according to claim 9, wherein the decorative film is a film having a thickness of 100 nm or less.

[0008] <5> A method for manufacturing a decorative film used to decorate a molded body, comprising the steps of: forming an adhesive layer on one side of a decorative layer to form a decorative laminate; preparing an adhesive layer protective sheet and covering the adhesive layer with the prepared adhesive layer protective sheet to form a decorative film precursor having the decorative layer, the adhesive layer, and the adhesive layer protective sheet; forming a first cutting line in the decorative layer, the first cutting line having a depth that is less than 100% of the thickness of the decorative layer from the surface side of the decorative layer, to separate a peelable portion from a non-peeling portion; and forming a second cutting line that passes through the decorative film precursor at a position where the second cutting line intersects with the first cutting line.

[0009] <6> a molded body; <1> ~ <4> and a non-peeled portion of the decorative laminate obtained by peeling the adhesive layer protection sheet and the peeled portion of the decorative laminate from the decorative film according to any one of the above items. <7> <1> ~ <4> a step of peeling off an adhesive layer protective sheet from the decorative film described in any one of the above to obtain a decorative laminate; a step of attaching the decorative laminate from which the adhesive layer protective sheet has been peeled off to the surface of a molded body via an adhesive layer; and a step of peeling off the peeled portion of the decorative laminate attached to the surface of the molded body. [Effects of the Invention]

[0010] According to one embodiment of the present invention, it is possible to provide a decorative film and a method for manufacturing a decorative film that can easily form any design pattern on an adherend without using a transfer sheet. According to another embodiment of the present invention, it is possible to provide a decorated molded body with good design properties and a method for manufacturing a decorated molded body, using a decorative film that can easily form any design pattern on an adherend without using a transfer sheet. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a schematic cross-sectional view showing an example of a decorative film of the present disclosure. [Figure 2]1 is a schematic plan view showing an example of a concave-shaped peeling aid portion in a decorative film of the present disclosure. FIG. [Figure 3] 1 is a schematic plan view showing an example of a tab that is a convex-shaped peeling aid in a decorative film of the present disclosure. FIG. [Figure 4] 10 is a schematic plan view showing one embodiment of a state in which a first cutting line is formed on a rectangular decorative film precursor in step III of the decorative film manufacturing method of the present disclosure. FIG. [Figure 5] 4 is a schematic plan view showing one embodiment of a state in which a second cutting line has been formed on a rectangular decorative film precursor on which a first cutting line has been formed in step IV of the decorative film manufacturing method of the present disclosure. FIG. [Figure 6] 1 is a schematic plan view showing an example of a partition between a peelable portion and a non-peeled portion of a decorative film of the present disclosure. [Figure 7] 1 is a partial schematic cross-sectional view showing an example of a decorated molded body according to the present disclosure. [Figure 8] 1 is a schematic cross-sectional view showing an example of a state in which a decorative laminate having a colored sheet according to the present disclosure is attached to a molded body and the colored sheet at the release portion is peeled off. [Figure 9] 10 is a partially enlarged view of a recess serving as a peeling aid formed on the decorative film of Example 4. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0012] The decorative film, the manufacturing method thereof, the decorated molded article, and the manufacturing method thereof 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 such 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 the present disclosure, the upper or lower limit value described in one numerical range may be replaced with the upper or 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 value of the numerical range may be replaced with the value shown in the examples. In the present disclosure, a combination of two or more preferred embodiments is a more preferred embodiment. 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.

[0013] In this disclosure, "room temperature" refers to 23°C unless otherwise specified. The "decorative film" in the present disclosure includes at least a decorative laminate having a decorative layer and an adhesive layer, and an adhesive layer protective sheet, in this order. In the present disclosure, a laminate of the decorative layer and the adhesive layer is referred to as a “decorative laminate.” That is, the decorative laminate is attached to a molded body, which is an adherend, via the adhesive layer, and then the peelable portion of the decorative laminate is peeled off, so that the non-peeled portion of the decorative laminate forms a design pattern on the molded body. Here, in the present disclosure, the "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 that includes that component. In the present disclosure, the resin that is the main component that constitutes a layer is also referred to as the "base resin." In the present disclosure, the term "molded article" refers to a molded article (base of a molded article) before decoration. In the present disclosure, the outermost layer of the decorative film, i.e., the side opposite the adhesive layer of the decorative layer, which is visible when attached to a molded body, is referred to as the surface of the decorative film.

[0014] [Decorative film] The decorative film of the present disclosure is a decorative film used to decorate a molded body, and comprises, in this order, a decorative layer having a peelable portion and a non-peeling portion, an adhesive layer, and an adhesive layer protective sheet, wherein the peelable portion and the non-peeling portion are defined by a cutting line whose depth from the surface side of the decorative layer is less than 100% of the thickness of the decorative layer. In the decorative film of the present disclosure, the peelable portion and the non-peeling portion are separated by a perforation line whose depth from the surface side of the decorative layer is less than 100% of the thickness of the decorative layer, so that after peeling the adhesive layer protective sheet from the decorative film and attaching the decorative layer to a molded body via the adhesive layer, the presence of the perforation line makes it easy to peel off only the peelable portion. Therefore, a design pattern consisting of the non-peeling portion of the decorative film can be easily formed on the surface of the molded body, even if it has a complex shape.

[0015] Fig. 1 is a schematic cross-sectional view showing an example of a decorative film of the present disclosure. The decorative film 10 shown in Fig. 1 has a decorative layer 12, an adhesive layer 14, and an adhesive layer protective sheet 16, and is provided with a perforation line 20 that separates the peeled portion from the non-peeled portion of the decorative layer 12. The decorative film 10 shown in Fig. 1 further has a skin layer 18 as an optional layer. 1 is formed at a depth that is less than 100% of the thickness of the decorative layer 12 from the surface side of the decorative layer 12. Therefore, the depth of the cut line is such that it does not reach the interface where the adhesive layer 14 and the decorative layer 12 contact each other.

[0016] When decorating a molded body, the decorative film 10 is attached to the molded body after peeling off the adhesive layer protective sheet 16, and a laminate of the skin layer 18, decorative layer 12, and adhesive layer 14 shown in Figure 1 is attached to the molded body. In the present disclosure, as described above, a laminate having at least the decorative layer 12 and the adhesive layer 14 is referred to as a "decorative laminate." In addition to the decorative layer 12 and the adhesive layer 14, the decorative laminate may further include any other layer, such as a skin layer 18 or a primer layer. In FIG. 1, the area indicated by A is the peeled portion of the decorative film, and the area indicated by B is the non-peeled portion.

[0017] (decorative layer) The non-peeling portion of the decorative layer in the decorative film of the present disclosure is attached to the molded body via an adhesive layer, and is a layer that imparts design to the molded body. The decorative layer is formed to contain a synthetic resin.

[0018] -Synthetic resin- Any synthetic resin can be used without particular limitation as long as it can be formed into a sheet, including, for example, acrylic resin, polyvinyl chloride (hereinafter also referred to as PVC) resin, acrylonitrile / butadiene / styrene copolymer (hereinafter also referred to as ABS resin), urethane resin, and olefin resin. Among these, it is preferable that the decorative film contains at least one resin selected from acrylic resin, PVC resin, and ABS resin, from the viewpoint of improving the durability of the decorative film.

[0019] Examples of acrylic resins that can be used in the decorative layer include polymers or copolymers of methacrylic acid or methacrylic acid esters, such as polymethyl methacrylate (PMMA), and copolymers of alkyl methacrylate, alkyl acrylate, and styrene. From the standpoint of formability, examples include mixtures of copolymers of alkyl methacrylate, alkyl acrylate, and styrene, and copolymers of methyl methacrylate and methyl acrylate.

[0020] The vinyl chloride resin (PVC) that can be used in the decorative layer can be any that has been used in vinyl chloride leather. Specifically, in addition to polyvinyl chloride with an average degree of polymerization of 800 to 2000, preferably about 800 to 1500, there are copolymer resins mainly composed of vinyl chloride and ethylene, vinyl acetate, methacrylic acid ester, etc., and mixed resins of these resins with polyester resin, epoxy resin, acrylic resin, vinyl acetate resin, urethane resin, acrylonitrile, styrene-butadiene copolymer resin, partially saponified vinyl alcohol, etc.

[0021] The ABS resin used in the decorative layer can be appropriately selected from known ABS resins. Only one type of ABS resin may be used, or two or more types with different copolymerization ratios may be used in combination. Furthermore, the ABS resin may be used in combination with the PVC resin.

[0022] The decorative layer may contain only one type of synthetic resin, or may contain two or more types depending on the purpose. When two or more synthetic resins are contained, it is preferable to combine resins that are highly compatible with each other.

[0023] In addition to the synthetic resin, the decorative layer may contain other components depending on the purpose, such as colorants, plasticizers, fillers, lubricants, processing aids, flame retardants, light stabilizers, and heat stabilizers.

[0024] -Coloring agent- By including a colorant in the decorative layer, any desired hue can be imparted to the decorative film. There are no particular restrictions on the colorants that can be contained in the decorative layer, and examples include dyes, pigments, pearl particles, metal powders such as aluminum powder, etc., and one or more selected from these colorants can be used depending on the purpose. When the decorative film is used for applications requiring durability and weather resistance, such as exterior materials for vehicles and interior and exterior materials for buildings, pigments are preferably used.

[0025] -Thickness of decorative layer- There are no particular limitations on the thickness of the decorative layer, but from the viewpoint of ease of application to the molded article, the thickness of the decorative layer is preferably in the range of 50 μm to 400 μm, and more preferably in the range of 100 μm to 350 μm.

[0026] -Method for forming decorative layer- The method for forming the decorative layer is not particularly limited, and any known sheet molding method may be used. Examples of molding methods include a calendar method, a casting method, a melt extrusion method, a solution method, etc., and any of these may be used. Among these, the calendar method is preferred from the viewpoints of ease of production and easy maintenance of the equipment. For example, by forming the decorative layer using the calendar method, decorative layers containing various colorants can be easily produced, and the cleaning inside the device required when changing the type or amount of colorant added can be easily performed, so various variations with the desired hue and desired grain pattern can be easily produced. This makes it suitable for small-lot production of decorative films with a wide variety of colors and patterns and excellent durability.

[0027] (Adhesive layer) The decorative film of the present disclosure includes an adhesive layer on one side of the decorative layer for the purpose of adhering the decorative laminate to the molded body. There are no particular restrictions on the adhesive or pressure-sensitive adhesive used to form the adhesive layer, and it may be selected appropriately depending on the type of molded article to which the decorative laminate is to be attached.

[0028] In particular, from the viewpoint of workability when attaching the decorative laminate to a molded body and ease of peeling the peeled portion, it is preferable that the adhesive layer be an adhesive layer with low initial tack.Furthermore, from the viewpoint of the stability of the decorative layer, it is preferable that the adhesive layer be an adhesive layer with good adhesion stability after attachment over time, as described below.

[0029] -Low initial tack of adhesive layer- As a guideline for low initial tack of the adhesive layer, the initial peel strength measured by the peel test method (I) below is preferably in the range of 0.1 N / cm to 5 N / cm, more preferably in the range of 1 N / cm to 5 N / cm. (Peel test method (I)) Peel off the adhesive layer protection sheet from the decorative film, attach the adhesive layer side of the decorative laminate to a stainless steel plate, and measure the peel strength in accordance with the 180° peel test for adhesive tape specified in JIS Z 0237 (2009).

[0030] -Adhesion stability after application of adhesive layer - From the viewpoint of adhesive stability after application over time of the adhesive layer, the peel strength after application over time measured by the following test method (II) is preferably 6.5 N / cm or more, more preferably 7 N / cm or more, and even more preferably 8 N / cm or more.

[0031] (Peel test method (II)) Peel off the adhesive layer protection sheet from the decorative film, attach the adhesive layer side of the decorative laminate to a stainless steel plate, and after keeping it at 20°C for 24 hours, measure the peel strength in accordance with the 180° peel test for adhesive tape specified in JIS Z 0237 (2009).

[0032] By adhering a test piece with an adhesive layer to the surface of the hard substrate (the adherend) and curing it for 24 hours, the contact area between the hard substrate and the adhesive layer becomes larger, intermolecular forces between the two occur at more points, and the adhesive layer matures, becoming more stably fixed to the hard substrate.

[0033] - Formation of adhesive layer - The adhesive layer is preferably an adhesive layer containing a pressure-sensitive adhesive or a hot melt adhesive containing at least one resin selected from ethylene vinyl acetate, acrylic resin, urethane resin, olefin resin, polyester, polyamide, and synthetic rubber. From the viewpoint of adhesive stability, the thickness of the adhesive layer formed from the pressure sensitive adhesive or hot melt adhesive is preferably in the range of 20 μm to 80 μm, more preferably 30 μm to 60 μm in dry thickness. As a method for forming an adhesive on the decorative layer, any known method for forming a layer, such as a transfer method or a coating method, can be used. From the viewpoint of being able to easily form an adhesive layer with a uniform thickness, it is preferable to use the transfer method. Furthermore, when the adhesive layer protective sheet is provided with irregularities as described below and the irregularities are transferred to the adhesive layer, a coating method may be used to form the adhesive.

[0034] (Adhesive layer protection sheet) The decorative film of the present disclosure has an adhesive layer protective sheet on the surface of the adhesive layer opposite the decorative layer. As the adhesive layer protective sheet, a synthetic resin film (synthetic resin substrate), a release-treated synthetic resin film, or the like can be used. There are no particular restrictions on the synthetic resin substrate used in the adhesive layer protective sheet, as long as it has the strength to form and maintain an adhesive layer on its surface as an adhesive layer protective sheet.

[0035] Examples of synthetic resins that can be used for the synthetic resin substrate in the adhesive layer protective sheet include olefin resins such as polyethylene (PE) and polypropylene (PP), polyethylene terephthalate (PET), and polyethylene naphthalate (PEN), among which PP and PET are preferred from the viewpoint of dimensional stability. The synthetic resin substrate may be a non-stretched substrate or a uniaxially or biaxially stretched substrate.

[0036] From the viewpoint of better strength, workability, and handleability, the thickness of the adhesive layer protective sheet is preferably 5 μm to 100 μm, and more preferably 40 μm to 80 μm. When the thickness of the adhesive layer protective sheet is within the above range, the workability when laminating and peeling the adhesive layer protective sheet is improved, and the adhesive layer protective sheet can be wound into a roll, which makes storage, transportation, etc. easier, resulting in good handleability.

[0037] The surface of the adhesive layer protective sheet that comes into contact with the adhesive may be smooth or may have irregularities. In particular, when the adhesive layer protective sheet has unevenness, the recesses in the adhesive layer formed corresponding to the protrusions of the adhesive layer protective sheet become channels for fluids such as air and moisture when the decorative laminate is attached to a molded body, allowing undesired fluids to be discharged more quickly, which is preferable from the viewpoint of improving attachment properties. The unevenness on the surface of the adhesive layer protective sheet can be provided by embossing the synthetic resin substrate that constitutes the adhesive layer protective sheet. By providing an adhesive layer in contact with the irregularities on the surface of the adhesive layer protective sheet, irregularities formed by the irregularities on the surface of the adhesive layer protective sheet are formed on the surface of the adhesive layer that comes into contact with the surface of the adhesive layer protective sheet. From the viewpoint of further improving the removability of fluids when adhering the decorative laminate to the molded body, it is preferable that the surface of the adhesive layer that comes into contact with the surface of the adhesive layer protective sheet has irregularities formed by the irregularities of the surface of the adhesive layer protective sheet, and that the irregularities of the adhesive layer surface are present over the entire surface of the adhesive layer, and it is particularly preferable that the recesses of the irregularities are formed continuously all the way to the edge of the adhesive layer protective sheet.

[0038] (Other layers) The decorative film of the present disclosure may further include any layer (referred to as "other layer") depending on the purpose, in addition to the decorative layer, adhesive layer, and adhesive layer protective sheet. Other layers include a skin layer that is provided on the surface of the decorative layer opposite the surface having the adhesive layer, i.e., on the surface of the decorative film, in order to further improve durability; a primer layer that is provided in order to further improve adhesion between the decorative layer and the adhesive layer; and a colored sheet of a different hue from the decorative layer that is provided in order to improve the visibility of the peeled and non-peeled portions of the decorative laminate.

[0039] (epidermal layer) The decorative film of the present disclosure may have a skin layer. The skin layer is provided on the outermost surface of the decorative film, and the skin layer can impart durability to the decorative film. The skin layer is preferably formed using a synthetic resin. From the viewpoint of durability of the decorative film, the surface layer preferably contains at least one synthetic resin selected from fluororesin, acrylic resin, and polyvinyl chloride (PVC) resin.

[0040] Fluorine resins that can be used for the skin layer include resins containing one or more fluorine atoms in the molecule, such as resins obtained by polymerizing olefins containing fluorine atoms. More specific examples of the fluororesin include tetrafluoroethylene resin, trifluorochloroethylene resin, hexafluoroethylene propylene resin, ethylene-tetrafluoroethylene copolymer, and vinylidene fluoride resin.

[0041] Examples of acrylic resins and polyvinyl chloride (PVC) resins that can be used for the surface layer include the same synthetic resins as those used for the decorative layer.

[0042] The skin layer may be formed by applying an extrusion method in which extrusion is formed using a T-die or the like, a calendar method, a casting method, or the like, or by applying a commercially available film. The thickness of the surface layer is preferably 5 μm to 100 μm, more preferably 10 μm to 60 μm, from the viewpoints of durability and retention of the concave-convex pattern when formed.

[0043] (Primer layer) The decorative film of the present disclosure may have a primer layer provided between the decorative layer and the adhesive layer for the purpose of further improving the adhesion between the decorative layer and the adhesive layer. The primer layer can be formed, for example, by dissolving a resin for forming the primer layer in an appropriate solvent, applying the solution to the back surface of the decorative layer, and drying it. The resin used to form the primer layer is preferably formed to contain a polyester resin or the like, from the viewpoint of affinity with the synthetic resin contained in the decorative layer and the resin serving as the adhesive or pressure-sensitive adhesive contained in the adhesive layer. There is no particular limit to the amount of primer layer applied, and it can be selected appropriately depending on the purpose. Generally, from the viewpoint of improving adhesion, 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:

[0044] (Colored sheet with a different hue from the decorative layer) The decorative film of the present disclosure may further include a colored sheet of a different hue from that of the decorative layer on the surface of the decorative layer opposite the adhesive layer side. A colored sheet (hereinafter sometimes simply referred to as "colored sheet") of a different hue from the decorative layer is provided on the surface of the decorative film in order to improve the visibility of the division between the peeled and non-peeled portions of the decorative laminate. The "hue" of the colored sheet is used to mean an achromatic color as well. When the decorative layer is achromatic, for example, when the decorative layer is white, an example of using a black sheet as the colored sheet is given. When the decorative layer is colored, for example, an example of using a colored sheet of a complementary color or a color close to the complementary color that is located opposite the hue of the decorative layer on the color wheel is given. It is preferable to select a colored sheet of a hue that contrasts with the hue of the decorative layer. The colored sheet may be made of any material such as synthetic resin or paper, and may be a commercially available product. The surface of the colored sheet that comes into contact with the surface layer or decorative layer of the decorative film preferably has an adhesive layer, so that the colored sheet is stably fixed until it is peeled off. Note that the adhesive layer of the colored sheet preferably has low adhesiveness similar to that described for the adhesive layer, from the viewpoint of achieving both stable fixation of the colored sheet and ease of peeling. The method for using the colored sheet will be described in detail in the method for producing the decorated molded article.

[0045] (Cutting line) The layer structure of the decorative film of the present disclosure is as described above. The decorative film having the above layer structure has a cut line for dividing the peeled portion and the non-peeled portion of the decorative laminate. The depth of the cut line is less than 100% from the surface side of the decorative layer with respect to the thickness of the decorative layer. In the present disclosure, the notches that separate the peelable portion from the non-peeled portion and that are formed in the decorative layer in a linear, continuous manner in a plan view of the decorative film are referred to as "perforation lines." The depth of the perforation lines is less than 100% of the thickness of the decorative layer from the surface side of the decorative layer, and by peeling the peelable portion separated by the perforation lines of the decorative film, a design pattern of the decorative film is formed on the adherend of the decorative film.

[0046] In the decorative film, the depth of the cut line separating the peelable and non-peeling portions of the decorative laminate is preferably 25% or more, and more preferably 60% or more, from the surface side of the decorative layer, when the thickness of the decorative layer is 100%, from the viewpoint of being able to achieve both connectivity between the peelable and non-peeling portions and ease of peeling of the peelable portion. The depth of the cut line is preferably less than 100% of the thickness of the decorative layer from the surface side of the decorative layer, and is preferably 98% or less from the surface side of the decorative layer. That is, the depth of the cut line in the decorative layer is preferably 25% or more and less than 100% of the thickness of the decorative layer from the surface side of the decorative layer. When the depth of the cut line is within the above range, the peelable portion of the decorative film can be easily peeled along the shape of the cut line without applying any particular force, making it easier to achieve design expression with a design pattern that has excellent design quality and corresponds to the shape of the cut line.

[0047] The depth of the cut line will be explained with reference to Fig. 1. In Fig. 1, when the thickness of the decorative layer 12 is α and the depth of the cut line 20 is β, α and β have the relationship expressed by the following formula. α>β formula Preferably, α>β≧(α×0.25), More preferably, (α×0.98)≧β≧(α×0.60).

[0048] If the depth of the cut line is less than 25%, a high stress is required to peel the peeled portion, which may make it difficult to peel the peeled portion. Furthermore, if the depth of the cut line is 100% or more of the thickness of the decorative layer, specifically, if the depth of the cut line is 100% or more of the thickness of the decorative layer and the tip of the cut line reaches the adhesive layer (100% depth), or if it reaches the inside of the adhesive layer (depth exceeding 100%), it is still possible to separate the peeled portion from the non-peeled portion, but the connection between the peeled portion and the non-peeled portion will be reduced, and if the adhesive layer protection sheet is not peeled off carefully from the decorative film, there is a risk that the peeled portion and the non-peeled portion of the decorative laminate will separate, which is not desirable.

[0049] In the decorative film of the present disclosure, the peeling portion may have a peeling aid portion for the purpose of efficiently peeling the peeling portion. The peeling aid is a partial structure provided to make it easier to peel the peeling portion, and examples of such a structure include a recess in the peeling portion so that the end of the recess can be pinched to peel it off, and a protrusion (tab) in the peeling portion so that the tab can be pinched to peel it off.

[0050] Fig. 2 is a schematic partial plan view showing an example of a state in which a recess is provided in a peeling portion. In Fig. 2, a recess 21A, which is a peeling aid, is formed in the area surrounded by a dashed line. The dashed line 20 shown in the plan view of Fig. 2 represents a cut line 20 provided in the decorative layer, with A indicating the peeling portion and B indicating the non-peeling portion. As shown in Fig. 2, when a triangular recess (peeling aid) 21A with an acute-angled tip is provided at the end of the decorative film, the peeling portion can be more easily peeled by pinching the peeling portion at the end of the decorative film opposite the tip of the recess. In FIG. 2, the recess 21A serving as the peeling aid is a triangular recess, but there is no limitation on the shape of the recess, and any shape can be selected. As shown in Figure 2, when the recess serving as the peeling aid is a triangular recess, it is preferable that the angle of the apex of the recess, i.e., the apex of the triangle where the two lines intersect, is an acute angle, from the viewpoint of making peeling easier.

[0051] Fig. 3 is a schematic plan view showing an embodiment in which a tab 21B, which is a peeling aid, is provided in the peeling portion. In Fig. 3, the location indicated by the arrow is the tab 21B, and the peeling portion can be easily peeled by pinching the tab protruding from the end of the decorative film, i.e., the convex peeling aid 21B. The dashed line 20 shown in the plan view of Fig. 3 represents the cutting line 20 provided in the decorative layer, and area A surrounded by the cutting line 20 indicates the peeling portion, and area B indicates the non-peeling portion. In FIG. 3, the shape of the tab or protrusion is shown as a parallelogram, but there is no particular limitation on the shape of the tab, and any shape can be selected. When manufacturing the decorative film, for example, in the decorative film manufacturing method described below, when forming the second cutting line in the decorative film precursor in step IV, the tab 21B as a convex portion can be easily formed by forming the second cutting line as shown by the imaginary dotted line in Figure 3 at the same time as forming the second cutting line.

[0052] The decorative film of the present disclosure has the above-described configuration, and therefore can easily form any design pattern on an adherend without using a transfer sheet. The decorative film of the present disclosure can provide complex design patterns on any molded object, and has a wide range of applications. Examples of applications include, but are not limited to, exterior materials for vehicles, interior and exterior materials for buildings, window displays, and interior and exterior materials for ships.

[0053] There are no particular limitations on the method for manufacturing the decorative film of the present disclosure, but by manufacturing the decorative film by the method for manufacturing the decorative film of the present disclosure described below, a decorative composite film having a complex design pattern can be efficiently manufactured.

[0054] [Decorative film manufacturing method] The manufacturing method of the decorative film of the present disclosure (hereinafter sometimes referred to as manufacturing method A of the present disclosure) is a manufacturing method of a decorative film used to decorate a molded body, comprising the steps of: forming an adhesive layer on one side of a decorative layer to form a decorative laminate (step I); covering the adhesive layer with an adhesive layer protective sheet to form a decorative film precursor having the decorative layer, the adhesive layer, and the adhesive layer protective sheet (step II); forming a first cutting line in the decorative layer, the first cutting line having a depth that is less than 100% of the thickness of the decorative layer from the surface side of the decorative layer, and dividing the peelable portion and the non-peeling portion (step III); and forming a second cutting line that passes through the decorative film precursor at a position where the second cutting line intersects with the first cutting line (step IV).

[0055] (Process I) In step I, an adhesive layer is formed on one surface of a decorative layer to form a decorative laminate. First, a decorative layer is formed using a decorative layer-forming composition containing a synthetic resin for forming the decorative layer, and an adhesive layer is formed on one surface of the resulting decorative layer to obtain a decorative laminate. The methods for forming the decorative layer and the adhesive layer are as described above. That is, the decorative layer is preferably formed by molding a decorative layer-forming composition, which contains at least one synthetic resin selected from PVC resin, acrylic resin, and ABS resin, and optionally contains a colorant, into a sheet by a calendering method or the like. The adhesive layer can be formed by a conventional method, and preferably by a coating method or a transfer method using a pressure sensitive adhesive or a hot melt adhesive used for forming the adhesive layer. The preferred thicknesses of the decorative layer and adhesive layer are as described above in the description of the decorative film. The resulting decorative laminate is applied to a molded body to decorate the molded body.

[0056] Step I may include a step (Step V) of forming a primer layer after forming the decorative layer, and then forming an adhesive layer. By providing a primer layer, the adhesion between the decorative layer and the adhesive layer can be further improved. The type of resin used to form the primer layer, the thickness of the primer layer, etc. are as described above. Step V, which is a step of forming the primer layer, is an optional step.

[0057] (Process II) In step II, an adhesive layer protective sheet is prepared, and the adhesive layer is covered with the prepared adhesive layer protective sheet to form a decorative film precursor having a decorative layer, an adhesive layer, and an adhesive layer protective sheet. In this disclosure, the term "decorative film precursor" refers to a laminate having a decorative layer, an adhesive layer, and an adhesive layer protective sheet, in which no cut lines are formed to separate the peelable portion from the non-peeling portion. As explained in the decorative film section, the adhesive layer protective sheet is a film whose surface in contact with the adhesive layer is smooth or has irregularities, and a synthetic resin film, a synthetic resin film with a release treatment, etc. can be used. The preferred thickness of the adhesive layer protective sheet is as described in the decorative film section. When one surface of the adhesive layer protective sheet is release-treated, the adhesive layer may be coated on the release-treated surface so that the release-treated surface is in contact with the adhesive layer of the decorative laminate. The adhesive layer protective sheet may be a commercially available product.

[0058] (Process III) Step III is a step of forming a first cut line in the decorative layer of the decorative film precursor obtained in Step II, which divides the peeled portion from the non-peeled portion and has a depth of less than 100% from the surface side of the decorative layer relative to the thickness of the decorative layer. The first cut line can be formed using a cutting device. Any cutting device can be used without particular restrictions as long as it can form a cut line of any depth. In step III, a cutting device is used to insert a blade into the decorative layer from the surface side thereof to form a first cutting line in the decorative layer. Any type of blade may be used in the cutting device. A cutter (blade) held by a cutter head of a cutting device is pressed against the decorative layer while the cutter head is moved in the X and Y directions, thereby forming a first cutting line 26 of a desired shape in the decorative layer.

[0059] FIG. 4 is a schematic plan view showing one embodiment of a state in which a first cutting line 26 has been formed on a rectangular decorative film precursor 24. The first cutting line 26 is formed continuously at a predetermined depth and should be represented by a solid line. However, in FIG. 4, the first cutting line 26 is represented by a dashed line for convenience in order to clearly distinguish it from other lines. In the embodiment shown in FIG. 4, the non-peeling portion is a continuous region forming a complex design pattern. In step III, an arbitrary design pattern is formed on the decorative film precursor using the first cutting line. The depth of the first cutting line is preferably 25% or more but less than 100% from the surface side of the decorative layer, assuming the thickness of the decorative layer to be 100%, from the viewpoint of achieving both connectivity between the peeling portion and the non-peeling portion and ease of peeling the peeling portion.

[0060] (Process IV) In step IV, a second cutting line is formed through the decorative film precursor at a position where the second cutting line intersects with the first cutting line. In step IV, a blade is inserted from the surface side of the decorative layer to form a second cutting line that penetrates the decorative film precursor having the decorative layer, adhesive layer, and adhesive layer protective sheet. Any type of blade may be used to form the second cut line. In step IV, a cutter (blade) held by a cutter head of a cutting device used to form the second cut line is pressed against the decorative layer while the cutter head is moved in the X and Y directions to form a second cut line that penetrates the decorative film precursor. When forming the second cutting line, the second cutting line is formed at a position where an intersection with the first cutting line occurs, resulting in the formation of a peeled portion having an intersection between the second cutting line and the first cutting line.

[0061] Fig. 5 is a schematic plan view showing one embodiment of a rectangular decorative film precursor 24 having first cutting lines 26 and second cutting lines 28 formed thereon. In Fig. 5, the second cutting lines 28 are indicated by dashed lines. The point indicated by the arrow is the intersection of the first cutting line 26 and the second cutting line 28. By forming the second cutting lines, the decorative film 10 is obtained. As described above, when forming the second cutting line, the decorative film precursor is formed in a shape that provides a convex portion at the end of the area corresponding to the peeling portion, so that in step IV a convex portion (tab) can be formed as a peeling aid portion.

[0062] FIG. 6 is a schematic plan view showing an example of peelable portions and non-peeled portions partitioned by first perforation lines 26 in a completed decorative film after the formation of the second perforation lines. In FIG. 6, the non-peeled portion area is indicated by B, and the peelable portion areas are indicated by A-1 to A-7. The hatched area B in FIG. 6 is fixed to the molded body as a design pattern of the non-peeled portion. As shown in FIG. 6, by dividing the peelable portion into multiple areas, even if the non-peeled portion has an acute tip, it can be easily peeled, and deformation of the design pattern consisting of the non-peeled portion can be suppressed when peeling the peelable portion.

[0063] (Optional process) The method for producing a decorative film of the present disclosure may further include any optional step in addition to the above-described steps I, II, III, and IV. Examples of optional steps include the step of forming a primer layer (step V), the step of forming a skin layer (step VI), and the step of applying a colored sheet (step VII).

[0064] (Process VI) The method for producing a decorative film of the present disclosure may include a step (step VI) of forming a skin layer on the surface of the decorative layer opposite to the adhesive layer side. The surface layer preferably contains at least one synthetic resin selected from fluororesin, acrylic resin, and polyvinyl chloride resin. The surface layer can be formed by a known method. Alternatively, a commercially available surface layer may be used. The skin layer can be formed by laminating a molded skin layer on the surface of the decorative layer (the surface opposite to the side having the adhesive layer). A preferred method is to laminate the surface layer on the decorative layer obtained in step I, and then use a pair of rolls to perform lamination processing, and then heat and pressure bonding the two together. The lamination temperature during heat and pressure bonding is preferably 100°C to 190°C. By forming the skin layer, the durability of the decorative film can be further improved.

[0065] (Process VII) In the method for producing a decorative film of the present disclosure, a colored sheet can be applied to the surface of the decorative layer or the optional skin layer to more clearly define the separation between the release layer and the non-release portion. By providing a colored sheet, the peeled portion and the non-peeled portion can be distinguished by color, thereby further improving the visibility of the peeled portion. For example, by using a white decorative layer and a black colored sheet as the peeled portion, the boundary between the peeled portion (black) and the non-peeled portion (white) becomes clear by first peeling the colored sheet of the peeled portion along the first cutting line, and it becomes easier to reliably peel off only the peeled portion even if the design pattern of the non-peeled portion has a complex shape with excellent design.

[0066] Step VII is carried out before the above-mentioned step III, ie, the formation of the first cutting line. First, a colored sheet having a hue that contrasts with the hue of the decorative layer in the decorative film is prepared. The colored sheet may be made of any material such as synthetic resin or paper, and commercially available products may also be used. The colored sheet has an adhesive layer on the side that comes into contact with the decorative layer or the skin layer of the decorative film. As described above, the adhesive layer only needs to temporarily fix the colored sheet to the decorative film precursor, so it is preferable that the adhesive layer has the same level of adhesiveness as the low adhesiveness of the adhesive layer described above. The colored sheet is laminated on the decorative layer or the surface layer of the decorative film precursor via the adhesive layer. The decorative film precursor having the obtained colored sheet is subjected to the above-described first cutting line forming step (step III) and second cutting line forming step (step IV) to form cutting lines, thereby obtaining a decorative film having the colored sheet.

[0067] [Decorative molding] The decorated molded body of the present disclosure is a decorated molded body having a molded body and a non-peeled portion of the decorative laminate obtained by peeling the peeled portion of the adhesive layer protection sheet and the decorative laminate from the decorative film of the present disclosure described above. Fig. 7 is a schematic cross-sectional view showing an example of a decorated molded body according to the present disclosure. The decorated molded body 30 shown in Fig. 7 has a molded body (molded body substrate) 32 and, on the surface of the molded body 32, a non-peeled portion of a decorative laminate having an adhesive layer 14, a decorative layer 12, and an optional skin layer 18. The decorated molded body 30 is formed by attaching a decorative laminate obtained by peeling the adhesive layer protection sheet 16 from the decorative film 10 shown in FIG. 1 to a molded body 32, and then peeling off the peeled portion of the decorative laminate.

[0068] There are no particular limitations on the molded article to which the decorative film of the present disclosure can be applied, and the film can be applied to any of resin molded articles, vehicles such as automobiles, window glass, exteriors of buildings, and the like. Therefore, according to the decorative film of the present disclosure, any molded article can be used as the object to be decorated and turned into a decorated molded article having a highly aesthetic design pattern. The decorated molded article of the present disclosure is formed using the decorative film of the present disclosure, and therefore has a complex design pattern and excellent design, and has a wide range of applications.

[0069] [Method of manufacturing decorated molded body] The decorated molded body of the present disclosure is preferably produced by the method for producing a decorated molded body of the present disclosure. The method for manufacturing the decorated molded body of the present disclosure includes a step (step i) of peeling off the adhesive layer protective sheet from the decorative film of the present disclosure described above, a step (step ii) of attaching the decorative laminate from which the adhesive layer protective sheet has been peeled off to the surface of the molded body via the adhesive layer, and a step (step iii) of peeling off the peeled-off portion of the decorative laminate attached to the surface of the molded body.

[0070] (Process i) In step i, the adhesive layer protective sheet is peeled off from the decorative film of the present disclosure. By peeling the adhesive layer protective sheet off from the decorative film to form a decorative laminate, the adhesive layer of the decorative laminate is exposed.

[0071] (Step ii) In step ii, the decorative laminate is attached to the surface of the molded body via the adhesive layer of the decorative laminate. The peeling of the adhesive layer protective sheet and the attachment of the decorative laminate to the molded body may be performed step by step by an operator. That is, in step i, the adhesive layer protective sheet is gradually peeled off to partially expose the adhesive layer of the decorative laminate. The adhesive layer of the decorative laminate exposed in step i is then placed against the surface of the molded body having a three-dimensional shape, and the decorative laminate is pressed against the surface of the molded body via the adhesive layer. The partial peeling of the adhesive layer protection sheet and the subsequent attachment of the decorative laminate may be carried out alternately in stages, and finally the entire decorative laminate may be attached to the molded article. In addition, in the case of a decorative film with a small area, it may be attached in one step.

[0072] (Step iii) In step iii, the peelable portion of the decorative laminate attached to the surface of the molded body is peeled off, leaving only the non-peeling portion of the decorative laminate attached to the surface of the molded body, and a design pattern consisting of the non-peeling portion of the decorative laminate is formed on the molded body, thereby obtaining a decorated molded body.

[0073] A case will be described in which a molded body is decorated with a decorative film having a colored sheet obtained in step VII, which is an optional step in the above-described method for producing a decorative film. The decorative film having the colored sheet is attached to the molded body, and then the colored sheet is peeled off only from the portion of the colored sheet corresponding to the peeled portion of the decorative film. Before the decorative film is attached to the molded body, the colored sheet may be peeled off only from the portion of the colored sheet corresponding to the peeled portion of the decorative film. 8 as an example of a schematic cross-sectional view, a decorative laminate having a skin layer 18, a decorative layer 12, and an adhesive layer 14 to which a colored sheet 22 has been attached is attached to the surface of the molded body 32 via the adhesive layer 14. The peeled portion (area A) of the decorative laminate is an area that does not have the colored sheet 22, and the non-peeled portion (area B) is an area to which a colored sheet 22 of a different hue from that of the peeled portion has been attached, so that the contrast between the peeled portion and the non-peeled portion of the decorative laminate is striking, making it easier to reliably peel off only the peeled portion. After being attached to the molded body, the peelable portion is peeled off in step iii, and then the colored sheet 22 remaining on the non-peeling portion is peeled off, thereby obtaining the decorated molded body 30 of the present disclosure having a layer structure as shown as an example in Figure 7.

[0074] The decorative molded body of the present disclosure is a molded body having a complex design pattern on any molded body. According to the manufacturing method of the decorative molded body of the present disclosure, any molded body can be exemplified by vehicles such as automobiles and trains, window glass, furniture, building decorations, and wall decorations. According to the manufacturing method of the decorative molded body of the present disclosure, complex design patterns can be easily imparted to these various molded bodies, and therefore the range of applications is wide. [Example]

[0075] The decorative film, its manufacturing method, decorated molded body and its manufacturing method of the present disclosure will be specifically described below using examples, but the present disclosure is not limited to the following specific examples. In the following examples, "%" indicating the concentration and content of each component is based on mass unless otherwise specified.

[0076] Example 1 (Step VI: Preparation of the epidermal layer) KFC film FT-50Y (product name), manufactured by Kureha Extec Co., Ltd. (thickness: 50 μm) was prepared as the skin layer. The skin layer was colorless and transparent.

[0077] (Step I: Molding of a decorative laminate having a decorative layer and an adhesive layer) 2 kg of pigment (PV MAF 725 (product name, Dainichiseika Color & Chemicals Mfg. Co., Ltd.) was added to 100 kg of PVC resin (TH800 (product name, Taiyo Vinyl Corporation)), and the mixture was formed into a sheet using a calendar method so that the thickness after drying would be 150 μm, obtaining a decorative layer. The decorative layer was visually black. The decorative layer and the skin layer were laminated together, and the laminate was then laminated using a pair of rolls at a lamination temperature of 150°C. An acrylic adhesive (Tg: -20°C, molecular weight: 200,000) was applied to the side of the decorative layer that did not have a skin layer in an amount that would result in a film thickness of 35 μm after drying, and this was dried to form an adhesive layer, thereby obtaining a decorative laminate. The peel strength of the resulting adhesive layer was measured by test method (I) to find that the initial peel strength was 4.7 N / cm, and the peel strength after aging measured by test method (II) was 7.1 N / cm.

[0078] (Step II: Attaching the adhesive layer protective sheet) A flat PP resin sheet with a smooth surface (Fujiko Co., Ltd., BK0A (trade name), thickness: 60 μm) was prepared, and irregularities were formed on the resin sheet by setting the surface temperature at 150°C. When the cross section of the PP resin sheet with irregularities formed was measured using an electron microscope, the size of the protrusions was found to be 120 μm in width and 25 μm in height. The adhesive layer of the decorative laminate obtained in step I was covered with the adhesive layer protection sheet having the resulting texture to obtain a decorative film precursor.

[0079] (Step III: Formation of first cutting line) Using a cutting device (manufactured by Kongsberg), the decorative film precursor obtained in step II was placed in a predetermined position on the cutting device so that the skin layer side of the decorative film precursor faced the cutting edge of the cutter held by the cutter head, and a first cut line was formed on the skin layer side of the decorative layer in the shape shown by the dashed line in Figure 4. The depth of the first cut line was 38.8 μm, which was 25.8% of the thickness of the decorative layer.

[0080] (Step IV: Formation of second cutting line) A second cutting line was formed that penetrated the decorative film precursor all the way to the adhesive layer protection sheet, so as to intersect with the first cutting line to form a peelable portion. The second cutting line had the shape shown by the dashed dotted line in Figure 5, and the second cutting line was formed so as to intersect with the first cutting line to form a peelable portion.

[0081] Through the above steps, a decorative film of Example 1 having peeled portions A-1 to A-7 and a non-peeled portion B shown in the schematic plan view of FIG. 6 was obtained.

[0082] Example 2 A decorative film of Example 2 was obtained in the same manner as in Example 1, except that in step III of Example 1, the depth of the first cut line was changed to 91.9 μm, which is 61.2% of the thickness of the decorative layer.

[0083] Example 3 A decorative film of Example 3 was obtained in the same manner as in Example 1, except that in step III of Example 1, the depth of the first cut line was changed to 147.0 μm, which was 98.0% of the thickness of the decorative layer.

[0084] Example 4 The decorative film of Example 4 was obtained in the same manner as Example 1, except that after steps III and IV of Example 1, the following peeling aid formation step was carried out to form a peeling aid (turning-over portion) as a recess as shown in the partially enlarged view of Figure 9(A). FIG. 9(A) is a partially enlarged plan view of the decorative film of Example 4, and the area where the recesses serving as peeling aids are formed is clearly indicated by being surrounded by a two-dot dashed line.

[0085] (Step of forming peeling aid) A concave peeling assisting portion (turning portion) was formed starting from the intersection of the first cutting line and the second cutting line formed in step IV. The turn-over portion was formed as a recess having a triangular tip with a base of 3 mm and an apex angle α of 30° as shown schematically in FIG. 9(B). In FIG. 9(A), the areas indicated by A-3 and A-4 are the peeling portions, and the peeling portions are expected to have recesses that serve as peeling aids, thereby making them easier to peel.

[0086] Example 5 A decorative film of Example 5 was obtained in the same manner as in Example 1, except that the colored sheet was applied in Step VII before Step III in Example 1. As the colored sheet, a white colored sheet manufactured by Lintec Sign Systems Co., Ltd., product number AP111, and having a thickness of 110 μm was prepared. The initial peel strength of the adhesive layer of the colored sheet was similar to that of the adhesive layer of Example 1. The colored sheet was laminated onto the surface layer of the decorative film via the adhesive layer of the colored sheet. Thereafter, the decorative film precursor having the colored sheet was subjected to steps III and IV in the same manner as in Example 1 to form the first cutting line and the second cutting line, thereby obtaining the decorative film of Example 5.

[0087] Comparative Example 1 A decorative film of Comparative Example 1 was obtained in the same manner as in Example 1, except that step III in Example 1 was not carried out and the first cutting line was not formed.

[0088] Comparative Example 2 A decorative film of Comparative Example 2 was obtained in the same manner as in Example 1, except that in step III of Example 1, the depth of the first cut line was changed to 150 μm, which is 100% of the thickness of the decorative layer.

[0089] [Evaluation of decorative films] Using the resulting decorative film, a decorated molded article was produced according to the procedure described below, and the following items were evaluated. The results are shown in Table 1.

[0090] (Manufacturing of decorative molded bodies) First, a molded body was prepared as an adherend. The molded body was a side door part of a vehicle having a curved surface. The adhesive layer protective sheets were peeled off from the decorative films obtained in Examples 1 to 5 and Comparative Examples 1 and 2 to obtain decorative laminates (Step i). The decorative laminate was attached to the molded body via the adhesive layer of the resulting decorative laminate. At this time, the adhesive layer protective sheet was peeled off and the decorative laminate was attached to the molded body manually by an operator. The adhesive layer protective sheet was gradually peeled off to partially expose the adhesive layer of the decorative laminate. The exposed adhesive layer of the decorative laminate was placed opposite the surface of the molded body having a three-dimensional shape, and the decorative laminate was pressed to attach the decorative laminate to the molded body via the adhesive layer. (Step ii)

[0091] After the attachment, the peeled portion of the decorative laminate attached to the surface of the molded body was peeled off (step iii). In this way, a decorated molded body was obtained in which only the non-peeled portion of the decorative laminate remained on the surface of the molded body and a design pattern consisting of the non-peeled portion of the decorative laminate was formed on the molded body. After the peeled portion was removed, the sample was left to age for 24 hours.

[0092] The evaluation criteria were based on the actual work of 10 workers, and the rank with the most evaluations was adopted.

[0093] -1. Connectivity between peeled and non-peeled areas- A: During the peeling process of the adhesive layer protection sheet, the connection between the peeled and non-peeled areas is maintained, so there is no problem. B: During the peeling process of the adhesive layer protection sheet, the connection between the peeled and non-peeled areas was lost, which was problematic. C: There is a problem because peeled and non-peeled parts are not formed. In the above, rank A is an evaluation result that presents no practical problems.

[0094] -2. Ease of peeling of peeling part- A: The peeling part of the decorative laminate was extremely easy to peel off, and there were no problems. B: The peeling part of the decorative laminate is easy to peel off, and there are no problems. C: Peeling of the decorative laminate at the peeling section is difficult and problematic. D: Peeling of the decorative laminated body is impossible and there is a problem. In the above, A and B are evaluation results that are practically acceptable.

[0095] -comprehensive evaluation- A: 1. Connectability and 2. Ease of peeling are both good and there are no problems. B: Both or either of the following are poor: 1. Connectability and 2. Ease of peeling. In the overall evaluation, A is an acceptable evaluation result.

[0096] [Table 1]

[0097] From the results in Table 1, it can be seen that the decorative films of Examples 1 to 5 were all suitable for producing decorated molded articles, and complex design patterns could be produced on the decorated molded articles. Furthermore, the decorative films of Examples 2 and 3, in which the depth of the cut line is 60% or more of the decorative layer, the decorative film of Example 4, which has a peeling aid portion, and the decorative film of Example 5, which has a colored sheet, had better peelability at the peeling portion than the decorative film of Example 1.

[0098] In contrast, the decorative film of Comparative Example 1, which did not have a first cut line, was less easy to peel, and the decorative film of Comparative Example 2, which had a first cut line that was too deep, had poor connectivity between the peelable and non-peeling parts, making it impossible to attach the entire decorative laminate to the molded body. [Explanation of symbols]

[0099] 10 Decorative film 12 Decorative layer 14 Adhesive layer 16 Adhesive layer protection sheet 18 Epidermal layer 20 Cutting lines 21A Peeling aid (recess) 21B Peeling aid (protrusion, tab) 22 coloring sheets 24 Decorative film precursor 26 First cutting line 28 Second cutting line 30 Decorative molding 32 Molded body A Peeling part B Non-peeling area α Thickness of decorative layer β Cut line depth

Claims

1. A decorative laminate having a decorative layer having a peelable portion and a non-peeling portion and an adhesive layer; and an adhesive layer protective sheet, in this order; The peeled portion and the non-peeled portion are demarcated by a cutting line whose depth is less than 100% from the surface side of the decorative layer with respect to the thickness of the decorative layer, The decorative layer is made of synthetic resin molded into a sheet, and the synthetic resin contains at least one resin selected from acrylic resin, polyvinyl chloride resin, acrylonitrile / butadiene / styrene copolymer, urethane resin, and olefin resin.The decorative film is used to decorate a molded body by peeling off the peeled portion and exhibiting design properties through a design pattern formed in the remaining non-peeled portion.

2. The decorative film according to claim 1 , wherein the depth of the cut line in the decorative layer is 25% or more and less than 100% of the thickness of the decorative layer from the surface side of the decorative layer.

3. The decorative film according to claim 1 or 2, wherein the peeling portion includes a peeling assisting portion.

4. The decorative film according to any one of claims 1 to 3, further comprising a colored sheet having a different hue from the decorative layer on the surface of the decorative layer opposite the adhesive layer.

5. A step of forming a decorative laminate by forming an adhesive layer on one side of a decorative layer made of a synthetic resin formed into a sheet shape; preparing an adhesive layer protective sheet, and covering the adhesive layer with the prepared adhesive layer protective sheet to form a decorative film precursor having the decorative layer, the adhesive layer, and the adhesive layer protective sheet; forming a first cutting line in the decorative layer, the first cutting line dividing the decorative layer into a peeled portion and a non-peeled portion, the first cutting line having a depth of less than 100% from the surface side of the decorative layer relative to the thickness of the decorative layer; forming a second cutting line that penetrates the decorative film precursor at a position where the second cutting line intersects with the first cutting line; the decorative layer contains at least one resin selected from an acrylic resin, a polyvinyl chloride resin, an acrylonitrile / butadiene / styrene copolymer, a urethane resin, and an olefin resin; A method for manufacturing a decorative film used to decorate a molded body by peeling off the peeled portion and providing a design pattern formed in the remaining non-peeled portion to exhibit design properties.

6. A step of peeling off the adhesive layer protective sheet from the decorative film according to any one of claims 1 to 4 to obtain a decorative laminate; A step of attaching the decorative laminate from which the adhesive layer protective sheet has been peeled off to the surface of the molded body via the adhesive layer; and A step of peeling off the peel-off portion of the decorative laminate attached to the surface of the molded body; A method for manufacturing a decorated molded body having the above structure.

Images