Decorative member, method for manufacturing a decorative member, emblem, and movable body

Abstract

To provide a decorative member which is a decorative molding comprising a molding part, a decorative part and a hard coat layer, achieving improved production efficiency by reducing the trouble of the decorative part to expand, cracking a hard coat layer, during injection molding; and a method for producing the same.SOLUTION: A decorative member 10 comprises a hard coat layer 31, a hard coat support layer 32 that is disposed at one side of the hard coat layer 31 and supports the hard coat layer 31, and a metal layer 41 that is disposed at one side of the hard coat support layer 32. The hard coat layer 31 will not crack when heated to 180°C and extended by 10%.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to a decorative member, a method for manufacturing the decorative member, an emblem, and a moving body.

Background Art

[0002] For example, as shown in Patent Document 1, a decorative molded body having a molded portion, a decorative portion, and a hard coat layer is known. The decorative member is produced by injection molding a resin on one side of the decorative portion to form a molded portion, and then forming a hard coat layer on the other side of the decorative portion. The hard coat layer is formed after the temperature of the heated decorative portion has dropped by injection molding. This is because if the hard coat layer is formed on the decorative portion and then the molded portion is injection molded, the decorative portion may expand during injection molding and the hard coat layer may crack.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, such a method for manufacturing a decorative member is complicated.

[0005] An embodiment of the present disclosure aims to improve the manufacturing efficiency of a decorative member.

Means for Solving the Problems

[0006] The decorative member according to the present disclosure includes a hard coat layer, a hard coat support layer disposed on one side of the hard coat layer to support the hard coat layer, and a metal layer disposed on one side of the hard coat support layer, and is provided with The aforementioned hard coat layer does not crack when heated to 180°C and stretched by 10%.

[0007] In the decorative member according to this disclosure, The hard coat layer does not need to crack when heated to 180°C and stretched by 20%.

[0008] The decorative member according to the present invention may have a primer layer for metal deposition disposed on any surface of the metal layer.

[0009] The decorative member described herein is An intermediate layer disposed on one side of the metal layer, A molded portion disposed on one side of the intermediate layer, It may also be provided with the following:

[0010] In the decorative member according to this disclosure, the metal layer may include a plurality of metal granules capable of reflecting visible light, and gaps may be provided between the plurality of metal granules.

[0011] The decorative member according to this disclosure may further include an opacity layer disposed between the hard coat support layer and the metal layer, which covers a portion of the metal layer when viewed in the direction from the hard coat layer toward the metal layer.

[0012] In the decorative member according to this disclosure, the concealing layer may have a surface that extends along a surface that intersects with one side surface of the hard coat support layer.

[0013] In the decorative member according to this disclosure, the thickness of the concealing layer may be 15 μm or more, preferably 20 μm or more.

[0014] In the decorative member according to this disclosure, the hard coat support layer and the concealing layer form an uneven surface facing the metal layer. The metal layer may be bent in accordance with the uneven surface.

[0015] The decorative member according to this disclosure comprises a bonding layer between the concealing layer and the metal layer, A gap may be formed between the side surface of the concealing layer and the bonding layer.

[0016] In the decorative member according to this disclosure, the hard coat layer has a flat portion and a curved portion connected to the flat portion. The thickness of the hard coat layer in the curved portion may be less than the thickness of the hard coat layer in the flat portion.

[0017] The method for manufacturing a decorative member according to this disclosure is: A laminate manufacturing step for producing a laminate comprising a hard coat layer, a hard coat support layer disposed on one side of the hard coat layer and supporting the hard coat layer, a metal layer disposed on one side of the hard coat support layer, and an intermediate layer disposed on one side of the metal layer, The process includes an injection molding step in which a molded portion is injection molded into the laminate produced in the laminate manufacturing step.

[0018] In the method for manufacturing a decorative member according to this disclosure, The aforementioned laminate manufacturing process is: A step of producing a hard coat film including the hard coat layer and the hard coat support layer, A step of depositing the metal layer onto one side of the hard coat film, The process may include a step of forming the intermediate layer on one side of the metal layer.

[0019] In the method for manufacturing a decorative member according to this disclosure, The aforementioned laminate manufacturing process is: A step of producing a hard coat film including the hard coat layer and the hard coat support layer, A step of producing a metal film including the metal layer and a metal support layer that supports the metal layer, A bonding step in which the hard coat support layer of the hard coat film and the metal support layer of the metal film are bonded together via a bonding layer, The process may include an intermediate layer forming step of forming the intermediate layer on one side of the metal film.

[0020] In the method for manufacturing a decorative member according to the present disclosure, the laminate manufacturing step may further include an air removal step for removing air between the hard coat film and the metal film bonded in the bonding step.

[0021] In the method for manufacturing a decorative member according to the present disclosure, the laminate manufacturing step may further include a step of forming an opacity layer on one side of the hard coat film that covers a portion of the metal layer when viewed in the direction from the hard coat layer toward the metal layer.

[0022] In the method for manufacturing the decorative member according to this disclosure, the thickness of the concealing layer may be 15 μm or more, preferably 20 μm or more.

[0023] The method for manufacturing a decorative member according to this disclosure may further include a laminate forming step for forming the laminate produced in the laminate manufacturing step.

[0024] The emblem according to this disclosure comprises the decorative member according to this disclosure as described above.

[0025] The movable body according to this disclosure comprises a decorative member or an emblem according to this disclosure. [Effects of the Invention]

[0026] According to the present invention, the manufacturing efficiency of decorative members can be improved. [Brief explanation of the drawing]

[0027] [Figure 1] Figure 1 is a diagram illustrating a first embodiment, and is a perspective view showing a movable body including a decorative member. [Figure 2] Figure 2 is a plan view showing the decorative member shown in Figure 1. [Figure 3]Figure 3 is a cross-sectional view along the line III-III in Figure 2, showing the decorative member from Figure 2 together with the sensor. [Figure 4] Figure 4 is a magnified view of the portion shown in IV of Figure 3. [Figure 5] Figure 5 is a magnified plan view showing the metal layer included in the decorative member of Figure 2. [Figure 6] Figure 6 illustrates an example of a manufacturing method for the decorative member shown in Figure 2. [Figure 7] Figure 7 illustrates an example of a manufacturing method for the decorative member shown in Figure 2. [Figure 8] Figure 8 illustrates an example of a manufacturing method for the decorative member shown in Figure 2. [Figure 9] Figure 9 illustrates an example of a manufacturing method for the decorative member shown in Figure 2. [Figure 10] Figure 10 illustrates an example of a manufacturing method for the decorative member shown in Figure 2. [Figure 11A] Figure 11A illustrates an example of a manufacturing method for the decorative member shown in Figure 2. [Figure 11B] Figure 11B illustrates an example of a manufacturing method for the decorative member shown in Figure 2. [Figure 12A] Figure 12A illustrates another example of the manufacturing method for the decorative member shown in Figure 2. [Figure 12B] Figure 12B illustrates another example of the manufacturing method for the decorative member shown in Figure 2. [Figure 13] Figure 13 is a magnified view of the portion indicated by XIII in Figure 3. [Figure 14] Figure 14 illustrates an example of a manufacturing method for the decorative member shown in Figure 2. [Figure 15] Figure 15 illustrates an example of a manufacturing method for the decorative member shown in Figure 2. [Figure 16] Figure 16 is a diagram corresponding to Figure 3, and illustrates a second embodiment. [Figure 17] Figure 17 is a magnified view of the portion indicated by XVII in Figure 16. [Figure 18]Figure 18 illustrates an example of a manufacturing method for the decorative member shown in Figure 16. [Figure 19] Figure 19 illustrates an example of a manufacturing method for the decorative member shown in Figure 16. [Figure 20] Figure 20 illustrates an example of a manufacturing method for the decorative member shown in Figure 16. [Figure 21A] Figure 21A corresponds to Figure 3 and illustrates modified examples of the first and second embodiments. [Figure 21B] Figure 21B is a diagram corresponding to Figure 3, illustrating other modifications of the first and second embodiments. [Figure 21C] Figure 21C is a diagram corresponding to Figure 3, illustrating yet another modification of the first and second embodiments. [Figure 21D] Figure 21D is a diagram corresponding to Figure 3, illustrating yet another modification of the first and second embodiments. [Figure 21E] Figure 21E is a diagram corresponding to Figure 3, illustrating yet another modification of the first and second embodiments. [Figure 21F] Figure 21F is a diagram corresponding to Figure 3, illustrating yet another modification of the first and second embodiments. [Figure 21G] Figure 21G is a diagram corresponding to Figure 3, illustrating yet another modification of the first and second embodiments. [Figure 21H] Figure 21H is a diagram corresponding to Figure 3, illustrating yet another modification of the first and second embodiments. [Figure 21I] Figure 21I is a diagram corresponding to Figure 3, illustrating yet another modification of the first and second embodiments. [Figure 22A] This figure illustrates a modified example of the manufacturing method for a laminate. [Figure 22B] This figure illustrates another variation of the manufacturing method for the laminate. [Figure 22C] This figure illustrates yet another variation of the method for manufacturing the laminate. [Figure 23]Figure 23 is a diagram corresponding to Figure 3, illustrating yet another modification of the first and second embodiments. [Figure 24] Figure 24 is a perspective view showing another application example of the decorative member. [Modes for carrying out the invention]

[0028] <<<First Embodiment>>> The first embodiment of this disclosure will be described below with reference to the drawings. Note that, for the sake of illustration and ease of understanding, the scale and aspect ratios of the drawings attached to this specification have been appropriately altered and exaggerated from those of the actual objects.

[0029] To clarify directional relationships between drawings, some drawings use arrows with common symbols to indicate common directions. Arrows pointing towards the viewer along the direction perpendicular to the drawing's plane are indicated by a symbol of a dot inside a circle, as shown in Figure 2, for example. Arrows pointing away from the viewer along the direction perpendicular to the drawing's plane are indicated by a symbol of an "x" inside a circle, as shown in Figure 3, for example.

[0030] In this specification, terms such as "parallel," "perpendicular," and "identical," as well as values ​​for length and angle, which specify shapes, geometric conditions, and their degrees, should not be interpreted strictly, but rather as encompassing a range that allows for the expectation of similar functionality.

[0031] Figures 1 to 15 illustrate the first embodiment. Of these, Figure 1 shows an example of application of the decorative member, and Figures 2 and 3 are plan views or cross-sectional views showing a specific example of the decorative member. The decorative member 10 displays a design and imparts a design to the article to which the decorative member 10 is applied. The decorative member 10 according to the first embodiment described below incorporates features to improve its manufacturing efficiency.

[0032] In the examples shown in Figures 1 to 3, the decorative member 10 is applied to the mobile body 1 as an emblem 3. The mobile body 1 shown in Figure 1 is an automobile. However, the mobile body 1 to which the emblem 3 and decorative member 10 are applied is not limited to automobiles. The emblem 3 and decorative member 10 can also be applied to other mobile bodies 1 as movable devices. Examples of mobile bodies 1 other than automobiles include railway cars, trolleys, ships, airplanes, helicopters, drones, and robots. Furthermore, the decorative member 10 is not limited to application to the emblem 3. As will be described later, the decorative member 10 can be applied to uses other than emblems. The decorative member 10 can be applied to building materials such as interior materials, exterior materials, ceiling materials, floor materials, and cases for home appliances, for example. The first embodiment will be described below with reference to the specific examples shown in the drawings.

[0033] Incidentally, as shown in Figures 1 to 3, the decorative member 10 is positioned facing a sensor 5 that uses electromagnetic waves with wavelengths longer than visible light. The sensor 5 monitors the surrounding conditions of the moving body 1, for example. The detection results of the sensor 5 are transmitted to the control device 4 of the moving body 1. Based on the detection results of the sensor 5, the control device 4 issues an alarm or controls the movement of the moving body 1. For example, the sensor 5 detects obstacles in front of the moving body 1. This sensor 5 is capable of both transmitting and receiving electromagnetic waves. By receiving reflected waves reflected by obstacles, the sensor 5 can detect the presence or absence of obstacles and the distance to them. The sensor 5 may also be a millimeter-wave radar device. The millimeter-wave radar device may use millimeter waves with wavelengths of 1 mm to 10 mm as electromagnetic waves.

[0034] As shown in Figure 3, the decorative member 10 has a first surface 11 and a second surface 12. The first surface 11 and the second surface 12 face each other. The first surface 11 is the back surface of the emblem 3. The second surface 12 is the front surface of the emblem 3. The sensor 5 faces the first surface 11 of the decorative member 10. The electromagnetic waves used by the sensor 5 pass through the decorative member 10 in a third direction D3 where the first surface 11 and the second surface 12 face each other. The first surface 11 and the second surface 12 are the emission surface and the incidence surface of the electromagnetic waves. The first surface 11 and the second surface 12 are flat in at least the region facing the sensor 5 in the third direction D3. By making them flat, a decrease in the sensitivity of the sensor 5 due to the diffusion of electromagnetic waves can be suppressed.

[0035] The thickness T10 of the decorative member 10 along the third direction D3, which lies between the first surface 11 and the second surface 12, is an integer multiple of half the wavelength of the electromagnetic wave used by the sensor 5, at least in the region facing the sensor 5 in the third direction D3. By adjusting the thickness T10 (mm) in this way, electromagnetic waves can pass through the decorative member 10 with high transmittance. That is, if the wavelength of the electromagnetic wave in the decorative member 10 is λ (mm), then the following relationship (1) holds. In the equation, "k" is a positive integer, i.e., a natural number. TT = (λ / 2) × k ···(1) When relation (1) holds, the phase of the electromagnetic wave reflected at the fixed end of the first surface 11 and the phase of the electromagnetic wave that is incident from the first surface 11 to the decorative member 10, reflected at the free end of the second surface 12, and then emitted from the first surface 11 are shifted by half a wavelength. Therefore, the electromagnetic wave reflected at the first surface 11 and the electromagnetic wave that is incident from the first surface 11 to the decorative member 10, reflected at the second surface 12, and then emitted from the first surface 11 cancel each other out. Similarly, the phase of the electromagnetic wave reflected at the fixed end of the second surface 12 and the phase of the electromagnetic wave that is incident from the second surface 12 to the decorative member 10, reflected at the free end of the first surface 11, and then emitted from the second surface 12 are shifted by half a wavelength. Therefore, the electromagnetic wave reflected at the second surface 12 and the electromagnetic wave that is incident from the second surface 12 to the decorative member 10, reflected at the first surface 11, and then emitted from the second surface 12 cancel each other out. This suppresses the reflection of electromagnetic waves from the decorative member 10. As a result, electromagnetic waves can pass through the decorative member 10 with high transmittance.

[0036] As shown in Figure 3, the decorative member 10 includes a laminate 20 and a molded portion 60 positioned on one side of the laminate 20. The laminate 20 has a first surface 21 facing the molded portion 60 and a second surface 22 facing the first surface 21. The second surface 22 of the laminate 20 forms the second surface 12 of the decorative member 10. In the illustrated example, the laminate 20 is shaped, and each layer of the laminate 20 has a flat portion 23 and a curved portion 24 that is circumferentially connected to the periphery of the flat portion 23. The flat portion 23 and the curved portion 24 form a recess that receives a part of the molded portion 60. However, the shape of the laminate 20 in the decorative member 10 is not limited to this. The laminate 20 may be flat.

[0037] The configuration of the decorative member 10 will be described in detail below with reference to Figures 3 and 4. Figure 4 is an enlarged view of the portion of the laminate 20 shown in Figure 3 that is enclosed by the dashed line IV.

[0038] <<Laminate>> As shown in Figure 4, the laminate 20 includes a hard coat film 30, a design layer 40, and an intermediate layer 50. The hard coat film 30, the design layer 40, and the intermediate layer 50 are laminated in this order.

[0039] <Hard coat film>

[0040] The hard coat film 30 has a hard coat function. Specifically, the hard coat film 30 includes a hard coat layer 31 and a hard coat support layer 32. The hard coat support layer 32 is positioned between the hard coat layer 31 and the design layer 40. The design layer 40 is observed by passing light through the hard coat film 30. Therefore, the hard coat film 30 is transparent. In this specification, "transparent" means that the visible light transmittance, which is determined as the average value of the transmittance at each wavelength when measured using a spectrophotometer (Shimadzu Corporation "UV-3100PC", compliant with JIS K 0115) in the range of measurement wavelengths from 380 nm to 780 nm, is 50% or more, preferably 80% or more.

[0041] The hard coat layer 31 forms the second surface 12 of the laminate 20. The hard coat layer 31 forms the outermost surface of the decorative member 10. The hard coat layer 31 has scratch resistance and other properties.

[0042] The hard coat layer 31 does not crack when heated to 180°C and stretched by 10%. In particular, in the illustrated example, the hard coat layer 31 does not crack when heated to 180°C and stretched by 20%. Such a hard coat layer 31 can be stretched without cracking even when heated in the injection molding process described later. Therefore, after manufacturing the laminate 20 including the hard coat layer 31, the molded part 60 can be formed by injection molding. This improves the manufacturing efficiency of the decorative member 10. Methods for manufacturing a hard coat layer 31 that does not crack when heated to 180°C and stretched by 10%, and a hard coat layer 31 that does not crack when heated to 180°C and stretched by 20%, are disclosed, for example, in Japanese Patent Application Publication No. 2020-193256. They are also disclosed in Japanese Patent Application No. 2021-060669.

[0043] The hard coat layer 31 can be evaluated, for example, as follows to determine whether it will crack when heated to 180°C and stretched by 10% or 20%. First, the hard coat film 30 described above is prepared, and a grid pattern is printed on the hard coat film 30. Next, the hard coat film 30 is heated to 180°C using a heating device to soften it. Next, the softened hard coat film 30 is vacuum-formed using a mold with a convex surface and a vacuum forming machine. At this time, the hard coat film 30 is adsorbed onto the convex surface of the mold and stretched along the convex surface. Next, the elongation rate of each part of the hard coat film 30 due to vacuum forming is calculated by comparing the grid pattern on the vacuum-formed hard coat film 30 with the grid pattern before vacuum forming. Specifically, the elongation rate of each part of the hard coat film 30 due to vacuum forming is calculated by comparing the area of ​​each square partitioned by the grid pattern on the hard coat film 30 before and after vacuum forming. In addition, the presence or absence of cracks in each part of the hard coat film 30 is observed visually. This allows us to evaluate how much the hard coat film 30 can be stretched without cracking. For example, the V.former desktop vacuum forming machine manufactured by Rayama Pack Co., Ltd. can be used as the vacuum forming machine for the above evaluation.

[0044] The hard coat layer 31 can be formed using a material for forming the hard coat layer. The material for forming the hard coat layer and the method for forming the hard coat layer 31 will be described in detail later.

[0045] The thickness of the hard coat layer 31 is not particularly limited and can be set as appropriate so as to be a thickness that allows the hard coat layer 31 to perform its function. For example, the thickness of the hard coat layer 31 is 1 μm or more and 100 μm or less, preferably 1 μm or more and 50 μm or less, and more preferably 1 μm or more and 30 μm or less.

[0046] The hard coat support layer 32 is a layer that supports the hard coat layer 31. The hard coat support layer 32 is formed from a film-like material. The hard coat support layer 32 transmits visible light and does not crack when heated to 180°C and stretched by 10%. Alternatively, the hard coat support layer 32 transmits visible light and does not crack when heated to 180°C and stretched by 20%. As a material for forming such a hard coat support layer 32, for example, organic glass can be used. Examples of organic glass include polycarbonate, polymethyl methacrylate, polyacrylate, polyethylene terephthalate, polyethylene naphthalate, polyolefin, and ABS (acrylonitrile butadiene styrene copolymer). Among these organic glasses, polycarbonate is suitable as a material for forming the hard coat support layer 32 because it has excellent impact resistance and transparency.

[0047] The thickness of the hard coat support layer 32 is not particularly limited, but for example, it is 50 μm or more and 5 mm or less, preferably 100 μm or more and 1 mm or less, and more preferably 100 μm or more and 500 μm or less.

[0048] The hard coat film 30 may include layers provided for functions other than hard coat functionality. Examples of functions other than hard coat functionality include ultraviolet absorption, anti-reflective, anti-glare, anti-static, and anti-fouling functions.

[0049] The thickness T30 of the hard coat film 30 having the above configuration may be 0.05 mm or more and 8 mm or less, 0.10 mm or more and 5 mm or less, or 0.20 mm or more and 3 mm or less.

[0050] <Design layer> The design layer 40 forms the design expressed by the decorative member 10. In the example shown in Figure 2, the design layer 40 forms a design in which the letter "D" is placed inside an elliptical shape. The design layer 40 includes a metal layer 41. The metal layer 41 provides a reflective surface to the design layer 40. In the illustrated example, the design layer 40 also includes an opacity layer 44 and a primer layer 47. The opacity layer 44 and the primer layer 47 are placed between the hard coat film 30 and the metal layer 41.

[0051] The concealing layer 44 covers a portion of the metal layer 41 when viewed from the hard coat film 30 toward the design layer 40. In the illustrated example, the concealing layer 44 hides a portion of the metal layer 41 when viewed from the hard coat film 30 toward the design layer 40. The concealing layer 44 is formed in a shape corresponding to the design displayed by the decorative member 10 when viewed from the hard coat film 30 toward the design layer 40. In the illustrated example, the concealing layer 44 is formed in a shape having an elliptical opening 44a and a "D" shaped opening 44b in the area enclosed by the elliptical opening. The concealing layer 44 and the metal layer 41 represent an elliptical figure and the letter "D" placed within it.

[0052] As the material for forming the opacity layer, a material capable of blocking visible light, such as titanium dioxide or carbon black pigments or dyes, can be used. The opacity layer 44 can be formed by printing the opacity layer-forming material onto the hard coat film 30. As the method for printing the opacity layer-forming material, known printing methods such as gravure printing, gravure offset printing, and screen printing can be used.

[0053] In the illustrated example, as shown in Figure 4, the concealing layer 44 has a side surface 45 that extends along a surface intersecting one side surface of the hard coat support layer 32. Because the concealing layer 44 has such a side surface 45, when the decorative member 10 is viewed from the second surface 12 side, the side surface 45 is visible, giving a three-dimensional effect to the design represented by the concealing layer 44 and the metal layer 41. The thickness T44 of the concealing layer 44 is not particularly limited, but it is preferable that the thickness T44 of the concealing layer 44 be 12 μm or more, and more preferably 15 μm or more, so that the observer can easily perceive the three-dimensional effect even when the decorative member 10 is viewed with the naked eye. In this case, it is desirable that the primer layer 47, described later, be as thin as possible (for example, about 1 μm).

[0054] The primer layer (hereinafter also referred to as the "Pr layer") 47 is formed from a primer for metal deposition. In the example shown in Figure 4, the primer layer 47 is provided to improve the adhesion between the metal layer 41 and the opacity layer 44 or hard coat film 30. The primer layer 47 is formed to cover the entire surface of one side of the hard coat film 30. If the adhesion between the metal layer 41 and the opacity layer 44 or hard coat film 30 is ensured by itself or by another layer, the design layer 40 does not need to include the primer layer 47.

[0055] Materials for forming the primer layer can include, but are not limited to, acrylic resins, urethane resins, vinyl chloride-vinyl acetate copolymer resins, polyester resins, and chlorinated polyolefin resins.

[0056] The primer layer 47 is formed by coating the above-described primer layer forming material onto the hard coat film 30 and the opacity layer 44, and curing it as necessary. The method for coating the primer layer forming material is not particularly limited, and the above-described known coating method can be used.

[0057] The thickness of the primer layer 47 is not particularly limited, but for example, it is 0.1 μm or more and 10.0 μm or less, preferably 0.5 μm or more and 5.0 μm or less. If it is desired to give a three-dimensional effect to the design represented by the concealing layer 44 and the metal layer 41, it is preferable to determine the thickness of the primer layer 47 according to the thickness of the concealing layer 44. For example, if the thickness of the concealing layer 44 is about 3 μm to 5 μm, a three-dimensional effect can be given to the design represented by the concealing layer 44 and the metal layer 41 if the thickness of the primer layer 47 is about 1 μm to 3 μm. Also, for example, if the thickness of the concealing layer 44 is about 6 μm to 14 μm, a three-dimensional effect can be given to the design represented by the concealing layer 44 and the metal layer 41 if the thickness of the primer layer 47 is about 1 μm to 10 μm. Furthermore, if the thickness of the concealing layer 44 is approximately 10 μm to 14 μm, and the thickness of the primer layer 47 is approximately 1 μm to 3 μm, then the design represented by the concealing layer 44 and the metal layer 41 can be effectively given a three-dimensional appearance. This is thought to be due to the following reason. Specifically, when a primer layer 47 is formed by coating a material for forming a primer layer onto a hard coat film 30 on which an opacity layer 44 is formed, if the thickness of the primer layer 47 is appropriate to the thickness of the opacity layer 44, a meniscus of the primer layer 47 is formed around the opacity layer 44 that protrudes from the hard coat film 30 (see Figure 4). Then, when the metal layer 41 is formed on this primer layer 47, a bevel 42, which will be described later, is formed at the boundary between the metal layer 41 and the opacity layer 44. For this reason, when light is incident on the second surface 12 of the decorative member 10, the bevel 42 of the metal layer 41 effectively reflects this light, and gloss appears at the boundary. Furthermore, in order for an observer to easily perceive the three-dimensional effect even when the decorative member 10 is observed with the naked eye, it is desirable to set the thickness T44 of the concealing layer 44 to 12 μm or more, preferably 15 μm or more, and the thickness of the primer layer 47 to about 1 μm, as described above.

[0058] The metal layer 41 is formed as a thin, film-like layer. The metal layer 41 is formed to cover the entire surface of one side of the hard coat film 30. As described above, electromagnetic waves used in the sensor 5 pass through the decorative member 10. If the metal layer 41 is formed as a layer that extends continuously across the entire surface of the hard coat film 30, the electromagnetic waves will be blocked or attenuated. Therefore, as shown in Figure 5, the metal layer 41 may include a plurality of metal granules 41a. The metal granules 41a have a metallic luster and are capable of reflecting visible light. The metal layer 41 forms islands in a so-called sea-island structure. The island-shaped metal granules 41a are spaced apart from each other. Between the plurality of metal granules 41a, gaps 41b are provided that form a sea in the sea-island structure. Electromagnetic waves used in the sensor 5, such as millimeter waves, pass through the metal layer 41 by passing through these gaps 41b. Furthermore, because a gap 41b is formed, the metal layer 41 can expand in accordance with the other layers of the laminate 20 when those layers are heated and expanded during the injection molding process described later. Such a metal layer 41 can be formed, for example, using indium as the material, by deposition such as sputtering or vacuum deposition.

[0059] The thickness of the metal layer 41 is not particularly limited, but from the viewpoint of electromagnetic wave transmission, it is preferably 10 nm to 300 nm, more preferably 30 nm to 150 nm, and even more preferably 30 nm to 100 nm.

[0060] As shown in Figure 4, the hard coat support layer 32 and the concealing layer 44 form an uneven surface facing the metal layer 41. In the illustrated example, the metal layer 41 is bent in accordance with this uneven surface. Therefore, the metal layer 41 has a slope 42 that extends along the surface intersecting one side of the hard coat support layer 32. Because the metal layer 41 has such a slope 42, the slope 42 is visible when the decorative member 10 is viewed from the second surface 12 side. This contributes to giving a three-dimensional effect to the design represented by the concealing layer 44 and the metal layer 41.

[0061] Furthermore, the design layer 40 may include a pattern layer. The pattern layer is a layer on which patterns such as colors, designs, figures, pictures, photographs, characters, marks, pictograms, letters, and numbers are formed. The pattern layer may be a printed layer formed by printing, or a transferred layer formed by transfer. The pattern layer may be included in the hard coat film 30.

[0062] <Middle class> The intermediate layer 50 is a layer provided for the purpose of bonding the molten resin injected in the injection molding process described later to the metal layer 41. Furthermore, the intermediate layer 50 may be provided for the purpose of suppressing heat transfer from the molten resin to the design layer 40 and the hard coat film 30. The intermediate layer 50 forms the first surface 21 of the laminate 20. As materials for forming the intermediate layer, for example, acrylic resin compositions, urethane resin compositions, polyester resins, and organic glass can be used. Examples of organic glass for forming the intermediate layer include polycarbonate, polymethyl methacrylate, polyacrylate, polyethylene terephthalate, polyethylene naphthalate, polyolefin, and ABS (acrylonitrile butadiene styrene copolymer). The intermediate layer 50 may be transparent or opaque. The intermediate layer 50 may be colored.

[0063] The intermediate layer 50 can be formed on the metal layer 41, for example, as follows. First, the intermediate layer forming material described above is coated onto a transfer substrate and cured as necessary to form the intermediate layer 50 on the transfer substrate. Next, the intermediate layer 50 formed on the transfer substrate is transferred onto the metal layer 41 by thermal lamination. This forms the intermediate layer on the metal layer 41. The method for coating the intermediate layer forming material onto the transfer substrate is not particularly limited, and the known coating method described above can be used. The intermediate layer 50 can also be formed by laminating a film-like member onto the metal layer 41.

[0064] The thickness of the intermediate layer 50 is not particularly limited. When the intermediate layer 50 is provided for the purpose of bonding the molten resin and the metal layer 41, the thickness of the intermediate layer 50 may be, for example, 1 μm or more and 50 μm or less, preferably 1 μm or more and 10 μm or less. When the intermediate layer 50 is provided for the purpose of suppressing heat transfer from the molten resin to the design layer 40 and the hard coat film 30, the thickness of the intermediate layer 50 may be, for example, 50 μm or more and 350 μm or less, preferably 110 μm or more and 130 μm or less.

[0065] <Other layers> The laminate 20 may further include a filler layer that fills in the irregularities of the metal layer 41. The filler layer flattens the surface of the design layer 40 facing the intermediate layer 50. The filler layer may be a transparent or opaque resin layer.

[0066] The thickness T40 of the design layer 40 having the above configuration may be 15 μm or more and 500 μm or less, 15 μm or more and 300 μm or less, or 15 μm or more and 125 μm or less.

[0067] <<Molding section>> The molded part 60 forms the first surface 11. The molded part 60 is manufactured by injection molding, as described later. The resin material forming the molded part 60 is not particularly limited. Examples of resin materials forming the molded part 60 include polymethyl methacrylate (PMMA), polypropylene (PP), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), acrylonitrile ethylene-propylene-diene styrene (AES), and acrylonitrile styrene acrylate (ASA). The molded part 60 may be transparent or opaque. The molded part 60 may be colored.

[0068] As described above, the decorative member 10 has a thickness T10 adjusted along the third direction D3 between the first surface 11 and the second surface 12 in order to allow electromagnetic waves used in the sensor 5 to pass through. The thickness T10 of the decorative member 10 can be easily adjusted by manufacturing the molded part 60 by injection molding. By manufacturing the molded part 60 by injection molding, decorative members 10 with large thicknesses can be manufactured easily and quickly.

[0069] As shown in Figure 3, the molded part 60 has a molded layer 61 that forms the second surface 12. The molded layer 61 is laminated on the laminate 20. In the illustrated example, the molded layer 61 is located in a recess formed by the flat portion 23 and the curved portion 24 of the laminate 20. The molded part 60 also has a molded shape portion 62 extending from the molded layer 61. The molded shape portion 62 has a shape according to the application of the decorative member 10. For example, the molded shape portion 62 may be a claw portion for attaching the emblem 3 to the front panel 2. With the molded part 60 made by injection molding, the molded layer 61 for adjusting the thickness T10 and the molded shape portion 62 having various shapes according to the application can be manufactured at the same time. However, the molded shape portion 62 may be omitted from the molded part 60.

[0070] The thickness of the molded layer 61 is not particularly limited, but may be 0.5 mm or more and 10 mm or less, 1 mm or more and 5 mm or less, or 2 mm or more and 5 mm or less.

[0071] <<Manufacturing Method for Decorative Components>> Next, the manufacturing method of the decorative member 10 will be described, mainly with reference to Figures 6 to 15. Figures 6 to 12 and Figures 14 to 15 are diagrams illustrating an example of the manufacturing method of the decorative member 10. Figure 13 is a magnified view of the portion of the laminate 20 shown in Figure 3 that is enclosed by the dashed line XII.

[0072] First, a laminate manufacturing process is carried out to produce the laminate 20. Specifically, as shown in Figure 6, a hard coat support layer 32 is prepared, and a hard coat layer 31 is formed on the other side of the hard coat support layer 32. The hard coat layer 31 is formed on the hard coat support layer 32 with a uniform thickness. The hard coat film 30 is formed by the hard coat layer 31 and the hard coat support layer 32.

[0073] Next, as shown in Figure 7, a concealing layer 44 is formed on one side surface of the hard coat support layer 32. Then, as shown in Figure 8, a primer layer 47 is formed on one side surface of the hard coat support layer 32 and the concealing layer 44. Then, as shown in Figure 9, a metal layer 41 is deposited on one side surface of the primer layer 47. Next, as shown in Figure 10, an intermediate layer 50 is formed on one side surface of the metal layer 41. The laminate 20 is then manufactured.

[0074] Next, a laminate shaping process is carried out to shape the laminate 20. Specifically, as shown in Figure 11A, a shaping mold 70 is prepared. The shaping mold 70 has a shape corresponding to the shape of the laminate 20 in the decorative member 10. In the illustrated example, the shaping mold 70 is formed so that the laminate 20 is shaped to have a flat portion 23 and a curved portion 24. The shaping mold 70 shown in Figure 11A has a female mold 71 and a male mold 72 that are arranged opposite each other. The space surrounded by the female mold 71 and the male mold 72 becomes the molding cavity.

[0075] As shown in Figure 11B, the laminate 20 is heated to approximately 180°C using a heating device to soften it, and then placed in the cavity of the female mold 71. Next, the female mold 71 and the male mold 72 are closed. As a result, the laminate 20 is shaped into a form having a flat portion 23 and a curved portion 24.

[0076] Alternatively, as shown in Figure 12A, first, a vacuum forming die 70 is prepared as the shaping mold. The vacuum forming die 70 has a shape corresponding to the shape of the laminate 20 in the decorative member 10. The vacuum forming die 70 is formed so that the laminate 20 is shaped to have a flat portion 23 and a curved portion 24. Next, the laminate 20 is heated to approximately 180°C using a heating device to soften it and placed on the vacuum forming die 70. Then, as shown in Figure 12B, the inside of the vacuum forming die 70 is vacuum-suctioned to make the laminate 20 adhere tightly to the vacuum forming die 70. As a result, the laminate 20 is shaped to have a flat portion 23 and a curved portion 24.

[0077] Furthermore, when the laminate 20 is formed, the hard coat film 30 stretches in the curved portion 24. As a result, as shown in Figure 13, the thicknesses T31 and T32 of each layer 31 and 32 of the hard coat film 30 in the curved portion 24 are smaller than the thicknesses T31 and T32 of each layer 31 and 32 of the hard coat film 30 in the flat portion 23.

[0078] Next, an injection molding process is carried out to injection mold a molded part 60 into the formed laminate 20. Specifically, the molded part 60 is formed by insert molding. First, as shown in Figure 14, an injection mold 75 is prepared. The injection mold 75 has a shape corresponding to the decorative member 10 to be manufactured. The injection mold 75 shown in Figure 14 has a first female mold 76 and a second female mold 77 that are arranged facing each other. A cavity is formed between the first female mold 76 and the second female mold 77. The injection mold 75 also has a male mold 78 that is positioned in the space between the first female mold 76 and the second female mold 77. The space surrounded by the first female mold 76, the second female mold 77 and the male mold 78 becomes the molding cavity.

[0079] As shown in Figure 14, the male mold 78 is placed in the cavity of the second female mold 77. Similarly, the laminate 20 is placed in the cavity of the first female mold 76. Next, as shown in Figure 15, the first female mold 76 and the second female mold 77 are closed. Then, molten resin is injected into the cavity of the injection mold 75 through the port 79. Inside the injection mold 75, the resin solidifies to form the molded part 60. The molded part 60 joins with the laminate 20 and becomes one during solidification.

[0080] As described above, the decorative member 10 is manufactured in the injection mold 75. When the laminate 20 is shaped in the shaping mold 70, the hard coat film 30 stretches in the curved portion 24. Also, when the molten resin is injected, heat from the molten resin is transferred to the laminate 20, causing the intermediate layer 50, the design layer 40, and the hard coat film 30 of the laminate 20 to stretch. Here, as described above, the hard coat layer 31 and the hard coat support layer 32 of the laminate 20 do not crack when heated to 180°C and stretched by 10% or 20%. Therefore, when heat from the heating device or molten resin is transferred to the laminate, the hard coat film 30 can stretch without cracking, following the other layers 40 and 50 of the laminate 20.

[0081] Furthermore, the laminate shaping process shown in Figures 11A and 11B and the injection molding process shown in Figures 14 and 15 may be carried out simultaneously. That is, the laminate 20 may be shaped in the injection mold 75 into a shape having a flat portion 23 and a curved portion 24.

[0082] <<<Second Embodiment>>> Next, a second embodiment of the present disclosure will be described with reference to Figures 16 to 20. The decorative member 110 shown in Figures 16 to 20 differs from the decorative member 10 shown in Figures 1 to 15 in that the design layer 40 has a metal support layer 81 and a bonding layer 85 that support the metal layer 41. The other configurations are substantially the same as those of the decorative member 10 shown in Figures 1 to 15. In the second embodiment shown in Figures 16 to 20, the same reference numerals are used for parts that are the same as those of the decorative member 10 shown in Figures 1 to 15, and detailed descriptions are omitted.

[0083] <Metal support layer> The metal support layer 81 is a film-like component. A primer layer 47 and a metal layer 41 are formed in that order on one side surface of the metal support layer 81. The other side surface of the metal support layer 81 faces the concealing layer 44. The material used for forming the metal support layer is one that transmits visible light and does not crack when heated to 180°C and stretched by 10% to 20%. For example, polymethyl methacrylate (PMMA) or polycarbonate (PC) can be used as the material for forming the metal support layer.

[0084] The thickness of the metal support layer 81 is not particularly limited, but is, for example, 50 μm or more and 500 μm or less, and preferably 50 μm or more and 100 μm or less.

[0085] In the examples shown in Figures 17 to 20, the primer layer 47 is provided to improve the adhesion between the metal layer 41 and the metal support layer 81. The primer layer 47 is formed to cover the entire surface of one side of the metal support layer 81. If the adhesion between the metal layer 41 and the metal support layer 81 is ensured by itself or by another layer, the design layer 40 does not need to include the primer layer 47.

[0086] In the examples shown in Figures 16 and 17, the metal film 80 is composed of a metal support layer 81, a primer layer 47, and a metal layer 41.

[0087] <Joining layer> The bonding layer 85 bonds (adheses, tacks, or heat-seals) the hard coat film 30 and the concealing layer 44 to the metal film 80.

[0088] As the material for forming the bonding layer, a thermoplastic resin that can transmit visible light or a (meth)acrylic acid ester copolymer can be used. The thermoplastic resin is not particularly limited, and for example, acrylic resin, vinyl chloride-vinyl acetate copolymer, polyamide resin, polyester resin, chlorinated polypropylene, chlorinated rubber, urethane resin, epoxy resin, styrene resin, etc. can be used. These resins may be used individually or in combination of two or more. As the material for forming the bonding layer, it is preferable that the material does not peel off from the layer adjacent to the bonding layer 85 when the laminate 20 is heated in the laminate forming process or injection molding process described later.

[0089] In the illustrated example, the bonding layer 85 is formed by coating the bonding layer-forming material described above onto the other side of the metal support layer 81, but is not limited to this. The bonding layer 85 may also be formed by coating the bonding layer-forming material described above onto one side of the hard coat film 30 and the concealing layer 44. The method for coating the bonding layer-forming material is not particularly limited, and the known coating methods described above can be used.

[0090] The bonding layer 85 may also be formed by transfer. That is, the release layer and the bonding layer 85 may first be laminated on a transfer substrate, and then the bonding layer 85 may be formed by transferring it onto the other side of the metal support layer 81 or onto one side of the hard coat film 30 and the concealing layer 44. In this case, the transfer substrate is peeled off together with the release layer when the bonding layer 85 is transferred to the metal support layer 81, etc. As the transfer substrate, for example, polyester resin film or polyolefin resin film, which are commonly used as release layers for transfer films, can be used. The release layer is formed using silicone resin or the like.

[0091] The thickness of the bonding layer 85 is not particularly limited, but is, for example, 10 μm or more and 200 μm or less, and preferably 10 μm or more and 50 μm or less.

[0092] <<Manufacturing Method for Decorative Components>> Next, the manufacturing method of the decorative member 110 of the second embodiment will be described, mainly with reference to Figures 18 to 20.

[0093] First, a laminate manufacturing process is carried out to produce the laminate 20. Specifically, a hard coat film 30 is produced in the same manner as shown in the example in Figure 6. Next, a concealing layer 44 is formed on the hard coat support layer 32 of the hard coat film 30, in the same manner as shown in the example in Figure 7. A metal film 80 is also produced. Specifically, as shown in Figure 18, a primer layer 47 is formed by coating one side surface of the metal support layer 81 with a material for forming a primer layer, and then the aforementioned material for forming a metal layer is vapor-deposited to form a metal layer 41.

[0094] Next, as shown in Figure 18, a bonding layer 85 is formed on the other side of the metal film 80. Then, the metal film 80, the hard coat film 30, and the concealing layer 44 are bonded together via the bonding layer 85. After that, air between the metal film 80 and the hard coat film 30 is removed by autoclaving or the like. As a result, as shown in Figure 19, the bonding layer 85 and the metal film 80 bend in accordance with the uneven surface formed by the hard coat support layer 32 and the concealing layer 44. Therefore, as shown in Figure 17, slopes 86 and 42 are formed on the bonding layer 85 and the metal layer 41, extending along the surface that intersects with one side of the hard coat support layer 32. This contributes to giving a three-dimensional effect to the design represented by the concealing layer 44 and the metal layer 41.

[0095] Subsequently, as shown in Figure 20, an intermediate layer 50 is formed on the metal layer 41. This completes the production of the laminate 20. Then, the laminate 20 is shaped in the same manner as shown in Figures 11A and 11B or Figure 12, and a molded portion 60 is formed in the same manner as shown in Figures 14 and 15. This completes the production of the decorative member 110.

[0096] Incidentally, in the decorative member 110 manufactured in this manner, a gap 88 is formed between the side surface 45 of the concealing layer 44 and the bonding layer 85, as shown in Figure 17. In such a decorative member 110, the bevels 86 and 42 of the bonding layer 85 and the metal layer 41 can be observed through the gap 88. This also contributes to giving a three-dimensional feel to the design represented by the concealing layer 44 and the metal layer 41.

[0097] <<<Modified Version>>> The first and second embodiments have been described above with reference to specific examples, but these examples are not intended to limit the first and second embodiments. The first and second embodiments described above can be implemented in various other examples, and various omissions, substitutions, modifications, and additions can be made without departing from the gist of the invention.

[0098] For example, as shown in Figure 21A, the laminate 20 does not need to include the concealing layer 44.

[0099] Furthermore, the primer layer 47 may be placed between the hard coat film 30 and the opacity layer 44. For example, as shown in Figure 21B, the laminate 20 may be manufactured by arranging the primer layer 47, opacity layer 44, metal layer 41 and intermediate layer 50 in this order on one side of the hard coat film 30.

[0100] Furthermore, the primer layer 47 may be supported by a primer support layer 48. In this case, the primer support layer 48 supports the primer layer 47 from the side opposite to the side of the primer layer 47 facing the metal layer 41. As the material for forming the primer support layer 48, for example, organic glass can be used. Examples of organic glass include polycarbonate, polymethyl methacrylate, polyacrylate, polyethylene terephthalate, polyethylene naphthalate, polyolefin, and ABS (acrylonitrile butadiene styrene copolymer). Among these organic glasses, polycarbonate is suitable as a material for forming the primer support layer 48 because it has excellent impact resistance and transparency.

[0101] In the example shown in Figure 21C, the laminate 20 is manufactured by arranging a concealing layer 44, a bonding layer 85, a primer support layer 48, a primer layer 47, a metal layer 41, and an intermediate layer 50 in that order on one side of the hard coat film 30. In the example shown in Figure 21D, the laminate 20 is also manufactured by arranging a bonding layer 85, a concealing layer 44, a primer support layer 48, a primer layer 47, a metal layer 41, and an intermediate layer 50 in that order on one side of the hard coat film 30.

[0102] Furthermore, the concealing layer 44 may be supported by a concealing layer support layer 46. In this case, the concealing layer support layer 46 may be located on either side of the concealing layer 44. As the material for forming the concealing layer support layer 46, for example, organic glass can be used. Examples of organic glass include polycarbonate, polymethyl methacrylate, polyacrylate, polyethylene terephthalate, polyethylene naphthalate, polyolefin, and ABS (acrylonitrile butadiene styrene copolymer). Among these organic glasses, polycarbonate is suitable as a material for forming the concealing layer support layer 46 because it has excellent impact resistance and transparency.

[0103] In the example shown in Figure 21E, the laminate 20 is manufactured by arranging the bonding layer 85, the concealing layer support layer 46, the concealing layer 44, the bonding layer 85, the primer support layer 48, the primer layer 47, the metal layer 41, and the intermediate layer 50 in this order on one side of the hard coat film 30. In the example shown in Figure 21F, the laminate 20 is also manufactured by arranging the bonding layer 85, the concealing layer 44, the concealing layer support layer 46, the bonding layer 85, the primer support layer 48, the primer layer 47, the metal layer 41, and the intermediate layer 50 in this order on one side of the hard coat film 30.

[0104] Furthermore, the metal layer 41 may be positioned facing the hard coat film 30 via the bonding layer 85. In the example shown in Figure 21G, the laminate 20 is manufactured by arranging the bonding layer 85, metal layer 41, primer layer 47, primer support layer 48, and intermediate layer 50 in this order on one side of the hard coat film 30. In the example shown in Figure 21H, the laminate 20 is manufactured by arranging the bonding layer 85, concealing layer 44, metal layer 41, primer layer 47, primer support layer 48, and intermediate layer 50 in this order on one side of the hard coat film 30. In the example shown in Figure 21I, the laminate 20 is manufactured by arranging the concealing layer 44, bonding layer 85, metal layer 41, primer layer 47, primer support layer 48, and intermediate layer 50 in this order on one side of the hard coat film 30.

[0105] The laminate 20 may also be manufactured by transferring a metal layer 41 or the like onto a hard coat film 30. In the example shown in Figure 22A, the laminate 20 is manufactured as follows. First, a transfer film 95 is prepared by laminating a release layer 97 onto a support substrate 96. Next, a primer layer 47 and a metal layer 41 are laminated on the release layer 97 of the transfer film 95 in that order. Next, the metal layer 41 laminated on the transfer film 95 and the hard coat support layer 32 of the hard coat film 30 are bonded together via a bonding layer 85. After that, the transfer film 95 is peeled off the primer layer 47. Then, the laminate 20 is obtained by laminating an intermediate layer 50 on the primer layer 47. In the example shown in Figure 22B, the laminate 20 is manufactured as follows. First, a transfer film 95 is prepared by laminating a release layer 97 onto a support substrate 96. Next, a primer layer 47, a metal layer 41, and an opacity layer 44 are laminated in this order on the release layer 97 of the transfer film 95. Then, the metal layer 41 and opacity layer 44 laminated on the transfer film 95 are bonded to the hard coat support layer 32 of the hard coat film 30 via a bonding layer 85. After that, the transfer film 95 is peeled off from the primer layer 47. Then, an intermediate layer 50 is laminated on the primer layer 47 to obtain the laminate 20. In the example shown in Figure 22C, the laminate 20 is made as follows. First, a transfer film 95 is prepared by laminating a release layer 97 onto a support base material 96. Next, a primer layer 47 and a metal layer 41 are laminated in this order on the release layer 97 of the transfer film 95. Also, an opacity layer 44 is formed on the hard coat support layer 32 of the hard coat film 30. Next, the metal layer 41 laminated on the transfer film 95 and the hard coat support layer 32 and the concealing layer 44 formed on the hard coat support layer 32 of the hard coat film 30 are bonded together via the bonding layer 85. After that, the transfer film is peeled off the primer layer 47. Then, the intermediate layer 50 is laminated on the primer layer 47 to obtain the laminate 20.

[0106] Furthermore, the concealing layer 44 may be formed from a material that can transmit visible light. In this case, the irregularities of the concealing layer 44 can give a pattern to the design represented by the concealing layer 44 and the metal layer 41. For example, if the concealing layer 44 is formed in a striated pattern, a striated pattern can be given to the design represented by the concealing layer 44 and the metal layer 41.

[0107] Furthermore, the design layer 40 does not have to include the concealing layer 44. Also, the metal layer 41 does not have to be formed to cover the entire surface of the hard coat film 30. The metal layer 41 may be formed to cover only a part of the hard coat film 30.

[0108] Furthermore, the metal layer 41 does not have to be bent in accordance with the uneven surface formed by the hard coat support layer 32 and the concealing layer 44. For example, as shown in Figure 23, the laminate 20 may include a filling layer 90 that fills the unevenness formed by the hard coat support layer 32 and the concealing layer 44, and the metal layer 41 may be formed on one side surface of the filling layer 90. The filling layer 90 may be a transparent or opaque resin layer.

[0109] Alternatively, the hard coat film 30 may be produced by transferring the hard coat layer 31 onto the hard coat support layer 32. In this case, for example, the hard coat film 30 can be produced by the following method. First, the hard coat layer 31, primer layer, and bonding layer are laminated on a transfer substrate in this order. Next, the hard coat layer 31, primer layer, and bonding layer laminated on the transfer substrate are bonded to the hard coat support layer 32. After that, the transfer substrate is peeled off from the hard coat layer 31. This produces the hard coat film 30.

[0110] Furthermore, the decorative members 10 and 110 do not necessarily have to include the molded portion 60 and the intermediate layer 50.

[0111] Furthermore, the decorative members 10 and 110 described above do not necessarily have to be positioned facing the sensor 5. As shown in the example in Figure 24, the decorative members 10 and 110 may be used as emblems 3 attached to the handle or dashboard of the mobile body 1. The decorative members 10 and 110 may also be used for purposes other than emblems 3.

[0112] The decorative members 10 and 110 may be used as exterior components such as the front panel 2 of the mobile body 1. Furthermore, the decorative members 10 and 110 are applicable to objects other than the mobile body 1. The decorative members 10 and 110 are applicable to building materials such as interior materials, exterior materials, ceiling materials, floor materials, and cases for home appliances, etc.

[0113] <<Materials for forming a hard coat layer and method for forming a hard coat layer>> The following describes in detail the materials for forming the hard coat layer 31 and the method for forming the hard coat layer 31.

[0114] [Material I for forming a hard coat layer] Materials for forming a hard coat layer include, for example, (A) A urethane compound which is a reaction product of a compound (a1) represented by the following general formula (1) and an isocyanate (a2) having an isocyanurate ring represented by the following general formula (2), (B) A compound having an isocyanurate ring represented by the following general formula (3), (C) Inorganic particles with an average primary particle size of 10 nm to 100 nm, This is a curable resin composition containing (hereinafter also referred to as "material I for forming a hard coat layer").

[0115] [ka] (In the formula, Z 1 R is a polymerizable carbon-carbon double bond-containing group. 1 R is a divalent hydrocarbon group that may contain an oxygen atom. 2 R is a hydrogen atom or a monovalent hydrocarbon group.3 is a single bond or a divalent hydrocarbon group. n is an integer from 1 to 3, m is an integer from 1 to 3, and n + m is a number satisfying 2 to 4. When n is 2 or more, two or more Z 1 and R 1 may be the same or different. When m is 2 or more, two or more R 3 may be the same or different. When 4 - n - m is 2, two R 2 may be the same or different.)

[0116]

Chemical formula

[0117]

Chemical formula

[0118] This material I for forming a hard coat layer can improve the intermolecular cohesive force by containing the above components (A) and (B) having an isocyanurate ring. Furthermore, hydrophobicity can be imparted by the group between the isocyanurate ring and the polymerizable carbon - carbon double bond - containing group. Therefore, excellent extensibility can be imparted to the cured product, and resistance to chemicals such as highly polar ethanol and methanol can be provided. Furthermore, by containing component (C), a cured product with excellent abrasion resistance can be obtained. If only component (A) is present, the chemical resistance due to the intermolecular cohesive force between the isocyanurate rings in the composition is insufficient, but by containing component (B), this can be compensated for, and excellent elongation and chemical resistance can be imparted to the cured product.

[0119] A. Urethane compound (A) The urethane compound (A) used in this hard coat layer forming material I is a reaction product of a compound (a1) represented by the following general formula (1) and an isocyanate (a2) having an isocyanurate ring represented by the following general formula (2).

[0120] [ka] (In the formula, Z 1 R is a polymerizable carbon-carbon double bond-containing group. 1 R is a divalent hydrocarbon group that may contain an oxygen atom. 2 R is a hydrogen atom or a monovalent hydrocarbon group. 3 Z is a single bond or a divalent hydrocarbon group. n is an integer from 1 to 3, m is an integer from 1 to 3, and n+m is a number satisfying 2 to 4. When n is 2 or greater, there are two or more Z 1 and R 1 They may be the same or different. When m is 2 or greater, there are two or more R 3 They may be the same or different. When 4-nm is 2, the two R 2 They may be the same or different.

[0121] [ka] (In the formula, R 4 Each of these is independently a divalent hydrocarbon group, which may contain an oxygen atom, and may be the same or different type.

[0122] 1. Compound (a1) represented by general formula (1) In the compound (a1) represented by the above general formula (1), Z 1 It is a polymerizable carbon-carbon double bond-containing group. The polymerizable carbon-carbon double bond-containing group is not particularly limited as long as it contains a polymerizable carbon-carbon double bond, but examples include the vinyl group, (meth)acryloyl group, (meth)acryloyloxy group, and allyl group. When n is 2 or more (i.e., 2 or 3), there are 2 or 3 Z 1 They may be the same or different.

[0123] R 1 R is a divalent hydrocarbon group which may contain an oxygen atom, and examples include a linear, branched, or cyclic divalent aliphatic hydrocarbon group having 1 to 3 carbon atoms, or a group which contains one or more ether bonds, ester bonds, or carbonyl groups between the carbon-carbon bonds of the aliphatic hydrocarbon group. Preferably, it is a linear alkylene group having 1 to 3 carbon atoms, and particularly preferably a methylene group, an ethylene group, or a propylene group. When n is 2 or more (i.e., 2 or 3), there are 2 or 3 R 1 They may be the same or different.

[0124] R 2 is a hydrogen atom or a monovalent hydrocarbon group, preferably a hydrogen atom or a linear, branched, or cyclic alkyl group having 1 to 3 carbon atoms, and particularly preferably a hydrogen atom or a methyl group. When 4-nm is 2, there are two R 2 These may be the same or different from one another.

[0125] R 3 R is a single bond or a divalent hydrocarbon group, preferably a single bond or a linear, branched, or cyclic alkylene group having 1 to 3 carbon atoms, and particularly preferably a single bond or a methylene group. When m is 2 or more (i.e., 2 or 3), there are 2 or 3 R 3 They may be the same or different.

[0126] n is an integer between 1 and 3, m is an integer between 1 and 3, and n+m is a number that satisfies between 2 and 4. That is, the combinations of n and m are (n, m) = (1, 1), (1, 2), (2, 1), (3, 1), (2, 2), or (1, 3).

[0127] As compound (a1), it is preferable that pentaerythritol is (meth)acrylic modified, that is, one, two, or three of the four hydroxyl groups contained in pentaerythritol have reacted with (meth)acrylic acid. When one hydroxyl group has reacted with (meth)acrylic acid, it is pentaerythritol monoacrylate, with n=1, m=3, Z 1 =(meth)acryloyloxy group, R 1 and R 3 This is a methylene group. The two hydroxyl groups react with (meth)acrylic acid to form pentaerythritol diacrylate, where n=2, m=2, Z 1 =(meth)acryloyloxy group, R 1 and R 3 This is a methylene group. The reaction of the three hydroxyl groups with (meth)acrylic acid results in pentaerythritol triacrylate (PETA), where n=3, m=1, Z 1 =(meth)acryloyloxy group, R 1 and R 3 It is a methylene group.

[0128] In particular, it is preferable that compound (a1) mainly consists of pentaerythritol triacrylate (PETA), in which the three hydroxyl groups in pentaerythritol are modified with (meth)acrylic acid. This is because if the proportion of pentaerythritol monoacrylate or pentaerythritol diacrylate is large, when it reacts with isocyanate (a2) having an isocyanurate ring represented by general formula (2) described later, the reactant urethane compound (A) may polymerize, which may reduce the dispersibility of the reactant urethane compound (A) and compound (B) described later, potentially adversely affecting various physical properties. Therefore, compound (a1) has n = 3, m = 1, and Z in the general formula (1) above. 1 (meth)acryloyloxy group, R 1 and R 3 It is preferable that the compound has a methylene group as its main component. Here, "main component" means, as described above, that pentaerythritol monoacrylate or pentaerythritol diacrylate may be included in an amount that does not polymerize the urethane compound (A) and does not adversely affect its various physical properties. The above compound (a1) may be used alone, or two or more may be used in combination.

[0129] Furthermore, 2-hydroxypropyl acrylate (HPA) is also preferred as compound (a1). In this case, n=1, m=1, Z 1 =(meth)acryloyloxy group, R 1 and R 3 It is a methylene group, and two R 2 These are a hydrogen atom and a methyl group.

[0130] 2. Isocyanates (a2) having an isocyanurate ring represented by general formula (2) In general formula (2), R 4 Each of these is independently a divalent hydrocarbon group, which may contain an oxygen atom, and may be the same or different type. The above R 4 Examples include linear, branched, or cyclic divalent aliphatic hydrocarbon groups having 6 to 13 carbon atoms, or divalent aliphatic hydrocarbon groups having 7 to 13 carbon atoms that include one or more ether bonds, ester bonds, or carbonyl groups.

[0131] Thus, R 4 When is an isocyanate (a2) which is an aliphatic hydrocarbon group having a predetermined number of carbon atoms, the cured product exhibits good extensibility and excellent processability. Furthermore, by imparting hydrophobicity, a cured product with excellent chemical resistance can be obtained. Moreover, it is presumed that the mobility of the isocyanurate rings within the cured product can be improved, thereby enhancing the bonding between isocyanurate rings due to intermolecular cohesive forces. Among these, alkylene groups having 6 to 8 carbon atoms are preferred, and hexylene groups and cyclohexylene groups are particularly preferred.

[0132] Such isocyanates having an isocyanurate ring are derived from diisocyanates having two isocyanate groups in the molecule. Examples of the above diisocyanates include hexamethylene diisocyanate, isophorone diisocyanate, dicyclohexylmethane-4,4'-diisocyanate, dicyclohexylmethane-2,4'-diisocyanate, 2,4-tolylene diisocyanate, 2,5-tolylene diisocyanate, 1,3-xylylene diisocyanate, 1,4-xylylene diisocyanate, diphenylmethane-4,4'-diisocyanate, 3-methyldiphenylmethane diisocyanate, and lysine diisocyanate, but hexamethylene diisocyanate and isophorone diisocyanate are particularly preferred.

[0133] 3. Others The urethane compound (A) of the hard coat layer forming material I is a compound obtained by urethane reaction between compound (a1) represented by the above general formula (1) and isocyanate (a2) having an isocyanurate ring represented by the above general formula (2). In particular, in the above general formula (1), n ​​is 3, m is 1, Z 1 (meth)acryloyloxy group, R 1 and R 3 Compound (a1) in which is a methylene group, and R in the above general formula (2) 4 It is preferable that the reaction product is with an isocyanate (a2) which is a linear, branched, or cyclic divalent aliphatic hydrocarbon group.

[0134] The method for obtaining the urethane compound (A) is not particularly limited and can be produced according to generally known methods. For example, the compound (a1) represented by the general formula (1) above, the isocyanate (a2) having an isocyanurate ring represented by the general formula (2) above, and optionally a urethane catalyst, polymerization inhibitor, and organic solvent are placed in a reaction vessel and the reaction is carried out while maintaining a predetermined temperature.

[0135] The reaction ratio of each component is preferably such that the hydroxyl group contained in compound (a1) represented by the general formula (1) above is equivalent to the isocyanate (a2) having an isocyanurate ring represented by the general formula (2) above. However, in production, the reaction is usually carried out in a range of 0.8 to 1.1 for the hydroxyl group / isocyanate group equivalent ratio.

[0136] Furthermore, the isocyanate (a2) and compound (a1) may be reacted by first adding one of the raw materials, and then adding the other raw materials dropwise. The urethane reaction is usually carried out in the range of 60 to 120°C. The endpoint of the urethane reaction is 2270 cm², where the isocyanate group is located. -1 This can be confirmed by the disappearance of the infrared absorption spectrum or by determining the isocyanate group content using the method described in JIS K 7301. As urethane catalysts, tin compounds such as dibutyltin dilaurate or amines such as triethylamine can be used.

[0137] Regarding the molecular weight of urethane compound (A), it is preferable that the weight-average molecular weight be between 1,000 and 25,000, in order to improve the dispersibility between the reactant urethane compound (A) and compound (B) described later, and to achieve uniform physical properties.

[0138] Here, the weight-average molecular weight (Mw) in this specification is determined by gel permeation chromatography (GPC) as a standard polystyrene equivalent. For example, the measuring device can be a Tosoh GPC HLC-8220, with two Shodex LF-404 columns connected in series, a differential refractive index (RI) detector, and Agilent Technologies Easy Type PS-2 polystyrene (molecular weight range 580-364,000) as the standard polystyrene.

[0139] The amount of urethane compound (A) in the curable resin composition, which is material I for forming the hard coat layer, is not particularly limited, but is preferably in the range of 18 to 60 parts by mass, and particularly preferably in the range of 36 to 54 parts by mass, per 100 parts by mass of solid content of the curable resin composition. This is because it is possible to obtain the various physical properties required for the cured product. Furthermore, when compounding urethane compound (A) and urethane compound (D) as shown in "D. Other Components" below, it is preferable that the amount of the mixture of urethane compound (A) and urethane compound (D) is within the range of 10 to 90 parts by mass, particularly 20 to 70 parts by mass, per 100 parts by mass of solid content of the curable resin composition, as this can further improve the various physical properties required of the cured product.

[0140] B. Compounds having an isocyanurate ring (B) Component (B) of material I for forming the hard coat layer is a compound having an isocyanurate ring represented by the following general formula (3).

[0141] [ka] (In the formula, Z 2 Each of these is independently a polymerizable carbon-carbon double bond-containing group, either identical or different. 5 Each of these is independently a divalent hydrocarbon group, which may contain an oxygen atom, and may be the same or different type.

[0142] By adding component (B), the balance between the crosslinking density of the cured product and the density of the isocyanurate rings can be improved, resulting in effects such as improved chemical resistance without impairing extensibility.

[0143] In the above general formula (3), Z 2 These are, independently, identical or different polymerizable carbon-carbon double bond-containing groups. Furthermore, the polymerizable carbon-carbon double bond-containing group is Z in the general formula (1) above. 1Examples similar to those exemplified above can be given. In particular, from the viewpoint of polymerizability, (meth)acryloyl groups and (meth)acryloyloxy groups are preferred.

[0144] R 5 Each of these is independently a divalent hydrocarbon group, either identical or different, which may contain an oxygen atom. Preferably, it is an alkylene group having 2 to 7 carbon atoms, or a divalent aliphatic hydrocarbon group having 5 to 15 carbon atoms that includes an ester group. This is because hydrophobicity can improve alcohol resistance and increase the mobility of the isocyanurate rings within the cured product, thereby improving the bonding between isocyanurate rings due to intermolecular cohesive forces. In this disclosure, there are three R's in particular. 5 Preferably, at least one of them is a compound in which a divalent aliphatic hydrocarbon group having 5 to 15 carbon atoms containing an ester group is present. In this case, the other R 5 Preferably, it is a linear alkylene group having 2 to 7 carbon atoms.

[0145] 3 R 5 As a compound in which at least one of the components is a divalent aliphatic hydrocarbon group having 5 to 15 carbon atoms and containing an ester group, commercially available products may be used as appropriate. For example, ε-caprolactone-modified tris-(2-acryloxyethyl) isocyanurate represented by the following formula (NK ester A9300-1CL, NK ester A9300-3CL (manufactured by Shin Nakamura Chemical Industry Co., Ltd.)) can be used. As for the other component (B), a non-ε-caprolactone-modified tris-(2-acryloxyethyl) isocyanurate represented by the following formula (NK ester A9300 (manufactured by Shin Nakamura Chemical Industry Co., Ltd.)) can be used.

[0146] A9300-1CL

[0147] [ka]

[0148] A9300-3CL

[0149] [ka]

[0150] A9300

[0151] [ka]

[0152] Furthermore, these three R's 5 Compounds in which at least one of the members is a divalent aliphatic hydrocarbon group having 5 to 15 carbon atoms and containing an ester group can be synthesized in two steps by adding ε-caprolactone to trishydroxyalkyl isocyanurate having a hydroxyl group (e.g., trishydroxyethyl isocyanurate), and then subsequently adding acrylic acid.

[0153] The amount of compound (B) is not particularly limited, but it is preferable that it be in the range of 36 to 82 parts by mass, and particularly in the range of 46 to 72 parts by mass, per 100 parts by mass of solid content of the curable resin composition, in order to obtain the various physical properties required for the cured product.

[0154] C. Inorganic particles (C) Component (C) of material I for hard coat layer formation consists of inorganic particles with an average primary particle size of 10 nm to 100 nm. Preferred inorganic particles include, for example, silica (colloidal silica, fumed silica, precipitated silica, etc.), alumina, zirconia, titania, and metal oxides such as zinc oxide. From the viewpoint of improving transparency and wear resistance, inorganic particles made of silica or alumina are preferred. The particle shape is not particularly limited and can be spherical, ellipsoidal, polyhedronal, or flake-shaped, but a spherical shape is preferred because it results in higher hardness and superior hard coat properties.

[0155] The inorganic particles may be non-reactive or reactive inorganic particles having reactive functional groups on their surface. Preferred reactive functional groups include vinyl groups, (meth)acryloyl groups, allyl groups, epoxy groups, and silanol groups, with vinyl groups, (meth)acryloyl groups, and allyl groups being more preferred from the viewpoint of improving hardness and scratch resistance.

[0156] The inorganic particles of component (C) of material I for hard coat layer formation, having an average primary particle size of 10 nm to 100 nm, may form linked and aggregated inorganic particle groups (irregularly shaped inorganic particles) with an average linkage number of 2 to 20. The linkage and aggregation may be regular or irregular. Furthermore, the irregularly shaped inorganic particles may have reactive functional groups on their surface. Preferred reactive functional groups include vinyl groups, (meth)acryloyl groups, allyl groups, epoxy groups, and silanol groups.

[0157] The curable resin composition, which is material I for forming the hard coat layer, does not have a particularly limited amount of component (C), but it is preferable that the amount is in the range of 5 to 20 parts by mass, particularly 10 to 15 parts by mass, per 100 parts by mass of solid content of the curable resin composition, in order to reliably obtain excellent wear resistance.

[0158] D. Other ingredients The material I for forming the hard coat layer preferably further contains a urethane compound (D) which is a reaction product of the compound represented by the general formula (1) above and an isocyanate that does not contain an isocyanurate structure but has an alicyclic structure. Examples of such isocyanates that do not contain an isocyanurate structure but have an alicyclic structure include isophorone diisocyanate (IPDI). Thus, including a urethane reaction product different from component (A) is preferable because it results in a cured product with even greater elongation properties.

[0159] Furthermore, the hard coat layer forming material I may contain a solvent to adjust the viscosity of the composition and to improve the smoothness, uniformity, and adhesion to the substrate of the cured film. Known solvents can be used, such as alcohols like ethanol, propanol, isopropanol, and butanol; aromatic hydrocarbons like toluene and xylene; esters like ethyl acetate and butyl acetate; ketones like acetone, methyl ethyl ketone, and methyl isobutyl ketone; and ethers such as 2-methoxyethanol, 2-ethoxyethanol, 2-ethoxypropanol, 2-(2-ethoxyethoxy)ethanol, 1,4-dioxane, and tetrahydrofuran. Two or more solvents may be mixed and used.

[0160] In the curable resin composition which is material I for forming a hard coat layer, the solvent content is not particularly limited and can be adjusted as appropriate depending on the purpose, but it is preferably 25 parts by mass or more and 70 parts by mass or less per 100 parts by mass of the curable resin composition, and more preferably 30 parts by mass or more and 50 parts by mass or less.

[0161] Furthermore, if the curable resin composition I, which is material I for forming the hard coat layer, is to be UV-curable using ultraviolet light for curing, a photopolymerization initiator, polymerization accelerator, photoinitiation aid, etc., may be added to the composition of this disclosure in order to expedite curing. Known photopolymerization initiators can be used, such as acetophenone compounds, benzoin ether compounds, benzophenone compounds, thioxanthone compounds, etc. Also, triethanolamine, methyldiethanolamine, triisopropanolamine, etc. can be used as polymerization accelerators and photoinitiation aids. Furthermore, when electron beam curing is used, there is no need to add photopolymerization initiators, polymerization accelerators, or photoinitiation aids. In this case, it is preferable because the proportion of urethane compound (A) and compound (B) in the solid content can be increased, making it easier to improve abrasion resistance and tensile elongation.

[0162] Furthermore, the material I for forming the hard coat layer may optionally contain various additives such as light stabilizers, antioxidants, plasticizers, flame retardants, surfactants, leveling agents, thermal polymerization inhibitors, antistatic agents, antifogging agents, antibacterial agents, fillers, pigments, dyes, and colorants.

[0163] E. Others Material I for forming a hard coat layer can be obtained by uniformly mixing a urethane compound (A), the above compound (B), inorganic particles (C), and various additives and solvents as needed in predetermined proportions using a conventional method.

[0164] [Method for forming a hard coat layer using material I for hard coat layer formation] The hard coat layer 31 is a cured product of the hard coat layer forming material I described above. The hard coat layer 31 can be formed by coating the hard coat layer forming material I onto the substrate (hard coat support layer 32) to a desired thickness, drying to remove the solvent if a solvent is used if desired, and then curing by irradiation with active energy rays. The resin cured product obtained in this way has excellent abrasion resistance, elongation, and chemical resistance.

[0165] The method for applying the above-mentioned hard coat layer forming material I onto the substrate (hard coat support layer 32) is not particularly limited, and any known method can be applied as appropriate. For example, the coating can be applied by any of the following methods: dipping, flow coating, spraying, spin coating, gravure coating, microgravure coating, die coating, slit reverse coating, roll coating, blade coating, air knife coating, offset coating, bar coating, etc. Furthermore, the coating can be applied in an image-like manner by printing methods such as gravure printing, gravure offset printing, or screen printing.

[0166] The amount of coating can be appropriately selected according to the purpose of the cured product and is not particularly limited. For example, when intended as a glass substitute, it is preferable to coat the product such that the thickness of the cured layer hardened by irradiation with active energy rays is 2 μm to 20 μm, preferably 3 μm to 15 μm, and more preferably 4 μm to 10 μm.

[0167] To evaporate the solvent added to the material I for forming the hard coat layer as needed, known drying methods such as hot air heating, infrared heating, and far-infrared heating can be used as appropriate. The preferred drying conditions vary depending on the boiling point of the solvent, the material of the substrate, the amount applied, etc., but generally, a method such as drying at a temperature of 60°C to 180°C for 10 seconds to 30 minutes is recommended.

[0168] As active energy rays, ultraviolet rays emitted from light sources such as xenon lamps, low-pressure mercury lamps, high-pressure mercury lamps, ultra-high-pressure mercury lamps, metal halide lamps, carbon arc lamps, and tungsten lamps, as well as electron beams, alpha rays, beta rays, and gamma rays typically extracted from particle accelerators of 20 to 2000 kV, can be used.

[0169] [Materials for forming hard coat layers II] Furthermore, the material for forming the hard coat layer may be a curable composition containing, for example, a thermosetting component and a curable component such as an active energy ray curable component (hereinafter also referred to as "material II for forming the hard coat layer"). From the viewpoint of weather resistance, abrasion resistance, and chemical resistance, an active energy ray curable component is preferred as the curable component included in the curable composition which is material II for forming the hard coat layer.

[0170] Examples of thermosetting components include thermosetting resins such as epoxy resins, melamine resins, guanamine resins, urea resins, unsaturated polyesters, thermosetting urethane resins, thermosetting (meth)acrylic resins, and aminoalkyd resins.

[0171] Active energy ray-curable components are components that harden upon irradiation with active energy rays. Examples of active energy rays include electromagnetic waves such as ultraviolet rays (UV), X-rays, and gamma rays; and charged particle beams such as electron beams (EB), alpha rays, and ion beams.

[0172] Examples of active energy ray curable components include polyfunctional (meth)acrylate monomers having three or more (meth)acryloyl groups in the molecule. Examples of polyfunctional (meth)acrylate monomers include urethane (meth)acrylate monomers; aliphatic monomers such as trimethylolpropane tri(meth)acrylate, ditrimethylolpropane tri(meth)acrylate, ditrimethylolpropane tetra(meth)acrylate, pentaerythritol tri(meth)acrylate, pentaerythritol tetra(meth)acrylate, dipentaerythritol tri(meth)acrylate, dipentaerythritol tetra(meth)acrylate, dipentaerythritol penta(meth)acrylate and dipentaerythritol hexa(meth)acrylate; monomers having an isocyanurate skeleton such as tris(2-(meth)acryloxyethyl) isocyanurate; and modified versions thereof.

[0173] Examples of the above-mentioned modified compounds include ethylene oxide (EO) modified compounds, propylene oxide (PO) modified compounds, and caprolactone (CL) modified compounds. CL modified compounds are preferred from the viewpoint of being less affected by hydrolysis in high-humidity environments and further improving the weather resistance of the hard coat layer. Specifically, examples of the above-mentioned modified compounds include EO-modified trimethylolpropane tri(meth)acrylate, PO-modified trimethylolpropane tri(meth)acrylate, EO-modified dipentaerythritol hexa(meth)acrylate, PO-modified dipentaerythritol hexa(meth)acrylate, CL-modified dipentaerythritol hexa(meth)acrylate, and CL-modified tris(2-(meth)acryloxyethyl) isocyanurate.

[0174] Urethane (meth)acrylate monomers are obtained by reacting polyisocyanate with a (meth)acrylate having a hydroxyl group, and are monomers having a urethane bond and a (meth)acryloyl group in their molecule.

[0175] Examples of polyisocyanates include aliphatic polyisocyanates such as hexamethylene diisocyanate, lysine diisocyanate, and lysine triisocyanate; and alicyclic polyisocyanates such as isophorone diisocyanate, norbornane diisocyanate, methylenebis(4-cyclohexyl isocyanate), 1,3-bis(isocyanatomethyl)cyclohexane, 2-methyl-1,3-diisocyanatocyclohexane, and 2-methyl-1,5-diisocyanatocyclohexane. Polyisocyanates can also be polymers of aliphatic or alicyclic polyisocyanates, such as trimers of isocyanurates. The number of isocyanate groups in the polyisocyanate is preferably 2 to 12, more preferably 2 to 8.

[0176] Examples of (meth)acrylates having a hydroxyl group include hydroxyethyl (meth)acrylate, hydroxypropyl (meth)acrylate, 4-hydroxybutyl (meth)acrylate, 2-(meth)acryloyloxyethyl-2-hydroxyethyl phthalic acid, trimethylolpropane di(meth)acrylate, glycerin di(meth)acrylate, bis((meth)acryloxyethyl)hydroxyethyl isocyanurate, pentaerythritol tri(meth)acrylate, ditrimethylolpropane tri(meth)acrylate, and dipentaerythritol penta(meth)acrylate; as well as EO, PO, or CL modified versions thereof. Among these, pentaerythritol tri(meth)acrylate and dipentaerythritol penta(meth)acrylate; as well as EO, PO, or CL modified versions thereof are preferred from the viewpoint of improving the abrasion resistance and weather resistance of the hard coat layer.

[0177] The number of (meth)acryloyl groups in the above-mentioned polyfunctional (meth)acrylate monomer is 3 or more, preferably 3 to 8, and more preferably 3 to 6, from the viewpoint of improving the abrasion resistance and weather resistance of the hard coat layer.

[0178] Among the polyfunctional (meth)acrylate monomers mentioned above, monomers having an isocyanurate skeleton and their modified forms are preferred. Monomers having an isocyanurate skeleton tend to be able to improve the elongation of the hard coat layer more than aliphatic monomers.

[0179] Among the polyfunctional (meth)acrylate monomers mentioned above, urethane (meth)acrylate monomers in which the polyisocyanate is a polymer of aliphatic polyisocyanate or alicyclic polyisocyanate are also preferred. Such urethane (meth)acrylate monomers tend to have a greater ability to improve the elongation of the hard coat layer compared to urethane (meth)acrylate monomers in which the polyisocyanate is aliphatic polyisocyanate or alicyclic polyisocyanate. This is thought to be because, by using the above polymer, the substructures that do not contribute to the curing reaction in the resulting urethane (meth)acrylate become larger, and therefore the soft segment and hard segment are clearly separated in the cured product obtained after curing, and the soft segment that contributes to the elongation is more likely to function.

[0180] Examples of active energy ray curable components include polymerizable oligomers that have been conventionally used as energy ray curable resins. Examples of polymerizable oligomers include oligomers having two or more (meth)acryloyl groups in the molecule, specifically urethane (meth)acrylate oligomers such as polyether-based urethane (meth)acrylate, polycarbonate-based urethane (meth)acrylate, and polyester-based urethane (meth)acrylate, epoxy (meth)acrylate oligomers, polyester (meth)acrylate oligomers, and polyether (meth)acrylate oligomers. Among these, urethane (meth)acrylate oligomers are preferred from the viewpoint of further improving the abrasion resistance and weather resistance of the hard coat layer.

[0181] Urethane (meth)acrylate oligomers are obtained by reacting an isocyanate compound, which is produced by reacting a polyol and a diisocyanate, with a (meth)acrylate having a hydroxyl group, and are oligomers having a urethane bond and a (meth)acryloyl group in the molecule.

[0182] Examples of polyols include polyether polyols, polycarbonate polyols, and polyester polyols. Examples of diisocyanates and (meth)acrylates having hydroxyl groups include the compounds mentioned above.

[0183] The number of (meth)acryloyl groups in the urethane (meth)acrylate oligomer is preferably 2 to 15, more preferably 4 to 8. This suppresses curing shrinkage of the hard coat layer, for example, and allows for the formation of a hard coat layer with high surface hardness and excellent durability.

[0184] In addition to the components described above, the active energy ray curing components may also include mono(meth)acrylates having one (meth)acryloyl group in the molecule, and di(meth)acrylates having two (meth)acryloyl groups in the molecule.

[0185] The polymerizable double bond equivalent of the active energy ray-curable component is preferably 2.0 mmol / g or more, more preferably 2.0 mmol / g to 8.0 mmol / g, and even more preferably 2.1 mmol / g to 7.5 mmol / g. The polymerizable double bond equivalent represents the value obtained by dividing the number of moles of polymerizable double bond groups (especially CH2=CH-) in one molecule of the above component by the molecular weight of the above component. If the active energy ray-curable component is an oligomer, the molecular weight refers to the number-average molecular weight. The polymerizable double bond equivalent can be adjusted, for example, by EO modification, PO modification, and CL modification of the above component.

[0186] Using a component with a large polymerizable double bond equivalent tends to result in a lower elongation rate of the hard coat layer, while using a component with a small polymerizable double bond equivalent tends to result in a higher elongation rate. Furthermore, when using two or more active energy ray curable components, the elongation rate of the hard coat layer can also be adjusted by changing the ratio of components with a large polymerizable double bond equivalent to components with a small polymerizable double bond equivalent.

[0187] The content of the active energy ray curable component is preferably 50% to 100% by mass, more preferably 60% to 100% by mass, and even more preferably 70% to 100% by mass, relative to the total solid content of the curable composition. This allows for further improvement of, for example, the abrasion resistance and weather resistance of the hard coat layer. Solid content refers to all components other than the solvent.

[0188] When ultraviolet light is used as the active energy ray, the curable composition preferably contains a photopolymerization initiator that can initiate the curing reaction by irradiation with ultraviolet light. Examples of photopolymerization initiators include acetophenone compounds, benzoin compounds, acylphosphine oxide compounds, benzophenone compounds, thioxanthone compounds, and aminobenzophenone compounds.

[0189] Material II for forming the hard coat layer may further contain a photosensitizer when ultraviolet light is used as the active energy ray. Examples of photosensitizers include tertiary amine compounds such as triethanolamine, N-methyldiethanolamine, and tributylamine; urea compounds such as o-tolylthiourea; and sulfur compounds such as sodium diethyldithiophosphate and s-benzylisothiuronium-p-toluenesulfonate.

[0190] The content ratio of the photopolymerization initiator and the photosensitizer is preferably 0.05% to 20% by mass, and more preferably 0.5% to 10% by mass, respectively, of the solid content of the curable composition which is material II for forming the hard coat layer. When a charged particle beam such as an electron beam is used as the active energy beam, it is not necessary to use the photopolymerization initiator and the photosensitizer.

[0191] Material II for forming the hard coat layer may contain a silicone compound in order to improve abrasion resistance and weather resistance and to obtain excellent transparency. Examples of silicone compounds include silicone oil made of polysiloxane, polyether-modified silicone oil, aralkyl-modified silicone oil, fluoroalkyl-modified silicone oil, long-chain alkyl-modified silicone oil, higher fatty acid ester-modified silicone oil, higher fatty acid amide-modified silicone oil, and phenyl-modified silicone oil. The silicone compound may be a reactive silicone compound having reactive functional groups such as amino groups, epoxy groups, mercapto groups, carboxyl groups, hydroxyl groups, (meth)acryloyl groups, and allyl groups, or it may be a non-reactive silicone compound that does not have such reactive functional groups.

[0192] The content of the silicone compound in the curable composition, which is material II for forming the hard coat layer, is preferably 0.05 parts by mass or more and 30 parts by mass or less, more preferably 0.05 parts by mass or more and 10 parts by mass or less, per 100 parts by mass of the curable component. This allows for, for example, excellent weather resistance and abrasion resistance, and suppression of curing shrinkage.

[0193] Material II for forming the hard coat layer and the hard coat layer may contain weather-resistant agents. This can improve the weather resistance of the hard coat layer, for example. Examples of weather-resistant agents include ultraviolet absorbers, antioxidants, and light stabilizers.

[0194] Examples of UV absorbers include inorganic UV absorbers such as titanium dioxide, cerium oxide, and zinc oxide; and organic UV absorbers such as benzotriazole UV absorbers, triazine UV absorbers, benzophenone UV absorbers, oxybenzophenone UV absorbers, salicylic acid ester UV absorbers, and cyano(meth)acrylate UV absorbers. Among these, organic UV absorbers are preferred, and triazine UV absorbers are more preferred.

[0195] Among triazine-based UV absorbers, hydroxyphenyltriazine-based UV absorbers are preferred. Examples of hydroxyphenyltriazine-based UV absorbers include 2-(2-hydroxy-4-[1-octyloxycarbonylethoxy]phenyl)-4,6-bis(4-phenylphenyl)-1,3,5-triazine, 2-[4-[(2-hydroxy-3-dodecyloxypropyl)oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine, and 2,4-bis[2-hydroxy-4-butoxyphenyl] Examples include [nyl]-6-(2,4-dibutoxyphenyl)-1,3,5-triazine, 2-[4-[(2-hydroxy-3-tridecyloxypropyl)oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine, and 2-[4-[(2-hydroxy-3-(2'-ethyl)hexyl)oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine.

[0196] Examples of antioxidants include phenolic antioxidants, phosphorus-based antioxidants, and ionic antioxidants.

[0197] Examples of light stabilizers include hindered amine light stabilizers. Examples of hindered amine light stabilizers include 2,2,6,6-tetramethyl-4-piperidine stearin, 2,2,4,4-tetramethyl-21-oxo-3,20-diaza-7-oxadispiro[5,1,11,2]henicosan-20-propanoate tetradecyl, tetrakis(2,2,6,6-tetramethylpiperidine-4-carboxylic acid)1,2,3,4-butanetetrayl, bis(2,2,6,6-tetramethyl-4-piperidinyl) sebacate, bis(1,2,2,6,6-pentamethyl-4-piperidyl) sebacate, and bis[1,2,2,6,6-pentamethyl-4-piperi]methyl 2-butylpropanediate bis[1,2,2,6,6-pentamethyl-4-piperi] Examples include [(2,2,6,6-tetramethyl-1-(octyloxy)piperidine-4-yl], tetrakis(1,2,2,6,6-pentamethyl-4-piperidyl)-1,2,3,4-butanetetracarboxylate, dimethyl succinate·1-(2-hydroxyethyl)-4-hydroxy-2,2,6,6-tetramethyl-4-piperidine polycondensate, 1,2,2,6,6-pentamethyl-4-piperidinyl methacrylate, and poly[[6-(1,1,3,3-tetramethylbutyl)amino]-1,3,5-triazine-2,4-diyl][(2,2,6,6-tetramethylpiperidyl)imino]hexamethylene[(2,2,6,6-tetramethylpiperidyl)imino]].

[0198] When a weather resistance improver is used, the content of the weather resistance improver in the solid content of the curable composition and in the hard coat layer is preferably 0.1% by mass or more and 30% by mass or less, more preferably 0.1% by mass or more and 20% by mass or less, and even more preferably 0.1% by mass or more and 15% by mass or less.

[0199] The curable composition and the hard coat layer may contain particles. This can, for example, improve the wear resistance of the hard coat layer. Examples of particles include inorganic particles and organic particles.

[0200] Examples of inorganic particles include inorganic particles composed of metal oxides such as alumina, silica, zirconia, titania, zinc oxide, and iron oxide, or inorganic particles composed of diamond or silicon carbide. Among these, inorganic particles composed of silica or alumina are preferred from the viewpoint of improving transparency and wear resistance. Examples of particle shapes include spheres, ellipsoids, polyhedra, and flakes, with spherical shapes being preferred from the viewpoint of achieving higher hardness and excellent wear resistance.

[0201] The inorganic particles may be non-reactive inorganic particles or reactive inorganic particles having reactive functional groups on their surface. Examples of reactive functional groups include (meth)acryloyl groups, vinyl groups, allyl groups, epoxy groups, and silanol groups, with (meth)acryloyl groups, vinyl groups, and allyl groups being preferred from the viewpoint of improving hardness and wear resistance.

[0202] Examples of organic particles include synthetic resin particles such as cross-linked (meth)acrylic resin particles and polycarbonate resin particles.

[0203] The average primary particle diameter of the particles is preferably 10 nm to 1000 nm, more preferably 10 nm to 100 nm. The average particle diameter is the volume-average particle diameter measured by a laser diffraction particle size distribution analyzer. Particles with an average primary particle diameter of 10 nm to 1000 nm may form aggregated particle groups (irregularly shaped particles) with an average number of linked particles between 2 and 20. The linked aggregation may be regular or irregular.

[0204] The particle content in the solid content of material II for forming the hard coat layer and in the hard coat layer is preferably less than 20% by mass, more preferably 5% by mass or more and less than 20% by mass, and even more preferably 5% by mass or more and 15% by mass or less. This allows for improved abrasion resistance while maintaining the weather resistance of the hard coat layer, for example. A higher particle content tends to reduce the elongation of the hard coat layer.

[0205] The area ratio of particles in the hard coat layer is preferably 22% or less, more preferably 20% or less. The lower limit of the above area ratio is not particularly limited, but for example, it is 6%.

[0206] The area ratio of particles in a hard coat layer can be measured by scanning transmission electron microscopy (STEM) observation of a thin film section of the hard coat layer and image analysis. The measurement method is as follows: First, a 70 nm thick thin film section is extracted from the hard coat layer using a microtome, and a cross-sectional image is obtained by STEM observation. Using the image analysis software ImageJ, the particles and binder (usually a hardened product of the curable component) in the cross-sectional image are binarized to extract a black and white image, and the area ratio of particles is calculated. Specifically, first, a 1024 × 512 pixel image is selected and extracted from the STEM image. Next, the baseline is adjusted using the Rolling Ball method, and then binarization is performed using the Otsu method. Finally, the ratio of the black area to the sum of the black and white areas (area of ​​the target region) is calculated. The analysis rules for the baseline and binarization are that, by human visual judgment of the actual image and the analyzed image, it is sufficient if obvious particles are not mistaken for binder. However, the thin film section described above does not include the outermost surface of the hard coat layer, but is selected from the middle portion of the hard coat layer.

[0207] The hard coat layer may contain additives. Examples of additives include polymerization inhibitors, antistatic agents, adhesion enhancers, leveling agents, thixotropic agents, coupling agents, plasticizers, defoamers, flame retardants, surfactants, antifogging agents, antibacterial agents, fillers, and colorants.

[0208] Material II for forming a hard coat layer may contain an organic solvent, for example, from the viewpoint of improving its coating property. Examples of the organic solvent include hydrocarbon solvents such as toluene, xylene, hexane, and octane; alcohol solvents such as ethanol, propanol, butanol, pentanol, hexanol, octanol, and decanol; ketone solvents such as acetone, methyl ethyl ketone, methyl isobutyl ketone, diisobutyl ketone, and cyclohexanone; and ester solvents such as ethyl acetate, butyl acetate, amyl acetate, ethyl butyrate, butyl butyrate, butyl stearate, methyl benzoate, methyl lactate, ethyl lactate, and butyl lactate.

[0209] [Method for forming a hard coat layer using Material II for forming a hard coat layer] The hard coat layer is formed, for example, as follows. A curable composition, which is Material II for forming a hard coat layer, is applied onto a substrate to a desired thickness to form a coating film. When an organic solvent is used, it is dried to remove the organic solvent and form a coating film. Then, when a thermosetting component is used, the coating film is heated to a temperature required for curing to cure it. When a radiation curable component is used, the coating film is irradiated with radiation to cure it. The irradiation of the radiation may be performed from the coating film side of the curable composition or from the substrate side. In this way, a hard coat layer can be formed. The curing treatment may be performed after the application of the curable composition and before the formation of other layers, or after the formation of other layers.

[0210] Examples of the method for applying Material II for forming a hard coat layer onto a substrate include dipping method, flow coating method, spraying method, spin coating method, gravure coating method, microgravure coating method, die coating method, slit reverse method, roll coating method, blade coating method, air knife coating method, offset method, and bar coating method.

[0211] When using an electron beam as the active energy ray, the irradiation dose of the electron beam is preferably 0.5 Mrad or more and 30 Mrad or less, more preferably 1 Mrad or more and 20 Mrad or less, and still more preferably 3 Mrad or more and 15 Mrad or less.

[0212] When using ultraviolet rays as the active energy ray, for example, light containing ultraviolet rays with a wavelength of 190 nm or more and 380 nm or less is irradiated. Examples of the light source include a xenon lamp, a low-pressure mercury lamp, a high-pressure mercury lamp, an ultra-high-pressure mercury lamp, a metal halide lamp, a carbon arc lamp, and a tungsten lamp.

[0213] In the first and second embodiments and the modified examples described above, the decorative members 10 and 110 include a hard coat layer 31, a hard coat support layer 32 disposed on one side of the hard coat layer 31 to support the hard coat layer 31, and a metal layer 41 disposed on one side of the hard coat support layer 32. The hard coat layer 31 does not crack when heated to 180°C and stretched by 10%. In particular, in the illustrated example, the hard coat layer 31 does not crack when heated to 180°C and stretched by 20%.

[0214] With these decorative members 10 and 110, the manufacturing efficiency of the decorative members 10 and 110 can be improved compared to the manufacturing efficiency of conventional decorative members. Specifically, since the hard coat layer 31 does not crack when heated to 180°C and stretched by 10% or 20%, there is less risk of the hard coat layer 31 cracking when the laminate 20, which includes the hard coat layer 31 and the metal layer 41, is heated and shaped using a shaping mold 70 or the like. In contrast, the hard coat layer of conventional decorative members cracks when heated to 180°C and stretched by 10%. For this reason, conventionally, decorative members had to be manufactured using the following procedure: a design layer including the metal layer is formed, the design layer is heated with a heating device and shaped with a shaping mold, and then, after the temperature of the design layer heated by the heating device has decreased, the hard coat layer is formed on the design layer. This is because if a hard coat layer is formed on the design layer and then the design layer and hard coat layer are heated and shaped using a shaping mold, there is a risk that the design layer will stretch during shaping, causing the hard coat layer to crack. Thus, the conventional method of manufacturing decorative members was complicated.

[0215] Furthermore, such decorative members 10 and 110 have excellent heat resistance. That is, the hard coat layer 31 does not crack when heated to 180°C and stretched by 10% or 20%, so even if the decorative members 10 and 110 are subjected to high temperatures, there is a low risk that the hard coat layer 31 will crack and become cloudy, and the aesthetic appearance of the decorative members 10 and 110 will not be impaired. For example, when decorative members are used on the exterior of automobiles, it is generally desirable that the decorative members can withstand high temperatures of 120°C. In this respect, the above-described decorative members 10 and 110 are suitable for application to the exterior of automobiles because there is a low risk that the hard coat layer 31 will become cloudy and its aesthetic appearance will be impaired even when heated to 180°C.

[0216] Furthermore, in the first embodiment and its modified form described above, the decorative member 10 further comprises a primer layer 47 for metal deposition, which is disposed on one of the surfaces of the metal layer 41. This improves the adhesion between the metal layer 41 and the layer adjacent to the metal layer 41.

[0217] Furthermore, in the first and second embodiments and modified examples described above, the decorative members 10 and 110 further include an intermediate layer 50 disposed on one side of the metal layer 41 and a molded portion 60 disposed on one side of the intermediate layer 50. In the case of such decorative members 10 and 110, the manufacturing efficiency of the decorative members 10 and 110 can be improved compared to the manufacturing efficiency of conventional decorative members. Specifically, since the hard coat layer 31 does not crack when heated to 180°C and stretched by 10% or 20%, even if the molded portion 60 is injection molded onto the laminate 20 including the hard coat layer 31, the metal layer 41, and the intermediate layer 50, there is little risk of the hard coat layer 31 cracking due to the heat applied during injection molding. Therefore, the decorative members 10 and 110 can be manufactured simply by first manufacturing the laminate 20 including the hard coat layer 31, and then injection molding the molded portion 60 onto the laminate 20. In contrast, the hard coat layer of conventional decorative members cracks when heated to 180°C and stretched by 10%. Therefore, conventionally, decorative members had to be manufactured using the following procedure: an intermediate layer was formed on a design layer containing a metal layer, and the molded part was injection molded onto the intermediate layer. After the temperature of the design layer and intermediate layer, which were heated by injection molding, had cooled, the hard coat layer was formed on the design layer. This is because if the molded part were injection molded after the hard coat layer was formed on the design layer, there was a risk that the design layer and intermediate layer would expand during injection molding, causing the hard coat layer to crack. Thus, the conventional manufacturing method for decorative members was complicated.

[0218] Furthermore, in the first and second embodiments described above, the metal layer 41 includes a plurality of metal granules 41a capable of reflecting visible light. Gaps 41b are also provided between the plurality of metal granules 41a. With such a metal layer 41, in this specific example, ambient light incident on the decorative members 10 and 110 is reflected with high reflectivity by the metal granules 41a. On the other hand, electromagnetic waves used in the sensor 5 can be transmitted through the decorative members 10 and 110 with high transmittance. In addition, such a metal layer 41 can be stretched to follow the other layers of the laminate 20 when the molded part 60 is injection molded onto the laminate 20.

[0219] Furthermore, in the first and second embodiments described above, the decorative members 10 and 110 further include a concealing layer 44. The concealing layer 44 is positioned between the hard coat support layer 32 and the metal layer 41, and covers a portion of the metal layer 41 when viewed from the hard coat layer 31 toward the metal layer 41. With such decorative members 10 and 110, a variety of designs can be displayed by combining the concealing layer 44 and the metal layer 41.

[0220] Furthermore, in the first and second embodiments described above, the concealing layer 44 has a side surface 45 that extends along a surface intersecting with one side surface of the hard coat support layer 32. Because the concealing layer 44 has such a side surface 45, the side surface 45 is visible when the decorative member 10 is viewed from the second surface 12 side, and a three-dimensional effect can be given to the design represented by the concealing layer 44 and the metal layer 41.

[0221] Furthermore, in the first and second embodiments described above, the hard coat support layer 32 and the concealing layer 44 form an uneven surface facing the metal layer 41. The metal layer 41 is bent in accordance with the above uneven surface. Such a metal layer 41 has a slope 42 that extends along a surface intersecting one side of the hard coat support layer 32. Because the metal layer 41 has such a slope 42, the slope 42 is visible when the decorative member 10 is viewed from the second surface 12 side. This contributes to giving a three-dimensional effect to the design represented by the concealing layer 44 and the metal layer 41.

[0222] Furthermore, in the second embodiment described above, the decorative member 110 includes a bonding layer 85 between the concealing layer 44 and the metal layer 41, and a gap 88 is formed between the side surface 45 of the concealing layer 44 and the bonding layer 85. In such a decorative member 110, the bonding layer 85 and the slopes 86,42 of the metal layer 41 are visible through the gap 88. This contributes to giving a three-dimensional effect to the design represented by the concealing layer 44 and the metal layer 41.

[0223] Furthermore, in the first and second embodiments described above, the hard coat layer 31 has a flat portion 23 and a curved portion 24 connected to the flat portion 23. The thickness of the hard coat layer 31 in the curved portion 24 is smaller than the thickness of the hard coat layer 31 in the flat portion 23.

[0224] Furthermore, in the first and second embodiments described above, the manufacturing method of the decorative members 10 and 110 includes a laminate manufacturing step and an injection molding step. In the laminate manufacturing step, a laminate 20 is manufactured, which includes a hard coat layer 31, a hard coat support layer 32 disposed on one side of the hard coat layer 31 to support the hard coat layer 31, a metal layer 41 disposed on one side of the hard coat support layer 32, and an intermediate layer 50 disposed on one side of the metal layer 41. In the injection molding step, a molded part 60 is injection molded into the laminate 20 manufactured in the laminate manufacturing step.

[0225] According to this method of manufacturing decorative members 10, 110, the manufacturing efficiency of the decorative members 10, 110 can be improved compared to the manufacturing efficiency of conventional decorative members.

[0226] Furthermore, the first embodiment described above, the laminate manufacturing process, includes the steps of: manufacturing a hard coat film 30 including a hard coat layer 31 and a hard coat support layer 32; depositing a metal layer 41 on one side of the hard coat film 30; and forming an intermediate layer 50 on one side of the metal layer 41.

[0227] Furthermore, the second embodiment described above, the laminate manufacturing process, includes the steps of: manufacturing a hard coat film 30 including a hard coat layer 31 and a hard coat support layer 32; manufacturing a metal film 80 including a metal layer 41 and a metal support layer 81 that supports the metal layer 41; a bonding step of bonding the hard coat support layer 32 of the hard coat film 30 and the metal support layer 81 of the metal film 80 via a bonding layer 85; and an intermediate layer forming step of forming an intermediate layer 50 on one side of the metal film 80.

[0228] Further, in the second embodiment described above, the laminate manufacturing process further includes an air removal process for removing air between the hard coat film 30 and the metal film 80 bonded in the bonding process.

[0229] Also, in the first and second embodiments described above, the laminate manufacturing process further includes a step of forming a hidden layer 44 that covers a part of the metal layer 41 when viewed in the direction from the hard coat layer 31 toward the metal layer 41 on one side of the hard coat film 30. According to the decorative members 10 and 110 manufactured in this way, a variety of designs can be displayed by the combination of the hidden layer 44 and the metal layer 41.

[0230] Also, in the first and second embodiments described above, the manufacturing method of the decorative members 10 and 110 further includes a laminate shaping process for shaping the laminate 20 manufactured in the laminate manufacturing process. Thereby, the laminate 20 can be made into a desired three-dimensional shape, and the decorative members 10 and 110 can display more complex designs.

Example

[0231] Hereinafter, the present disclosure will be described more specifically based on examples. These descriptions do not limit the present disclosure in any way.

[0232] <Example 1 of Hard Coat Layer> · Fabrication of Laminate α1 for Hard Coat Layer Elongation Evaluation The following material α for forming a hard coat layer was applied onto a PET film to form a hard coat layer 31 with a thickness of 4 μm. Next, a primer layer was formed on the hard coat layer 31. Further, a heat seal layer was formed on the primer layer. In this way, a transfer film was fabricated. The transfer film includes a PET film as a base material for the transfer film and a transfer layer formed on the PET film. The transfer layer includes the hard coat layer 31, the primer layer, and the heat seal layer. Next, a two-layer film (product name: Technoloy® C001, manufactured by Sumika Acrylic Sales Co., Ltd.) containing methacrylic resin and polycarbonate resin was prepared as a substrate for a laminate for evaluating the elongation of the hard coat layer (hereinafter also simply referred to as the "evaluation laminate"). The thickness of the substrate for the evaluation laminate was 125 μm. A grid pattern was printed on the entire surface of the substrate for the evaluation laminate. Each square in the grid pattern was a square with a side length of 10 mm. Next, the transfer film was placed on the substrate for the evaluation laminate so that the heat-sealed layers of the substrate and the transfer film were in contact, and the two were pressed together using a vacuum press. The vacuum press and pressing conditions were as follows. • Vacuum press machine: Mikado Technos VS30-3030 Press conditions Press temperature: 125℃ Press time: 20 seconds Pressing force: 10kN Subsequently, the PET film, which is the substrate for the transfer film, was peeled off to obtain the evaluation laminate α1. The layer structure of the evaluation laminate is evaluation laminate substrate / heat seal layer / primer layer / hard coat layer 31. The thickness of the hard coat layer 31 of the obtained evaluation laminate α1 was 4 μm.

[0233] [Material α for forming a hard coat layer] Material α for hard coat layer formation was prepared by mixing 27 parts by mass of urethane compound (A), 18 parts by mass of acrylate compound (B), 12.5 parts by mass of inorganic particles (C), and 42.5 parts by mass of solvent, as described above for material I for hard coat layer formation. The urethane compound (A), acrylate compound (B), inorganic particles (C), and solvent used in the preparation of material α for hard coat layer formation were as follows.

[0234] • Urethane compound (A) ※ :HDI nulate-(PETA)3 *Mixed with IPDI-(PETA)2 (HDI-(PETA)3: Reaction product of pentaerythritol triacrylate and isocyanate having an isocyanurate ring derived from hexamethylene diisocyanate; IPDI-(PETA)2: Reaction product of pentaerythritol triacrylate and isophorone diisocyanate) • Acrylate compound (B): NK ester A9300-1CL (manufactured by Shin-Nakamura Chemical Industry Co., Ltd.) represented by the following formula.

[0235] [ka]

[0236] • Inorganic particles (C): Silica ELCON V8803-25 (manufactured by JGC Catalysts & Chemicals Co., Ltd.), solid content 40%, maximum particle size 25 nm, solvent MIBK (methyl isobutyl ketone), reactive heteromorphic silica, consisting of 2 to 20 linked silica particles with an average primary particle size of 10 nm to 100 nm, and the reactive group is an ethylenically unsaturated bond-containing group. • Solvent: MEK (methyl ethyl ketone)

[0237] <Example 2 of the hard coat layer> An evaluation laminate α2 was prepared in the same manner as in Example 1 of the hard coat layer, except that the thickness of the hard coat layer 31 of the transfer film was set to 8 μm. The thickness of the hard coat layer 31 of the obtained evaluation laminate α2 was 8 μm.

[0238] <Example 3 of the hard coat layer> An evaluation laminate β was prepared in the same manner as in Example 2 of the hard coat layer, except that the following material β was used as the material for forming the hard coat layer. The thickness of the hard coat layer 31 of the obtained evaluation laminate β was 8 μm.

[0239] [Material β for forming a hard coat layer] Material β for hard coat layer formation was prepared by mixing 100 parts by mass of the curable component of Material II for hard coat layer formation described above with 20 parts by mass of an organic solvent. The curable component and organic solvent used to prepare Material β for hard coat layer formation were as follows.

[0240] • Curing component: NK ester A9300-1CL (CL-modified tris-(2-acryloxyethyl) isocyanurate, manufactured by Shin Nakamura Chemical Industry Co., Ltd.) • Organic solvent: Methyl ethyl ketone

[0241] <Example 4 of the hard coat layer> An evaluation laminate γ was prepared in the same manner as in Example 2 of the hard coat layer, except that the following material γ was used as the material for forming the hard coat layer. The thickness of the hard coat layer 31 of the obtained evaluation laminate γ was 8 μm.

[0242] [Material γ for forming a hard coat layer] Material γ for hard coat layer formation was prepared by mixing 100 parts by mass of the curable component of Material II for hard coat layer formation described above with 20 parts by mass of an organic solvent. The curable component and organic solvent used to prepare Material γ for hard coat layer formation were as follows. ·Curable component: • NK Ester A9300-1CL (CL-modified tris-(2-acryloxyethyl) isocyanurate, manufactured by Shin-Nakamura Chemical Industry Co., Ltd.) 65 parts by mass ·UA-184E ※ 35 parts by mass * UA-184E: Urethane acrylate, a synthetic product resulting from the reaction of an isocyanate having an isocyanurate ring derived from hexamethylene diisocyanate with 1 molar chlorine-modified hydroxyethyl acrylate. Organic solvent: Methyl ethyl ketone

[0243] <Comparative Example 1 of Hard Coat Layers> An evaluation laminate δ was prepared in the same manner as in Example 1 of the hard coat layer, except that the following material δ was used as the material for forming the hard coat layer. The thickness of the hard coat layer of the obtained evaluation laminate δ was 4 μm.

[0244] [Material for forming a hard coat layer δ] • Hexafunctional urethane acrylate oligomer 50 parts by mass • Bifunctional caprolactone-based urethane acrylate oligomer 50 parts by mass • Halogenated phosphate ester flame retardant (product name: CR-570, manufactured by Daihachi Chemical Co., Ltd.) 30 parts by mass • Hydroxyphenyltriazine-based UV absorber (product name: Tinuvin479, manufactured by BASF Japan) 0.7 parts by mass • Light stabilizer with reactive functional groups (1,2,2,6,6-pentamethyl-4-piperidinyl methacrylate, product name: Sanol LS-3410, manufactured by Nippon Emulsifier Co., Ltd.) 4.2 parts by mass • Non-reactive silicone compound (polyether-modified silicone oil) 0.3 parts by mass • Scratch-resistant filler (silica particles, average particle size: 2 μm) 0.8 parts by mass

[0245] [Evaluation of hard court layer expansion] The elongation of the hard coat layer of each evaluation laminate was evaluated using the following method. First, as a mold having the convex surface described above, a mold with a semi-cylindrical outer surface was prepared. The evaluation laminate was heated to 180°C to soften and placed on the semi-cylindrical curved surface of the mold. Next, the evaluation laminate was vacuum-formed at 180°C using this mold and a vacuum forming machine. The vacuum forming machine used was the V.former desktop vacuum forming machine manufactured by Rayama Pack Co., Ltd. Due to vacuum forming, the evaluation laminate stretched along the semi-cylindrical outer surface of the mold in the circumferential direction of the curved surface and in a direction perpendicular to the circumferential direction (hereinafter also referred to as the "vertical direction"). Next, the hard coat layer of the vacuum-formed evaluation laminate was visually inspected to check for cracks in the hard coat layer. By repeating the procedure described above, the maximum elongation rate of the hard coat layer in each evaluation laminate without cracking was measured. The elongation rate was calculated from the amount of deformation of the dimensions of each square in the grid pattern drawn on the evaluation laminate. Specifically, the average value of the elongation rate in the circumferential direction (circumferential elongation rate) and the average value of the elongation rate in the longitudinal direction (longitudinal elongation rate) were determined for the portion of the evaluation laminate molded along the outer surface of the semi-cylindrical shape of the mold, and the product of these average values ​​was taken as the elongation rate (area elongation rate) of the evaluation laminate. In this specification, "when the hard coat layer is stretched by (X)%" means "when the area elongation rate of the hard coat layer is (100+X)%."

[0246] Table 1 below shows the maximum elongation rate at which cracking does not occur in the hard coat layer of each evaluation laminate.

[0247] [Table 1]

[0248] As can be seen from Table 1, hard coat layers formed using materials α to γ ​​for hard coat layer formation did not crack when heated to 180°C and stretched by 10%. In particular, hard coat layers formed with a thickness of 8 μm using materials α to γ ​​for hard coat layer formation did not crack when heated to 180°C and stretched by 20%. On the other hand, the maximum elongation without cracking for hard coat layers formed using material δ for hard coat layer formation was 105.1%. This means that hard coat layers formed using material δ for hard coat layer formation cracked when heated to 180°C and stretched by 10%.

[0249] <<Example 1 of decorative component>> The laminate α1 and the decorative member α1 were fabricated using the following method.

[0250] <Preparation of hard coat layer transfer film> First, a hard coat layer transfer film α was prepared. Specifically, a polyester film (product name: Cosmoshine® A4100, manufactured by Toyobo Co., Ltd.) was prepared as the substrate for the transfer film. The thickness of the substrate for the transfer film was 50 μm.

[0251] Next, the hard coat layer forming material α was applied to the transfer film substrate to form a hard coat layer 31 with a thickness of 4 μm.

[0252] Next, after corona discharge treatment was performed on the surface of the hard coat layer 31, the following resin composition for primer layer formation was applied to form a primer layer with a thickness of 4 μm. (Resin composition for primer layer formation) • Polycarbonate-based urethane acrylic copolymer ※1 :100 parts by mass • Hydroxyphenyltriazine-based UV absorbers ※2 :17 parts by mass • Hydroxyphenyltriazine-based UV absorbers ※3 :13 parts by mass • Hindered amine light stabilizers ※4 :8 parts by mass • Blocking prevention agent ※5 :9 parts by mass • Hardening agent (hexanemethylene diisocyanate): 25 parts by mass *1, In polycarbonate-based urethane-acrylic copolymer, the mass ratio of urethane component to acrylic component is 70 / 30. *2, Chinuvin 400 (product name), 2-[4-[(2-hydroxy-3-dodecyloxypropyl)oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine, manufactured by BASF Japan Ltd. *3, Chinuvin 479 (product name), 2-(2-hydroxy-4-[1-octyloxycarbonylethoxy]phenyl)-4,6-bis(4-phenylphenyl)-1,3,5-triazine, manufactured by BASF Japan Ltd. *4, Chinuvin 123 (product name), Bis(1-octyroxy-2,2,6,6-tetramethyl-4-piperidyl) sebacate), manufactured by BASF Japan Ltd. *5, Silica particles, average particle size: 3μm

[0253] Subsequently, an acrylic resin (weight-average molecular weight (Mw): 7.6 × 10) is applied to the primer layer. 4 A bonding layer (thickness: 5 μm) with a thickness of 4 μm was applied to form a bonding layer. This prepared a hard coat layer transfer film α. The hard coat layer transfer film α comprises a substrate for transfer film and a transfer layer formed on the substrate for transfer film. The transfer layer includes a hard coat layer 31, a primer layer, and a bonding layer.

[0254] <Production of hard coat film> Next, a two-layer film (product name: Technoloy® C001, manufactured by Sumika Acrylic Sales Co., Ltd.) containing methacrylic resin and polycarbonate resin was prepared as the hard coat support layer 32. The thickness of the hard coat support layer 32 was 200 μm. Next, the hard coat layer transfer film α was placed on the hard coat support layer 32 such that the bonding layer 85 of the hard coat support layer 32 and the hard coat layer transfer film α were in contact, and the transfer layer of the hard coat layer transfer film α was heat-transferred to the hard coat support layer 32. Subsequently, the transfer film substrate was peeled off the hard coat layer transfer film α to obtain the hard coat film α. The layer structure of the hard coat film is hard coat support layer 32 / bonding layer / primer layer / hard coat layer 31.

[0255] <Formation of a concealed layer> Next, a screen printing ink (product name: XFM-971, manufactured by Teikoku Ink Mfg. Co., Ltd.) was prepared as a material for forming the concealing layer. Then, the material for forming the concealing layer was screen printed onto the hard coat support layer 32 of the hard coat film α to form the concealing layer 44. The thickness of the concealing layer 44 was 12 μm.

[0256] <Formation of the primer layer> Next, as a material for forming the primer layer, 100 parts by mass of acrylic polyol (product name: Aracoat DA105, manufactured by Arakawa Chemical Industries, Ltd.) and 9 parts by mass of isocyanate compound (product name: Aracoat CL102H, manufactured by Arakawa Chemical Industries, Ltd.) were mixed and diluted with a diluent solvent (a mixed solvent of methyl ethyl ketone (MEK), ethyl acetate, and methyl isobutyl ketone (MIBK)). Next, the material for forming the primer layer was applied to the hard coat film α on which the opacity layer 44 was formed, thereby forming a primer layer 47 on the hard coat film α and the opacity layer 44. The thickness of the primer layer 47 was 1 μm.

[0257] <Formation of a metal layer> After curing the hard coat film α, on which the primer layer 47 was formed, at room temperature for one week, indium was vacuum deposited onto the primer layer 47 using an EX-900 high-vacuum deposition system manufactured by ULVAC, Inc. to form a metal layer 41. The thickness of the metal layer 41 was 80 nm.

[0258] <Formation of the middle layer> Next, an intermediate layer 50 was formed on the metal layer 41. The intermediate layer 50 includes a first intermediate layer and a second intermediate layer. Specifically, as the material for forming the first intermediate layer, a mixture of 100 parts by mass of SIVM HS manufactured by Showa Ink Industries Co., Ltd. and 5 to 10 parts by mass of OP No. 81 curing agent manufactured by Showa Ink Industries Co., Ltd. was prepared. In addition, an ABS sheet with a thickness of 125 μm (product name: PZ100BK, manufactured by Nichimo Co., Ltd.) was prepared as the second intermediate layer. Next, the material for forming the first intermediate layer was coated onto the metal layer 41 to form the first intermediate layer. The thickness of the first intermediate layer was 1 μm. Next, the second intermediate layer was laminated onto the first intermediate layer. This formed the intermediate layer 50. As a result, the laminate α1 was fabricated.

[0259] <Formation of molded part> Next, the laminate α1 was vacuum-formed using the method shown in Figures 12A to 12B to create a shape having a flat portion 23 and a curved portion 24. Then, a resin PC / ABS (product name: Psycholoy, manufactured by SABIC Innovative Plastics Japan LLC) for forming the molded portion was prepared. The heated resin for forming the molded portion was injection-molded onto the formed laminate α1 using the method shown in Figures 14 to 15 to injection-molde the molded portion 60 onto the intermediate layer 50. This produced the decorative member α1. The temperature of the hard coat layer 31 during injection molding was approximately 180°C.

[0260] <<Example 2 of decorative member>> The laminate α2 and decorative member α2 were fabricated in the same manner as in Example 1 of the decorative member, except that the thickness of the hard coat layer 31 was set to 8 μm.

[0261] <<Example 3 of decorative component>> The laminate α3 and decorative member α3 were fabricated in the same manner as in Example 2 of the decorative member, except that the thickness of the concealing layer 44 was set to 8 μm.

[0262] <<Example 4 of decorative member>> The laminate α4 and decorative member α4 were fabricated in the same manner as in Example 2 of the decorative member, except that the thickness of the concealing layer 44 was set to 4 μm.

[0263] <<Example 5 of decorative member>> The laminate α5 and decorative member α5 were fabricated in the same manner as in Example 2 of the decorative member, except that the thickness of the primer layer 47 was set to 10 μm.

[0264] <<Example 6 of decorative member>> The laminate α6 and decorative member α6 were fabricated in the same manner as in Example 2 of the decorative member, except that the thickness of the concealing layer 44 was set to 8 μm and the thickness of the primer layer 47 was set to 10 μm.

[0265] <<Example 7 of decorative member>> The laminate α7 and decorative member α7 were fabricated in the same manner as in Example 2 of the decorative member, except that the thickness of the concealing layer 44 was 4 μm and the thickness of the primer layer 47 was 10 μm.

[0266] <<Example 8 of decorative member>> The laminate α8 and the decorative member α8 were manufactured in the same manner as in Example 2 of the decorative member, except that a primer layer 47 was not formed between the concealing layer 44 and the metal layer 41.

[0267] <<Example 9 of decorative member>> The laminate α9 and decorative member α9 were manufactured in the same manner as in Example 2 of the decorative member, except that a primer layer 47 was not formed between the concealing layer 44 and the metal layer 41, and the thickness of the concealing layer 44 was set to 8 μm.

[0268] <<Example 10 of decorative member>> The laminate α10 and the decorative member α10 were manufactured in the same manner as in Example 2 of the decorative member, except that a primer layer 47 was not formed between the concealing layer 44 and the metal layer 41, and the thickness of the concealing layer 44 was set to 4 μm.

[0269] <<Example 11 of decorative member>> The laminate α11 and decorative member α11 were manufactured in the same manner as in Example 2 of the decorative member, except that gravure ink (product name: Chemical X (NT), manufactured by Showa Ink Industries Co., Ltd.) was prepared as a material for forming the opacity layer, and the opacity layer 44 was formed by gravure printing with this gravure ink.

[0270] <<Example 12 of decorative member>> The laminate β1 and decorative member β1 were manufactured in the same manner as in Example 2 of the decorative member, except that the hard coat layer material β described above was used as the material for forming the hard coat layer.

[0271] <<Example 13 of decorative member>> The laminate γ1 and decorative member γ1 were manufactured in the same manner as in Example 2 of the decorative member, except that the hard coat layer material γ described above was used as the material for forming the hard coat layer.

[0272] <<Comparative Example 1 of Decorative Components>> The laminate δ1 and decorative member δ1 were manufactured in the same manner as in Example 2 of the decorative member, except that the hard coat layer material δ described above was used as the material for forming the hard coat layer.

[0273] <<Example 14 of decorative member>> The laminate α12 and the decorative member α12 were fabricated using the following method.

[0274] <Production of hard coat film> A hard coat film α was prepared in the same manner as in Example 1 of the decorative member.

[0275] <Formation of a concealed layer> Next, a concealing layer 44 was formed in the same manner as in the first example of the decorative member.

[0276] <Fabrication of metal films> Furthermore, a metal film 80 was prepared using the following method. Specifically, as the metal support layer 81, we prepared an acrylic substrate with a thickness of 125 μm (product name: Technoloy (registered trademark) S001, manufactured by Sumitomo Chemical Acrylic Sales Co., Ltd.). Next, a primer layer 47 was formed by coating the metal support layer 81 with a material for forming a primer layer. The material for forming the primer layer was the same as the material for forming the primer layer in Example 1 of the decorative member. The thickness of the primer layer 47 was 1 μm. After curing the metal support layer 81 on which the primer layer 47 was formed at room temperature for one week, indium was vacuum deposited onto the primer layer 47 using an EX-900 high-vacuum deposition system manufactured by ULVAC, Inc. to form a metal layer 41. The thickness of the metal layer 41 was 80 nm.

[0277] <Formation of the middle layer> Next, an intermediate layer 50 was formed on the metal layer 41 of the metal film 80. The intermediate layer 50 includes a first intermediate layer and a second intermediate layer. Specifically, as the material for forming the first intermediate layer, a mixture of 5 to 10 parts by mass of 5 to 10 parts by mass of HS100 for SIVM manufactured by Showa Ink Industries Co., Ltd. and OP No. 81 curing agent manufactured by Showa Ink Industries Co., Ltd. was prepared. In addition, a 50 μm thick ABS sheet (product name: PZ100BK, manufactured by Nichimo Co., Ltd.) was prepared as the second intermediate layer. Next, the material for forming the first intermediate layer was coated onto the metal layer 41 to form the first intermediate layer. The thickness of the first intermediate layer was 1 μm. Next, the second intermediate layer was laminated onto the first intermediate layer. This formed the intermediate layer 50.

[0278] <Formation of the bonding layer> Next, an Aron Attack MPT series adhesive manufactured by Toagosei Co., Ltd. was prepared, and its adhesive layer was transferred onto the metal support layer 81 of the metal film 80 to form a bonding layer 85.

[0279] <Fabrication of laminates> Next, the concealing layer 44 of the hard coat film α and the bonding layer 85 on the metal film 80 were brought into contact, and the hard coat film α and concealing layer 44 were bonded to the metal film 80. After that, an autoclave treatment (heating temperature: 80°C, pressure: 0.5 MPa, heating and pressurizing time: 30 minutes) was performed to remove the air between the hard coat film α and concealing layer 44 and the metal film 80. This resulted in obtaining the laminate α12.

[0280] <Formation of molded part> Next, after the laminate α12 was thoroughly dried, the laminate α12 was shaped in the same manner as in Example 1 of the decorative member, and the molded portion 60 was injection molded onto the intermediate layer 50 of the shaped laminate α12. This produced the decorative member α12.

[0281] <<Example 15 of decorative member>> The laminate α13 and the decorative member α13 were manufactured in the same manner as in Example 14 of the decorative member, except that the thickness of the hard coat layer 31 was set to 8 μm.

[0282] <<Example 16 of decorative member>> The laminate α14 and the decorative member α14 were manufactured in the same manner as in Example 15 of the decorative member, except that the thickness of the concealing layer 44 was set to 8 μm.

[0283] <<Example 17 of decorative member>> The laminate α15 and the decorative member α15 were manufactured in the same manner as in Example 15 of the decorative member, except that the thickness of the concealing layer 44 was set to 4 μm.

[0284] <<Example 18 of decorative member>> The laminate β2 and decorative member β2 were manufactured in the same manner as in Example 15 of the decorative member, except that the hard coat layer material β described above was used as the material for forming the hard coat layer.

[0285] <<Example 19 of decorative member>> The laminate γ2 and decorative member γ2 were manufactured in the same manner as in Example 15 of the decorative member, except that the hard coat layer material γ described above was used as the material for forming the hard coat layer.

[0286] <<Comparative Example 2 of Decorative Materials>> The laminate δ2 and decorative member δ2 were manufactured in the same manner as in Example 15 of the decorative member, except that the hard coat layer material δ described above was used as the material for forming the hard coat layer.

[0287] [Evaluation of decorative components] The decorative components were evaluated using the following method. The hard coat layer 31 of each decorative member was visually inspected to check for any cracks in the hard coat layer 31. Furthermore, the concealing layer 44 of each decorative component was visually inspected to check for any cracks in the concealing layer 44. The evaluation results are shown in Table 2 below.

[0288] [Table 2]

[0289] As can be seen from Table 2, the hard coat layers of decorative members α1-15, β1-2, and γ1-2, which were made using materials α-γ for hard coat layer formation, did not crack. On the other hand, the hard coat layers of decorative members δ1-2, which were made using material δ for hard coat layer formation, did crack. Furthermore, no cracks occurred in the concealing layer 44, whether XFM-971 or X(NT) was used as the material for forming the concealing layer.

[0290] [Evaluation of three-dimensionality] Furthermore, for the decorative members α1 to α10 of Examples 1 to 10, the three-dimensional effect of the design represented by the metal layer 41 and the concealing layer 44 was evaluated. Specifically, the degree of gloss at the boundary between the metal layer 41 and the concealing layer 44 of each decorative member was evaluated. The stronger the gloss, the more clearly a three-dimensional effect appeared at the boundary between the metal layer 41 and the concealing layer 44. The evaluation results are shown in Table 3 below.

[0291] [Table 3] In Table 3, "○" and "△" indicate that a sense of three-dimensionality was present, while "×" indicates that a sense of three-dimensionality was not present. Furthermore, "○" indicates that a clearer sense of three-dimensionality was present than "△".

[0292] As can be seen from Table 3, when the thickness of the primer layer 47 was 1 μm, a three-dimensional effect appeared at the boundary between the metal layer 41 and the concealing layer 44, and a particularly clear unevenness appeared when the thickness of the concealing layer 44 was 12 μm. Also, when the thickness of the primer layer 47 was 10 μm, a three-dimensional effect appeared when the thickness of the concealing layer 44 was between 8 and 12 μm. On the other hand, when the decorative member did not include the primer layer 47, no three-dimensional effect appeared. Furthermore, when the thickness of the concealing layer 44 was 4 μm and the thickness of the primer layer 47 was 10 μm, no three-dimensional effect appeared. [Explanation of symbols]

[0293] 1: Moving body, 3: Emblem, 5: Sensor, 10, 110: Decorative member, 11: First surface, 12: Second surface, 20: Laminate, 30: Hard coat film, 31: Hard coat layer, 32: Hard coat support layer, 40: Design layer, 41: Metal layer, 41a: Metal granule part, 41b: Gap, 42: Slope, 44: Concealing layer, 45: Side surface, 47: Primer layer, 50: Intermediate layer, 60: Molded part, 61: Molded layer, 62: Molded shape part, 80: Metal film, 81: Metal support layer, 85: Bonding layer, 88: Gap

Claims

1. Hard court layer, A hard coat support layer is disposed on one side of the hard coat layer and supports the hard coat layer, A metal layer disposed on one side of the hard coat support layer, A concealing layer is disposed between the hard coat support layer and the metal layer, and covers a portion of the metal layer when viewed in the direction from the hard coat layer toward the metal layer. A primer layer for metal deposition is disposed between the hard coat support layer and the concealing layer and the metal layer, Equipped with, The hard coat support layer and the concealing layer form an uneven surface facing the metal layer. The metal layer is bent in accordance with the uneven surface and has a slope that extends along a surface intersecting one side of the hard coat support layer at the boundary with the concealing layer when viewed in the direction from the hard coat layer toward the metal layer. The hard coat layer contains a compound having an isocyanurate ring represented by the following general formula (3), The hard coat layer is a decorative member that does not crack when heated to 180°C and stretched until its area elongation rate reaches 110%. 【Chemistry 1】 (In the formula, Z2 is independently one or different polymerizable carbon-carbon double bond-containing group. R5 is independently one or different divalent hydrocarbon group that may contain an oxygen atom.)

2. The decorative member according to claim 1, wherein the thickness of the concealing layer is 6 μm to 14 μm, and the thickness of the primer layer is 1 μm to 10 μm.

3. The decorative member according to claim 1, wherein the thickness of the concealing layer is 3 μm to 14 μm, and the thickness of the primer layer is 1 μm to 3 μm.

4. A hard coat layer, A hard coat support layer is disposed on one side of the hard coat layer and supports the hard coat layer, A metal layer disposed on one side of the hard coat support layer, A concealing layer is disposed between the hard coat support layer and the metal layer, and covers a portion of the metal layer when viewed in the direction from the hard coat layer toward the metal layer. A bonding layer disposed between the concealing layer and the metal layer, Equipped with, The concealing layer has a surface that extends along a surface that intersects with one side of the hard coat support layer. The hard coat support layer and the concealing layer form an uneven surface facing the metal layer. A gap is formed between the side surface of the concealing layer and the bonding layer. The bonding layer and the metal layer are bent in accordance with the uneven surface, and have a slope that extends along a surface that intersects with one side of the hard coat support layer at the boundary with the concealing layer when viewed in the direction from the hard coat layer toward the metal layer. The hard coat layer contains a compound having an isocyanurate ring represented by the following general formula (3), The hard coat layer is a decorative member that does not crack when heated to 180°C and stretched until its area elongation rate reaches 110%. 【Chemistry 2】 (In the formula, Z2 is independently one or different polymerizable carbon-carbon double bond-containing group. R5 is independently one or different divalent hydrocarbon group that may contain an oxygen atom.)

5. The decorative member according to any one of claims 1 to 4, wherein the hard coat layer does not crack when heated to 180°C and stretched until the area elongation rate is 120%.

6. The decorative member according to claim 4, further comprising a primer layer for metal deposition disposed on any surface of the metal layer.

7. An intermediate layer disposed on one side of the metal layer, A molded portion disposed on one side of the intermediate layer, The decorative member according to any one of claims 1 to 6, further comprising the above.

8. The decorative member according to any one of claims 1 to 7, wherein the metal layer includes a plurality of metal granules capable of reflecting visible light, and gaps are provided between the plurality of metal granules.

9. The decorative member according to any one of claims 1 to 3, wherein the concealing layer has a side surface that extends along a surface intersecting with one side surface of the hard coat support layer.

10. The hard coat layer has a flat portion and a curved portion connected to the flat portion. The decorative member according to any one of claims 1 to 9, wherein the thickness of the hard coat layer in the curved portion is smaller than the thickness of the hard coat layer in the flat portion.

11. A laminate comprising: a hard coat layer; a hard coat support layer disposed on one side of the hard coat layer and supporting the hard coat layer; a metal layer disposed on one side of the hard coat support layer; a concealing layer disposed between the hard coat support layer and the metal layer and covering a portion of the metal layer when viewed in the direction from the hard coat layer toward the metal layer; a primer layer for metal deposition disposed between the hard coat support layer, the concealing layer and the metal layer; and an intermediate layer disposed on one side of the metal layer, wherein the hard coat support layer and the concealing layer form uneven surfaces facing the metal layer, the metal layer is bent in correspondence with the uneven surfaces, and the portion of the metal layer having a slope that extends along a surface intersecting one side of the hard coat support layer at the boundary with the concealing layer when viewed in the direction from the hard coat layer toward the metal layer; An injection molding step is performed to injection mold a molded portion into the laminate produced in the laminate manufacturing step, Equipped with, The hard coat layer contains a compound having an isocyanurate ring represented by the following general formula (3), A method for manufacturing a decorative member, wherein the hard coat layer does not crack when heated to 180°C and stretched until the area elongation rate reaches 110%. 【Transformation 3】 (In the formula, Z2 is independently one or different polymerizable carbon-carbon double bond-containing group. R5 is independently one or different divalent hydrocarbon group that may contain an oxygen atom.)

12. A laminate comprising: a hard coat layer; a hard coat support layer disposed on one side of the hard coat layer and supporting the hard coat layer; a metal layer disposed on one side of the hard coat support layer; a concealing layer disposed between the hard coat support layer and the metal layer and covering a portion of the metal layer when viewed in the direction from the hard coat layer toward the metal layer; a bonding layer disposed between the concealing layer and the metal layer; and an intermediate layer disposed on one side of the metal layer, wherein the concealing layer has a side surface that extends along a plane intersecting one side of the hard coat support layer; the hard coat support layer and the concealing layer form an uneven surface facing the metal layer; a gap is formed between the side surface of the concealing layer and the bonding layer; the bonding layer and the metal layer are bent in correspondence with the uneven surface; and the portion that forms the boundary with the concealing layer when viewed in the direction from the hard coat layer toward the metal layer has a slope that extends along a plane intersecting one side of the hard coat support layer; An injection molding step is performed to injection mold a molded portion into the laminate produced in the laminate manufacturing step, Equipped with, The hard coat layer contains a compound having an isocyanurate ring represented by the following general formula (3), A method for manufacturing a decorative member, wherein the hard coat layer does not crack when heated to 180°C and stretched until the area elongation rate reaches 110%. 【Chemistry 4】 (In the formula, Z2 is independently one or different polymerizable carbon-carbon double bond-containing group. R5 is independently one or different divalent hydrocarbon group that may contain an oxygen atom.)

13. The aforementioned laminate manufacturing process is: A step of producing a hard coat film including the hard coat layer and the hard coat support layer, A step of forming an opaque layer on one side of the hard coat film that covers a portion of the metal layer when viewed in the direction from the hard coat layer toward the metal layer, A step of forming the primer layer on one side of the hard coat film and the opacity layer, A step of depositing the metal layer onto one side of the hard coat film, A step of forming the intermediate layer on one side of the metal layer, A method for manufacturing a decorative member according to claim 11 or 12, including the method described above.

14. The aforementioned laminate manufacturing process is: A step of producing a hard coat film including the hard coat layer and the hard coat support layer, A step of producing a metal film including the metal layer and a metal support layer that supports the metal layer, A bonding step of bonding the hard coat support layer of the hard coat film and the metal support layer of the metal film via the bonding layer, An intermediate layer forming step of forming the intermediate layer on one side of the metal film, A method for manufacturing a decorative member according to claim 12, including the method described in claim 12.

15. The method for manufacturing a decorative member according to claim 14, wherein the laminate manufacturing step further includes an air removal step of removing air between the hard coat film and the metal film bonded in the bonding step.

16. The process further comprises a laminate forming step for forming the laminate produced in the laminate manufacturing step, A method for manufacturing a decorative member according to any one of claims 11 to 15.

17. An emblem comprising a decorative member according to any one of claims 1 to 10.

18. A mobile body comprising a decorative member according to any one of claims 1 to 10 or an emblem according to claim 17.

Images