Decorative film for insert molding, method for manufacturing decorative film for insert molding, and method for manufacturing resin molded product

Patent metadata

Field	Value
Publication number	US-12103282-B2
Application number	US-202218552757-A
Country	US
Kind code	B2
Filing date	Feb 9, 2022
Priority date	Mar 29, 2021
Publication date	Oct 1, 2024
Grant date	Oct 1, 2024

Abstract

A decorative film for insert molding includes a gravure-printed graphic layer and a light-transmissive patterned layer and has high dimensional accuracy and delicate and rich tone expression. A multilayer film includes first and second layers containing an acrylic-based resin, and a polycarbonate resin layer located between the first and second layers and containing a polycarbonate-based resin. The multilayer film is transmissive to visible light. A first gravure print layer is located on a first main surface of the multilayer film, includes a first graphic layer, and is transmissive. A backer film contains a polycarbonate-based resin and is transmissive. The first graphic layer includes a first image at a predetermined position in a three-dimensional shape of a decorative film formed in the three-dimensional shape. A patterned layer includes a pattern patterned to allow visible light to pass through the first image at the predetermined position in the three-dimensional shape.

First claim

The invention claimed is:

1. A decorative film for insert molding to be formed in a three-dimensional shape before insert molding, the decorative film comprising:
a multilayer film having a first main surface and a second main surface, the multilayer film including a first acrylic resin layer comprising an acrylic-based resin, a second acrylic resin layer comprising an acrylic-based resin, and a polycarbonate resin layer between the first acrylic resin layer and the second acrylic resin layer, the polycarbonate resin layer comprising a polycarbonate-based resin, the multilayer film being transmissive to visible light;
a first gravure print layer on the first main surface of the multilayer film, the first gravure print layer including a first graphic layer including a gravure-printed graphic element, the first gravure print layer being transmissive to visible light;
a second gravure print layer on the second main surface of the multilayer film;
a lamination adhesive layer bonded to the first gravure print layer, the lamination adhesive layer including an adhesive transmissive to visible light;
a backer film comprising a polycarbonate-based resin, the backer film being bonded to the first gravure print layer with the lamination adhesive layer by dry laminating, the backer film being transmissive to visible light; and
a light-transmissive patterned layer formed by screen printing on the backer film, the light-transmissive patterned layer including a light-transmissive pattern transmissive to visible light, wherein
the first graphic layer includes a first image at a predetermined position,
the light-transmissive pattern in the light-transmissive patterned layer is patterned to allow visible light to pass through the first image at the predetermined position,
the second gravure print layer has surface roughness measured in accordance with Japanese Industrial Standards B0601, and the surface roughness has a distance between a highest peak and a lowest valley being greater than or equal to 20 μm, and
the lamination adhesive layer has a thickness greater than or equal to 16 μm.

2. The decorative film according to claim 1 , wherein
the second gravure print layer includes a second graphic layer including a gravure-printed graphic element, the second gravure print layer including a second image at a position with respect to the first image.

3. The decorative film according to claim 1 , wherein
the first gravure print layer includes a primer layer between the first graphic layer and the lamination adhesive layer, the primer layer comprises a thermoplastic resin, and the primer layer is transmissive to visible light.

4. The decorative film according to claim 1 , wherein the light-transmissive patterned layer is formed on an opposite side of the backer film from the first gravure print layer.

5. The decorative film according to claim 1 , wherein the backer film has a thickness of 150 μm to 250 μm.

6. A method for manufacturing a decorative film for insert molding to be formed in a three-dimensional shape before insert molding, the method comprising:
printing, by gravure printing, a first gravure print layer transmissive to visible light on a first main surface of a multilayer film, the multilayer film including a first acrylic resin layer comprising an acrylic-based resin, a second acrylic resin layer comprising an acrylic-based resin, and a polycarbonate resin layer between the first acrylic resin layer and the second acrylic resin layer, the polycarbonate resin layer comprising a polycarbonate-based resin, the multilayer film being transmissive to visible light;
printing, by gravure printing, a second gravure print layer on a second main surface of the multilayer film;
forming an elongated first member by dry laminating a backer film and the multilayer film including the first gravure print layer at a temperature of 100° C. or lower, with a lamination adhesive layer placed between the backer film and the multilayer film, the backer film comprising a polycarbonate-based resin and being transmissive to visible light; and
forming a light-transmissive patterned layer on the backer film in the first member by screen printing, the light-transmissive patterned layer including a light-transmissive pattern transmissive to visible light, wherein
the first gravure print layer includes a first image at a predetermined position in the three-dimensional shape of the decorative film formed in the three-dimensional shape,
the light-transmissive pattern in the light-transmissive patterned layer is patterned to allow visible light to pass through the first image at the predetermined position in the three-dimensional shape,
the second gravure print layer has surface roughness measured in accordance with Japanese Industrial Standards B0601, and the surface roughness has a distance between a highest peak and a lowest valley being greater than or equal to 20 μm, and
the lamination adhesive layer has a thickness greater than or equal to 16 μm.

7. The method according to claim 6 , wherein
the printing the first gravure print layer and the printing the second gravure print layer are performed at a same time.

8. The method according to claim 6 , further comprising:
cutting the first member into a shorter second member before the forming the light-transmissive patterned layer,
wherein the forming the light-transmissive patterned layer includes forming the light-transmissive patterned layer on the backer film in the second member.

9. The method according to claim 6 , wherein
the forming the light-transmissive patterned layer includes forming the light-transmissive patterned layer on the backer film in the first member with roll-to-roll processing.

10. The method according to claim 6 , wherein forming the light-transmissive patterned layer comprises forming the light-transmissive patterned layer on an opposite side of the backer film from the first gravure print layer.

11. A method for manufacturing a resin molded product, the method comprising:
forming the decorative film according to claim 1 in a three-dimensional shape;
trimming an excess portion of the decorative film formed in the three-dimensional shape; and
injecting a polycarbonate-based resin into a mold with the decorative film placed in the mold to obtain a polycarbonate resin molded product decorated with the decorative film and transmissive to visible light,
wherein the resin molded product has a three-dimensional shape with a specific portion including the first image and allows visible light passing through the light-transmissive pattern to pass through the first image or a portion adjacent to the first image.

Assignees

• Nissha Co Ltd

Inventors

• Okuda Michiyasu
• Ueno Yusuke
• Kuwasaka Shintaro

Classifications

• B60R13/02

  {Internal} Trim mouldings {; Internal} Ledges; Wall liners {for passenger compartments}; Roof liners (B60R13/01 takes precedence {; padded linings for the vehicle interior B60R21/04; arrangements or adaptations of floor mats or carpets in vehicles B60N3/04; internal lining for trains B61D17/18}) · CPC title

• B32B2307/538

  Roughness · CPC title

• B32B2307/412

  Transparent · CPC title

• B32B2255/28

  Multiple coating on one surface · CPC title

• B32B2255/26

  Polymeric coating · CPC title