Films expressing metallic appearance using ultraviolet curable resin and method of manufacturing thereof

Patent metadata

Field	Value
Publication number	US-9956588-B2
Application number	US-201314647386-A
Country	US
Kind code	B2
Filing date	Jul 18, 2013
Priority date	Dec 10, 2012
Publication date	May 1, 2018
Grant date	May 1, 2018

Abstract

The present invention relates to a film in which a protective layer ( 100 ), a base material sheet ( 200 ), a UV-curable resin layer ( 300 ) having a concave-convex surface, a metallic layer ( 400 ), a primer layer ( 500 ), and an adhesion layer ( 600 ) are laminated in sequential order. Also, the present invention relates to a method for manufacturing said film.

First claim

The invention claimed is:

1. A method for manufacturing an interior film for providing a metallic appearance, the method comprises:
preparing a base sheet;
forming a UV-curable resin layer on a lower surface of the base sheet, wherein the UV-curable resin layer has hairlines on a surface thereof, the hairlines have a depth ranging from 0.3 μm to 0.7 μm, and the hairlines comprise:
hairlines extending in a length direction of the film;
hairlines extending in a width direction of the film, wherein the hairlines extending in the width direction of the film satisfy Equation 1:
a>b  <Equation 1>

a: an angle defined between a length direction (l) of the hairlines extending in the width direction of the film and a length direction of the film, and
b: an angle defined between the length direction (l) of the hairlines extending in the width direction of the film and a width direction of the film;

forming a metal layer on a lower surface of the UV-curable resin layer;
forming a primer layer on a lower surface of the metal layer;
forming an adhesive layer on a lower surface of the primer layer; and
forming a protective layer on an upper surface of the base sheet,
wherein forming the UV-curable resin layer comprises:
preparing a first roll with the base sheet placed on a surface thereof;
placing the first roll adjacent to a second roll having a convex-concave pattern on a surface thereof to form a gap between the first roll and the second roll, and placing a curing lamp in proximity to the first roll and the second roll; and
supplying a UV-curable resin to the gap between the first roll and the second roll and rotating at least one of the first roll or the second roll to form the UV-curable resin layer having the hairlines on the surface thereof.

2. The method according to claim 1 , wherein the base sheet has a thickness of 20 μm to 50 μm.

3. The method according to claim 1 , wherein the base sheet comprises polyester resins, acrylic resins, urethane reins, or olefin resins.

4. The method according to claim 1 , wherein the UV-curable resin layer has a thickness of 10 μm to 30 μm.

5. The method according to claim 1 , wherein the UV-curable resin layer is formed of a C 1 to C 12 alkyl group-containing acrylate or a urethane acrylate.

6. The method according to claim 1 , wherein the hairlines of the UV-curable resin layer is located on a side opposite to the base sheet.

7. The method according to claim 1 , wherein the protective layer has a thickness of 10 μm to 30 μm.

8. The method according to claim 1 , wherein the base sheet is placed on all or part of a surface of the first roll.

9. The method according to claim 1 , wherein the curing lamp is placed in a direction opposite a feeding direction of the UV-curable resin with respect to the first or second roll.

10. The method according to claim 1 , wherein the convex-concave pattern of the second roll is transferred to the UV-curable resin to form the hairlines, and the UV-curable resin layer is formed on the lower surface of the base sheet at the same time.

11. The method according to claim 1 , wherein protrusions of the convex-concave pattern of the second roll have a height of 0.3 μm to 0.7 μm.

12. The method according to claim 1 , wherein protrusions formed on the surface of the second roll have a smaller area than depressions formed thereon.

Assignees

• Lg Hausys Ltd

Inventors

• Shin Jun Beom
• Lee Min Ho
• Hwang Jae Bong

Classifications

• B32B27/32

  comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)} · CPC title

• B32B2419/00

  Buildings or parts thereof · CPC title

• B44B5/0047

  by rolling (B44B5/0061 takes precedence) · CPC title

• B05D1/36

  Successively applying liquids or other fluent materials, e.g. without intermediate treatment · CPC title

• B32B27/40

  comprising polyurethanes · CPC title