US 12,251,907 B2
Laminated member for decoration and method for producing decorative molded article
Takamitsu Watanabe, Hirakata (JP); Takeki Hosokawa, Hirakata (JP); Yusuke Nakata, Hirakata (JP); Keigo Kitamoto, Hirakata (JP); Satoshi Hirose, Hirakata (JP); Kei Takigawa, Hirakata (JP); and Kazuhito Kobayashi, Hirakata (JP)
Assigned to NIPPON PAINT AUTOMOTIVE COATINGS CO., LTD., Osaka (JP)
Appl. No. 17/299,168
Filed by NIPPON PAINT AUTOMOTIVE COATINGS CO., LTD., Osaka (JP)
PCT Filed Dec. 5, 2019, PCT No. PCT/JP2019/047678
§ 371(c)(1), (2) Date Jun. 2, 2021,
PCT Pub. No. WO2020/116576, PCT Pub. Date Jun. 11, 2020.
Claims priority of application No. 2018-229462 (JP), filed on Dec. 6, 2018.
Prior Publication US 2022/0032587 A1, Feb. 3, 2022
Int. Cl. B32B 27/08 (2006.01); B29B 11/04 (2006.01); B29B 11/14 (2006.01); B29C 70/78 (2006.01); B29K 69/00 (2006.01); B29K 623/00 (2006.01); B29K 633/04 (2006.01); B29L 31/34 (2006.01); B32B 7/06 (2019.01); B32B 7/12 (2006.01); B32B 27/30 (2006.01); B32B 27/32 (2006.01); B32B 27/36 (2006.01); B32B 37/02 (2006.01); B32B 37/12 (2006.01); B32B 37/24 (2006.01); B32B 37/26 (2006.01); B32B 38/00 (2006.01); B32B 38/10 (2006.01); G02B 1/14 (2015.01); B29L 31/00 (2006.01)
CPC B32B 27/08 (2013.01) [B29B 11/04 (2013.01); B29B 11/14 (2013.01); B29C 70/78 (2013.01); B32B 7/06 (2013.01); B32B 7/12 (2013.01); B32B 27/308 (2013.01); B32B 27/32 (2013.01); B32B 27/365 (2013.01); B32B 37/02 (2013.01); B32B 37/12 (2013.01); B32B 37/24 (2013.01); B32B 37/26 (2013.01); B32B 38/0008 (2013.01); B32B 38/10 (2013.01); G02B 1/14 (2015.01); B29C 2795/002 (2013.01); B29K 2069/00 (2013.01); B29K 2623/12 (2013.01); B29K 2633/12 (2013.01); B29K 2995/0022 (2013.01); B29K 2995/0026 (2013.01); B29K 2995/0065 (2013.01); B29K 2995/007 (2013.01); B29K 2995/0082 (2013.01); B29K 2995/0098 (2013.01); B29L 2031/3475 (2013.01); B29L 2031/722 (2013.01); B32B 2037/268 (2013.01); B32B 2250/24 (2013.01); B32B 2255/10 (2013.01); B32B 2307/406 (2013.01); B32B 2307/536 (2013.01); B32B 2307/584 (2013.01); B32B 2307/714 (2013.01); B32B 2307/724 (2013.01); B32B 2307/732 (2013.01); B32B 2310/0831 (2013.01); B32B 2323/10 (2013.01); B32B 2333/12 (2013.01); B32B 2369/00 (2013.01); B32B 2451/00 (2013.01); B32B 2457/20 (2013.01)] 12 Claims
 
1. A method for producing a decorative molded article using a laminated member for decoration, the method comprising:
forming an uncured coating layer on a resin substrate,
forming a laminated member for decoration, wherein forming the laminated member comprises laminating a protective film comprising an adhesive layer, the adhesive layer comprising an adhesive side and a non-adhesive side, and arranging the adhesive side adjacent to the uncured coating layer on an opposite side of the uncured coating layer from the resin substrate,
forming a decorative layer on an opposite side of the resin substrate from the uncured coating layer, and
peeling the protective film from the uncured coating layer to obtain the decorative molded article,
wherein
a surface roughness Rz(a) of the adhesive layer on the adhesive side, the surface roughness being taken in a state where the adhesive layer is not in contact with the uncured coating layer, and a surface roughness Rz(b) of the uncured coating layer in an unheated sample comprising the resin substrate and the uncured coating layer formed by peeling the protective film from the uncured coating layer at 25° C. at a rate of 5.0 mm/sec with a peeling direction set to 170°, the surface roughness being taken on a side opposite from the resin substrate, exhibits a relationship of
85%<Rz(b)/Rz(a)×100≤110%  (1);
the surface roughness Rz(b), and
a surface roughness Rz(bh) of the uncured coating layer in a heated sample obtained by heating the unheated sample in an atmosphere of 160° C. for 30 seconds, the surface roughness being taken on a side opposite from the resin substrate, satisfy at least one of Formulas (2) and (3) below:
0%≤Rz(bh)/Rz(b)×100<30%  (2), and
0≤Rz(bh)≤Rz(b)<0.5 μm  (3);
the uncured coating layer has unreacted (meth)acryloyl groups; and
in a state where the heated sample has been irradiated with ultraviolet light having a wavelength of 380 nm or less of 500 mJ/cm2, 10 to 1000% of the unreacted (meth)acryloyl groups of the uncured coating layer disappear when cured,
Rz(a) is 0.01 m or more and 2.0 m or less,
Rz(b) is 0.01 μm or more and 2.0 m or less, and
Rz(bh) is 0.01 m or more and less than 0.7 m.