KR102773263B1 - Sheet front patterning method using belt-type pattern slave - Google Patents

Abstract

The present invention relates to a decoration film, and more particularly, to a method for manufacturing a matte effect decoration film using a rubbing method, wherein the method uses a patterning method using a belt-type pattern slave, thereby contributing to improved productivity and reduction in raw material and process costs.

Description

Sheet front patterning method using belt-type pattern slave {Sheet front patterning method using belt-type pattern slave}

The present invention relates to a decoration film, and more particularly, to a method for manufacturing a matte effect decoration film using a rubbing method, wherein the method uses a patterning method using a belt-type pattern slave, thereby contributing to improved productivity and reduction in raw material and process costs.

In general, decoration films with various patterns printed on them are attached to furniture, electronic products, and building materials for interior purposes, and are used in various fields such as wrapping, window treatments, and surface finishing of various electronic products.

For example, in electronic devices using glass, interest is increasing in the effects of forming various external aesthetics that can be implemented through glass. In particular, technology development is actively being conducted regarding decoration films or decoration sheets for glass (also referred to as 'decorative films or decorative sheets'). For example, if a decoration film is attached to glass, a metallic texture or three-dimensional effect can be imparted to the appearance of the electronic device. In particular, the fields of mobile and automobile design are increasingly demanding designs that implement dynamic and dramatic effects.

Recently, the design of smartphones or various mobile communication terminals has been trending toward having the front window be simply a single color (e.g., black, etc.) and changing the back cover design to various colors and three-dimensional patterns. In line with this trend, various decoration implementation methods have been sought to differentiate the back cover, but the conventional method has had limitations.

For example, in decorative films, there is a need for a method to implement a differentiated decorative aesthetic in which the shape and depth of various three-dimensional patterns formed on the back surface are implemented in various ways.

Meanwhile, matte films are gradually being used because they can prevent eye fatigue and the disclosure of packaged contents that are seen in glossy films by reflecting external light, and they can also provide elegance to products.

In order to manufacture existing matte films, expensive matte paints were used, but recently, a more economical method has been used, using a rubbing method that uses patterns to create matte effects, anti-fingerprint effects, texture effects, and design haze effects on decorative films.

In order to manufacture existing matte films, expensive matte paints were used, but recently, a rubbing method using patterns that can produce matte effects, anti-fingerprint effects, texture effects, and design haze effects on decorative films in a more economical way has been utilized.

In this way, in the matte film manufacturing method using the pattern-using rubbing method, there is a need for research and development of technologies and devices that can contribute to productivity improvement and cost reduction through, for example, shortening of process steps and process times while maintaining or improving overall physical properties compared to existing technologies.

Republic of Korea Patent Publication No. 10-1231508

The present invention is intended to solve the above problems, and provides a method for manufacturing a decoration film with a matte effect using a rubbing method, which can contribute to improving productivity and reducing raw material and process costs through a patterning method using a belt-type pattern slave.

The above and other objects and advantages of the present invention will become apparent from the following description of preferred embodiments.

The above object can be achieved by a method for manufacturing a matte effect decoration film, which comprises the steps of: preparing a base film; forming a shielding printing layer on the back surface of the base film; forming a coating layer on the front surface of the base film using a solvent-based resin coating solution and performing primary curing; using a rubbing device having a belt-shaped pattern slave to rub a pattern exhibiting a matte effect onto the primary cured coating layer; and completely curing the coating layer from which the pattern exhibiting the matte effect is rubbed.

The above base film is characterized in that it is a PC (Polycarbonate) sheet or a PCPMMA (Polycarbonate Polymethyl methacrylate) sheet. The above base film is characterized in that it has a thickness of 0.5 to 0.8 mm.

The above solvent-based resin coating solution is characterized by containing 40 wt% of oligomer, 3 wt% of monomer, 0.2 wt% of fluorine, 53.8 wt% of solvent, and 3 wt% of additive. The thickness of the coating layer is characterized by being 10 to 15 ㎛.

The above primary curing is characterized by forming the coating layer into a moldable gel state by drying at 60 to 80°C for 30 seconds to 1.2 minutes using IR (infrared rays).

The above-mentioned rubbing device is characterized in that it has an LED irradiation unit, and during the rubbing step, the coating layer is irradiated with an LED or the like at a light amount of 100 to 400 mJ/cm ² and an illuminance of 50 to 80 mW/cm ² , thereby performing secondary curing.

The above complete curing is characterized in that it is performed by irradiating with a mercury lamp at a light dose of 950 to 1,200 mJ/cm ² and an illuminance of 200 to 250 mW/cm ² .

According to the present invention, in the manufacture of a matte effect decoration film, a patterning method using a belt-shaped pattern slave enables multiple slave reuse, thereby contributing to improved productivity and reduction of raw material and process costs.

In addition, according to the present invention, in the manufacture of a matte effect decoration film through a rubbing method using a pattern, the IR drying time can be effectively shortened and the process steps can be reduced by using a solvent-based resin during the slot die process, thereby exhibiting the effect of increasing productivity compared to existing methods.

In addition, according to the present invention, by exhibiting a matte effect through a rubbing process using a pattern, a matte film can be mass-produced economically. Therefore, an anti-fingerprint effect due to the matte effect, a texture effect with excellent slipperiness, a design haze effect, etc. can be exhibited on the entire surface of the decoration film in an economical manner, and the pattern can implement various designs as well as a matte effect by using various shapes.

In addition, by forming a coating layer having a matte effect pattern on the base film, the durability against scratches in daily life can be enhanced. Furthermore, by additionally performing a UV molding process and a deposition process on the back of the base film, the matte effect and the effect of the UV pattern layer can be combined to produce a new visual effect.

However, the effects of the present invention are not limited to the effects mentioned above, and other effects not mentioned will be clearly understood by those skilled in the art from the description below.

FIG. 1 is a schematic diagram showing part of the steps of manufacturing a matte effect decoration film according to one embodiment of the present invention.
FIG. 2 is a schematic diagram showing a belt-type pattern slave device according to one embodiment of the present invention.
Figure 3 is a schematic diagram showing a layer-by-layer exploded view of a matte effect decoration film manufactured according to one embodiment of the present invention.
FIG. 4 is an actual photograph of a matte effect decoration film implemented on a smartphone back cover according to one embodiment of the present invention.

Hereinafter, the present invention will be described in detail with reference to examples and drawings of the present invention. It will be apparent to those skilled in the art that these examples are presented only as examples to more specifically explain the present invention, and that the scope of the present invention is not limited by these examples.

Additionally, unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs, and in case of conflict, the description in this specification, including definitions, shall prevail.

In order to clearly explain the invention proposed in the drawings, parts that are not related to the description have been omitted, and similar parts have been given similar drawing reference numerals throughout the specification. In addition, when a part is said to "include" a certain component, this does not mean that other components are excluded, but rather that other components can be further included, unless otherwise specifically stated. In addition, a "part" described in the specification means a single unit or block that performs a specific function.

The identification codes (1st, 2nd, etc.) for each step are used for convenience of explanation and do not describe the order of each step. Each step may be performed in a different order than stated unless the context clearly indicates a specific order. That is, each step may be performed in the same order as stated, may be performed substantially simultaneously, or may be performed in the opposite order.

One aspect of the present invention provides a method for manufacturing a matte effect decoration film, comprising the steps of: preparing a base film; forming a shielding printing layer on the back surface of the base film; forming a coating layer on the front surface of the base film using a solvent-based resin coating solution and performing primary curing; using a rubbing device having a belt-type pattern slave to rub a pattern exhibiting a matte effect onto the primary cured coating layer; and completely curing the coating layer from which the pattern exhibiting a matte effect is rubbed.

Hereinafter, implementation examples and embodiments of the present invention will be described in detail with reference to the attached drawings. However, the present invention may not be limited to these implementation examples and embodiments and drawings.

FIG. 1 is a schematic diagram showing part of the steps of manufacturing a matte effect decoration film according to one embodiment of the present invention.

Referring to Fig. 1(a), first, a base film (200) can be prepared. It is preferable that the base film (200) is a PC (Polycarbonate) sheet or a PCPMMA (Polycarbonate Polymethyl methacrylate) sheet.

PC (Polycarbonate) sheet is a type of thermoplastic plastic with characteristics such as impact resistance, heat resistance, weather resistance, self-extinguishing, and transparency. It has an impact resistance of about 150 times that of tempered glass, so it has excellent flexibility and processability. It is widely used as a substitute for acrylic, which is easily broken and deformed, and as a supplement to general plate glass.

PCPMMA (Polycarbonate Polymethyl methacrylate) sheet is a type of special resin formed into a composite sheet by compressing PC (Polycarbonate) and PMMA (Polymethyl methacrylate).

PMMA is a type of special resin and is a polymer component of methyl methacrylate. It is characterized by excellent optical properties, weather resistance, surface strength, hardness, and moldability.

Meanwhile, the thickness of the base film (200) is preferably 0.5 to 0.8 mm. If it is outside this range, the radius of curvature that can be formed on the outer surface of the film is limited during the subsequent forming process, which may cause difficulties in implementing various designs.

Next, a shielding printing layer (not shown) can be formed on the back surface of the base film (200).

The above shielding printing layer (not shown) has the function of blocking the transmission of light, and can be implemented by printing a dark color, and prevents the lower side of the shielding printing layer from being seen when looking down from the upper side of the decoration film according to the present invention. The shielding printing layer may be, for example, a silk printing layer formed by a silk screen printing method. The shielding printing layer may be formed to a thickness of 15 to 25 ㎛.

Next, a coating layer (300) can be formed on the entire surface of the base film (200). The coating layer (300) can be formed on the entire surface of the base film (200) to form a pattern exhibiting a matte effect. The coating layer (300) can be a UV coating layer formed using a resin coating solution for UV pattern forming, specifically, a solvent-based resin coating solution.

The above coating layer (300) may be formed through a coating method such as a slot die, but is not limited thereto, and may be formed using a coating method commonly used in the art.

The above coating layer (300) can be first cured into a moldable gel state so that a rubbing can be made in the next process, which is the rubbing step, after application for coating. The first curing can be performed by a method of hot air drying at about 60 to 80° C., for example, 70° C., using IR (infrared rays). If the temperature is out of the above range, there is a problem that the curing is insufficient, causing the pattern slave to stick to the coating layer later, or the curing is excessive, causing the rubbing not to be made.

At this time, the drying time of the first curing can be shortened to 1 minute or less, specifically, to a short time of 30 seconds to 1.2 minutes, by the solvent-type resin coating solution according to one embodiment of the present invention.

Specifically, the solvent-based resin coating solution is a fast-drying solvent-based resin with a faster volatilization rate than general UV coating solutions, whereby the fluorine component floats during the volatilization process of the solvent, and by completely curing in the open state, the drying time for primary curing can be significantly shortened from about 4.5 minutes (conventional) to 60 seconds, and the application time of the resin coating solution can also be shortened from about 27 seconds (conventional) to 12 seconds, thereby solving the problem of delay time. As a result, while significantly increasing production efficiency, it is possible to secure improved physical properties compared to conventional surface characteristics, such as thickness reduction and improvement of bubble problems.

The above solvent-based resin coating solution may contain, based on the total weight, 40 to 50 wt%, for example, 40 wt%, of an oligomer including polyurethane acrylate, 2 to 7 wt%, for example, 3 wt%, of a monomer including dipentaerythritol hexaacrylate (DHPA), 0.1 to 3 wt%, for example, 0.2 wt%, of a fluorine, 50 to 60 wt%, for example, 53.8 wt%, of a solvent including acetone, ethyl acetate or a combination thereof, and 1 to 5 wt%, for example, 3 wt%, of an additive including an initiator.

The above coating layer (300) is preferably formed to a thickness that allows for a rubbing when performing the rubbing step later, for example, a thickness of 10 to 15 ㎛.

Next, a pattern exhibiting a matte effect can be copied using a pattern slave on the first cured coating layer (300) (b in FIG. 1).

The above rubbing can be performed specifically using a rubbing device including a belt-shaped pattern slave. Referring to Fig. 2, the rubbing device (10) can be equipped with a patterning start portion (32), a belt-shaped pattern slave (30), an LED irradiation portion (31), and a deformation portion (33).

For example, in the above-described rubbing device (10), the first cured coating layer (300) on the base film (200) may pass through the patterning start portion (32) and be pressed against the belt-shaped pattern slave (30), thereby allowing a pattern to be rubbed on the coating layer (300).

The above pattern slave (30) of the present invention is formed in a belt shape, so that multiple slave reuse is possible during patterning work, and thus, a significant reduction in raw materials and production costs can be achieved compared to existing roll-shaped slaves.

The above pattern slave can exhibit various pattern shapes. The above pattern slave can be formed of a material such as thermoplastic polyurethane (TPU) or polyethylene terephthalate (PET), and can have a thickness of 0.15 to 0.20 mm.

The above-mentioned rubbing device (10) is equipped with the LED irradiation unit (31) so that secondary curing can be performed simultaneously after pattern rubbing so that the rubbed pattern can be fixed and maintained. As a result, the complexity of the process of having to additionally perform secondary curing after performing the rubbing step as in the past is simplified, thereby significantly shortening the process time and contributing to improved productivity.

The secondary curing performed within the above-described rubbing device (10) can be performed by irradiating with light of 100 to 400 mJ/cm ² and illuminance of 50 to 80 mW/cm ² using, for example, an LED or the like. If the range is exceeded, the secondary curing may not be performed effectively.

Next, the decoration film on which the coating layer (300) is formed can further undergo a forming process to shape the outer surface of the film into a curved shape. The forming process can be performed according to a known technique widely known in the art.

Next, referring to Fig. 1 (c), the coating layer (300) can be completely cured. At this time, the complete curing can be performed by irradiating with, for example, 950 to 1200 mJ/cm ² and an illuminance of 200 to 250 mW/cm ² using a mercury lamp. This complete curing process can be repeated two or more times, and preferably can be repeated about three times.

Thereafter, a step of cutting the decoration film in which the patterned coating layer (300) is completely cured can be performed. The cutting step can be performed by cutting the decoration film using equipment such as CNC or laser, depending on the shape and size of the adherend.

Meanwhile, in the method for manufacturing a matte effect decoration film according to the present invention, prior to the step of forming a shielding printing layer on the back surface of the base film (200), a step of forming a UV pattern layer on the back surface of the base film for a variety of refraction effects and a step of forming a deposition layer on the UV pattern layer may be further included.

The above UV pattern layer serves to display a three-dimensional design pattern, or to display the visibility and colorful refractive effects of the matte effect coating layer (300) formed later.

The above UV pattern layer can be formed by UV molding using a transparent UV pattern forming paint to have a predetermined pattern shape. At this time, the predetermined pattern shape can include various pattern shapes including a super precision machine pattern and a hologram pattern, and in addition, any UV pattern shape obvious to a person skilled in the art can be applied. At this time, the manufacturing method can be formed by a UV molding method using a micro optical mold.

When a UV pattern layer is formed using the above UV molding method, it is possible to improve aesthetics by enabling various design expressions depending on the angle of light.

The paint for UV pattern forming may include a binder material. The binder material may include at least one of an epoxy resin, an acrylic resin, a polyolefin resin, a polyamide resin, a polyester resin, a polyvinyl chloride resin, a polyvinyl acetate resin, a petroleum resin, a phenol resin, a polystyrene resin, and a urethane resin.

The above UV pattern layer may have a first translucent color. In addition, the UV pattern layer may be provided with a predetermined receiving groove, which may be utilized as a space filled with ink having a second translucent color, which is a tint color of a different color from the first translucent color.

In addition, the UV pattern layer forms a photocurable resin layer by applying a photocurable resin composition for UV molding, and then forms a micro pattern on the surface, thereby simultaneously including color and pattern, and thus enables expression of various colors and patterns such as two-tone colors, multi-colors, and colors with various depths, thereby dramatically improving aesthetics.

Next, a deposition layer can be formed on the UV pattern layer.

The above deposition layer is performed to protect the UV pattern layer and to clearly display the three-dimensional effect by the UV pattern layer. The deposition layer can be formed in the form of an inorganic thin film on the UV pattern layer using a deposition method commonly used in the art, such as a non-conductive vacuum metallization (NCVM) method including a physical or chemical deposition method.

The physical vapor deposition method melts compounds to create a solid target when depositing oxide semiconductors or GaAs on a substrate, volatilizes them with heat or an electron beam, and deposits them on the substrate. At this time, the raw material is blown away in a gaseous state using heat, laser, electron beam, etc., and when the blown-away gaseous raw material touches the substrate, it changes into a solid state.

Chemical vapor deposition is an industrial method that uses chemical reactions to create thin films of silicon, etc., on substrates during the manufacturing process of ICs, etc. It is used to create silicon oxide films, silicon nitride films, amorphous silicon films, etc. When heat or light is applied to a gas containing chemicals, or when plasma is created using high frequency, the raw materials become radicals, greatly increasing their reactivity, and are adsorbed and deposited on the substrate.

In addition, the deposition layer may be formed as a color deposition layer, for example, a gradient deposition layer, to improve aesthetics with various colors such as two-tone colors, multi-colors, and colors with various depths. The gradient deposition layer may be formed using, for example, a conventional electron beam deposition device.

Figure 3 is a schematic diagram showing a layer-by-layer exploded view of a matte effect decoration film manufactured according to one embodiment of the present invention.

Referring to FIG. 3, the matte effect decoration film includes a base film, a UV pattern layer sequentially formed on the back surface of the base film; a deposition layer; and a shielding printing layer, and may include a coating layer (UV pattern) exhibiting a matte effect formed on the front surface of the base film.

FIG. 4 is an actual photograph of a matte effect decoration film implemented on a smartphone back cover according to one embodiment of the present invention.

Referring to FIG. 4, the decoration film manufactured in this way can express various colors that exhibit a matte effect, as shown in FIG. 4, and can produce various effects by combining the effects of the UV pattern layer.

The best embodiments have been disclosed in the drawings and the specification. Although specific terms have been used herein, they have been used only for the purpose of describing the present invention and have not been used to limit the meaning or the scope of the present invention described in the claims. Therefore, those skilled in the art will understand that various modifications and equivalent other embodiments are possible from this. Therefore, the true technical protection scope of the present invention should be determined by the technical idea of the appended claims.

200: Base film 300: Coating layer
10: Rubbing device 30: Belt-type pattern slave
31: LED irradiation section 32: Patterning start section
33: Lee Hyung-bu

Claims (8)

Steps to prepare the base film;
A step of forming a shielding printing layer on the back surface of the base film;
A step of forming a coating layer using a solvent-based resin coating solution on the entire surface of the base film and performing primary curing;
A step of rubbing a pattern exhibiting a matte effect using a rubbing device having a belt-shaped pattern slave on a first cured coating layer; and
A step of completely curing a coating layer having a pattern showing a matte effect;
The above solvent-based resin coating solution comprises, with respect to the total weight, 40 wt% of an oligomer including polyurethane acrylate, 3 wt% of a monomer including dipentaerythritol hexaacrylate (DHPA), 0.2 wt% of a fluorine agent, 53.8 wt% of a solvent including acetone, ethyl acetate or a combination thereof, and 3 wt% of an additive including an initiator.
The above primary curing is performed by drying the coating layer at 60 to 80°C for 30 seconds to 1.2 minutes using IR (infrared rays) to form the coating layer into a moldable gel state.
The above-mentioned rubbing device is equipped with an LED irradiation unit, and during the rubbing step, the coating layer is irradiated with a light amount of 100 to 400 mJ/cm ² and an illuminance of 50 to 80 mW/cm ² using an LED, etc., thereby performing secondary curing.
A method for manufacturing a matte effect decoration film, characterized in that the above complete curing is performed by irradiating with a mercury lamp at a light amount of 950 to 1,200 mJ/cm ² and an illuminance of 200 to 250 mW/cm ² . In the first paragraph,
A method for manufacturing a matte effect decoration film, characterized in that the base film is a PC (Polycarbonate) sheet or a PCPMMA (Polycarbonate Polymethyl methacrylate) sheet. In the first paragraph,
A method for manufacturing a matte effect decoration film, characterized in that the base film has a thickness of 0.5 to 0.8 mm. delete In the first paragraph,
A method for manufacturing a matte effect decoration film, characterized in that the thickness of the coating layer is 10 to 15㎛. delete delete delete