JP7153924B2 - 欠陥を低減したペイントフィルムアップリケ、物品および方法 - Google Patents
欠陥を低減したペイントフィルムアップリケ、物品および方法 Download PDFInfo
- Publication number
- JP7153924B2 JP7153924B2 JP2018562367A JP2018562367A JP7153924B2 JP 7153924 B2 JP7153924 B2 JP 7153924B2 JP 2018562367 A JP2018562367 A JP 2018562367A JP 2018562367 A JP2018562367 A JP 2018562367A JP 7153924 B2 JP7153924 B2 JP 7153924B2
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- layer
- paint film
- film
- carrier layer
- applique
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- C—CHEMISTRY; METALLURGY
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Description
本明細書において「キャリア層(carrier layer)」という用語を用いることにより、キャリア層を備えるポリマーフィルムは、ペイントフィルムアップリケ内において、少なくとも接着層と、別体の着色層とを有している(すなわち、支持している)と理解されたい。着色層および/または接着層の厚さはキャリア層の厚さよりも大きくてもよいが、キャリア層は、(美粧性、機能性、または他の特性であるかに関わらず)所望の特性を有するペイントフィルムアップリケを提供するために不可欠な要素である。
本発明のペイントフィルムアップリケにおいて複数の着色層を使用することが可能であるものの、以下においては、単に簡略化のために1つの層のみに言及して説明を行う。複数の着色層が使用される場合、各着色層は同一でも異なっていてもよいと認識されたい。
接着層が設けられている場合、少なくとも1つのキャリア層と、少なくとも1つの着色層とを含む積層物の主要平面側に接着層は隣接して設けられ、これは任意のトップコート層が設けられる側とは反対側である。本発明に係る接着層に適宜の接着剤を使用することが可能である。好適な実施形態において、接着層は感圧接着剤を含む。
一般的に、本発明のペイントフィルムアップリケの接着層とは反対側にある、キャリア層および着色層の積層物の主要平面側において外側に露出した非接着層は、「トップコート層」と称する。この名称と整合して、任意で設けられたトップコート層は、ペイントフィルムアップリケが物品に適用されたときに外側に露出したペイントフィルムアップリケの外層である。本発明のペイントフィルムアップリケのトップコート層に、適宜の種類の材料を用いることが可能である。例えば、トップコート層は、ベースポリマーとして、ポリカーボネート、ポリフッ化ビニル、ポリ(メタ)アクリレート(例えば、ポリアクリレートまたはポリメタクリレート)、ポリウレタン、それらの変性(例えば、ハイブリッド)ポリマー、またはそれらの組合せを含むことができる。本発明のトップコート層に有用な例示的なポリカーボネート系ポリウレタンの説明については、米国特許第4,476,293号を参照のこと。また、更なる例示的なトップコート層の説明については、本願に参照により組み込まれる米国特許出願公開第2008-0286576号も参照のこと。
当業者の知識に従って、ペイントフィルムアップリケの各層がそれぞれ形成され、多層ペイントフィルムアップリケに組み立てられる。しかしながら、キャリア層を形成するにあたり、キャリア層を着色層上にin-situで形成して、キャリア層と支持された着色層の積層物を得た後に、この積層物の一方の主面にペイントフィルムアップリケの任意の接着層および/または任意のトップコート層を形成してもよい。
本発明のペイントフィルムアップリケは、例えば、運輸、建築およびスポーツ用品の産業といった様々なインドア用途およびアウトドア用途に有用である。有利なことに、本願のペイントフィルムアップリケは、塗装が所望される任意の物品の表面の少なくとも一部に使用することが可能である。そうした物品としては、他の多数の用途の中でも、例えば、モータ付きの乗り物(例えば、自動車および飛行機)ならびにモータ付きでない乗り物(例えば、従来的な自転車)が挙げられる。ペイントフィルムアップリケが適用される表面は、塗装されていても、塗装されていなくてもよい。
本発明の例示的な実施形態および用途を、以下の試験法と関連づけて説明する。
TA Instruments社(ニューカッスル,DE)製の動的機械分析装置(商品名:TA Instruments DMA Q800)を用いて、当該試験を引張モードで行った。公称試料サイズとして、長さ5~12mm、幅4~8mm、厚さ0.02~0.2mmを使用した。周波数1Hz、歪0.3%、および傾斜率3℃/minを使用して、試料の損失係数を決定するための値を測定した。
TA Instruments社(ニューカッスル,DE)製の動的機械特性分析装置(商品名:TA Instruments DMA Q800)を用いて、当該試験を引張モードで行った。公称試料サイズとして、長さ5~12mm、幅4~8mm、厚さ0.02~0.2mmを使用した。周波数1Hz、歪0.3%、および傾斜率3℃/minを使用して、試料の貯蔵弾性率を決定するための値を測定した。
各材料について、小ディスク(直径25mm×厚さ0.16mm)を、それぞれ別個に、16mLのテトラヒドロフラン(THF)が入ったジャーに浸漬した。5分後に各実施例のディスクの溶解および/または膨出を評価した。各試料を評価するに当たり、ディスクがそのまま残っていなければ、ジャーの内容物を200メッシュのステンレススチール製フィルタに通した。固形またはゲル残留物がフィルタスクリーンに保持された場合、ディスクの材料は、完全に溶解かつ簡単に微細片に分解されていないと認定された。浸漬5分後にディスクがそのまま残っていた場合は、合計6時間にわたって、ディスクをTHFに浸漬した状態で保持した。合計6時間浸漬した後でも、ディスクは依然として残っていたので、ジャーから取り出して、その直径を速やかに測定した。その後、ディスクを空気中で乾燥させた。約24時間後、ディスクの直径を再度測定した。
Argotec社(グリーンフィールド,MA)製の熱可塑性ポリウレタンフィルム(ARGOTEC 49510)のディスクを、上記の耐溶剤性試験法に従って評価した。5分後、ディスクはそのままの状態で残っておらず、完全に溶解していることが確認された。
Argotec社(グリーンフィールド,MA)製の熱可塑性ポリウレタンフィルム(ARGOTEC 46510)のディスクを、上記の耐溶剤性試験法に従って評価した。5分後、ディスクはそのままの状態で残っておらず、完全に溶解していることが確認された。
下記の例示的な配合(表2および表5を参照)に従って用意されたフィルム3のディスクを、上記の耐溶剤性試験法に従って評価した。6時間浸漬した後に測定されたディスクの直径は、元のサイズの160%であった。空気中で乾燥させた後、ディスクは、元の直径25mmに戻り、THFが蒸発したことが確認された。
欠陥フリーポリマーフィルム、およびこのフィルムを備えるペイントフィルムアップリケは、米国特許第8,828,303号に記載された方法に従って、かつ下記の各層の成分を用いて用意することができる。
本発明のペイントフィルムアップリケの3つの異なるキャリア層は、表2に記載の成分と、表3から表5に示された割合とに基づいて形成される。重量割合は、キャリア層を含む最終的なフィルムの全重量に基づいて記載している。表2に記載された成分は、(下記で説明する)着色層の上にin-situで重合されている。
着色層は、entrochem社(コロンバス、オハイオ)から販売される溶媒系ポリウレタンコーティング(商品名:ECA-518)を、entrochem社(コロンバス、オハイオ)から販売される着色料濃縮物(商品名:ECA-505)と混合することによって形成される。この混合物は、乾燥膜厚が約10ミクロンから約100ミクロンになるまで塗布される。
本発明のペイントフィルムアップリケに用いるアクリル系ポリウレタントップコート層は、脂肪族アクリルポリオールおよび脂肪族ポリイソシアネートポリマーから形成される。これらの成分は、約10ミクロンの厚さにコーティングされた後、キャリア層上においてin-situで重合される。
本発明のペイントフィルムアップリケに用いる接着層は、表2に記載された接着剤成分に基づいて形成され、キャリア層とは反対側で着色層の上に配置される。
なお、本発明は、態様として以下の内容を含む。
〔態様1〕
任意のトップコート層と、
in-situで重合されたキャリア層と、
着色層と、
任意の接着層と
を備えるペイントフィルムアップリケ。
〔態様2〕
態様1に記載のペイントフィルムアップリケにおいて、前記ペイントフィルムアップリケが不透明である、ペイントフィルムアップリケ。
〔態様3〕
態様1に記載のペイントフィルムアップリケにおいて、前記着色層が顔料を含む、ペイントフィルムアップリケ。
〔態様4〕
態様1に記載のペイントフィルムアップリケにおいて、前記着色層はin-situで重合される、ペイントフィルムアップリケ。
〔態様5〕
態様1に記載のペイントフィルムアップリケにおいて、前記キャリア層が欠陥フリーである、ペイントフィルムアップリケ。
〔態様6〕
態様1に記載のペイントフィルムアップリケにおいて、前記キャリア層がポリウレタン系である、ペイントフィルムアップリケ。
〔態様7〕
態様1に記載のペイントフィルムアップリケにおいて、前記in-situで重合されたキャリア層が、未反応の溶媒を基本的に含んでいない、ペイントフィルムアップリケ。
〔態様8〕
態様1に記載のペイントフィルムアップリケにおいて、前記ペイントフィルムアップリケは、前記トップコート層と、前記in-situで重合されたキャリア層と、前記着色層と、前記接着層とをこの順に備える、ペイントフィルムアップリケ。
〔態様9〕
態様1に記載のペイントフィルムアップリケにおいて、前記ペイントフィルムアップリケは、前記トップコート層と、前記着色層と、前記in-situで重合されたキャリア層と、前記接着層とをこの順に備える、ペイントフィルムアップリケ。
〔態様10〕
態様1に記載のペイントフィルムアップリケにおいて、前記in-situで重合されたキャリア層も、前記着色層と同様に着色されている、ペイントフィルムアップリケ。
〔態様11〕
態様1に記載のペイントフィルムアップリケにおいて、前記トップコート層を備えるペイントフィルムアップリケ。
〔態様12〕
態様11に記載のペイントフィルムアップリケにおいて、前記トップコート層がポリウレタン系である、ペイントフィルムアップリケ。
〔態様13〕
態様1に記載のペイントフィルムアップリケにおいて、損失係数試験法に従って単体フィルムとして検査した場合、前記in-situで重合されたキャリア層のピーク損失係数が少なくとも約0.5である、ペイントフィルムアップリケ。
〔態様14〕
態様1に記載のペイントフィルムアップリケにおいて、損失係数試験法に従って単体フィルムとして検査した場合、前記in-situで重合されたキャリア層のピーク損失係数が少なくとも約35℃の温度付近で生じる、ペイントフィルムアップリケ。
〔態様15〕
態様1に記載のペイントフィルムアップリケにおいて、損失係数試験法に従って単体フィルムとして検査した場合、前記in-situで重合されたキャリア層の半値損失係数が、約40℃未満の温度間隔にわたって生じる、ペイントフィルムアップリケ。
〔態様16〕
態様1に記載のペイントフィルムアップリケにおいて、前記接着層が設けられており、かつ感圧接着剤を含む、ペイントフィルムアップリケ。
〔態様17〕
態様16に記載のペイントフィルムアップリケにおいて、前記接着層の外面に剥離フィルムをさらに備える、ペイントフィルムアップリケ。
〔態様18〕
態様1に記載のペイントフィルムアップリケにおいて、前記ペイントフィルムアップリケの全体厚さが約130ミクロンよりも薄い、ペイントフィルムアップリケ。
〔態様19〕
少なくとも1つの表面の少なくとも一部に、態様1に記載のペイントフィルムアップリケを備える物品。
〔態様20〕
態様19に記載の物品において、前記物品がモータ付き乗り物である、物品。
〔態様21〕
態様1に記載のペイントフィルムアップリケを用いてモータ付き乗り物の表面を塗装する方法であって、
態様1に記載の前記ペイントフィルムアップリケを提供することと、
前記モータ付き乗り物の前記表面に前記シートを適用することと、
を含む方法。
〔態様22〕
態様1に記載のペイントフィルムアップリケを形成する方法であって、
少なくとも前記in-situで重合されたキャリア層と前記着色層とが、in-situで重合されて同時に前記少なくとも2つの層を形成する重合性組成物の共押出成形によって形成される、方法。
〔態様23〕
態様1に記載のペイントフィルムアップリケを形成する方法であって、
前記着色層が流涎される、方法。
〔態様24〕
態様1に記載のペイントフィルムアップリケを形成する方法であって、
前記着色層が有機溶媒から流涎される、方法。
〔態様25〕
態様1に記載のペイントフィルムアップリケを形成する方法であって、
前記着色層が水性溶液から流涎される、方法。
Claims (21)
- ペイントフィルムアップリケを形成する方法であって、
着色層を形成する工程と、
in-situで重合されたポリウレタン系のキャリア層を、前記着色層に隣接するように形成する工程と、を備え、
任意で、トップコート層を形成する工程を備え、
任意で、前記トップコート層の反対側に接着層を形成する工程を備える、方法。 - 請求項1に記載の方法であって、前記ペイントフィルムアップリケが不透明である、方法。
- 請求項1または2に記載の方法であって、前記着色層が顔料を含む、方法。
- 請求項1から3のいずれか一項に記載の方法であって、前記キャリア層が欠陥フリーである、方法。
- 請求項1から4のいずれか一項に記載の方法であって、前記in-situで重合されたキャリア層が、未反応の溶媒を基本的に含んでいない、方法。
- 請求項1から5のいずれか一項に記載の方法であって、前記ペイントフィルムアップリケは、前記トップコート層と、前記in-situで重合されたキャリア層と、前記着色層と、前記接着層とをこの順に備える、方法。
- 請求項1から5のいずれか一項に記載の方法であって、前記ペイントフィルムアップリケは、前記トップコート層と、前記着色層と、前記in-situで重合されたキャリア層と、前記接着層とをこの順に備える、方法。
- 請求項1から7のいずれか一項に記載の方法であって、前記トップコート層を形成する工程を備える方法。
- 請求項8に記載の方法であって、前記トップコート層がポリウレタン系である、方法。
- 請求項1から9のいずれか一項に記載の方法であって、損失係数試験法に従って単体フィルムとして検査した場合、前記in-situで重合されたキャリア層のピーク損失係数が少なくとも0.5である、方法。
- 請求項1から10のいずれか一項に記載の方法であって、損失係数試験法に従って単体フィルムとして検査した場合、前記in-situで重合されたキャリア層のピーク損失係数が35℃以上の温度で生じる、方法。
- 請求項1から11のいずれか一項に記載の方法であって、前記in-situで重合されたキャリア層の半値損失係数の温度間隔が40℃未満である、方法。
- 請求項1から12のいずれか一項に記載の方法であって、前記接着層が形成されて設けられており、かつ感圧接着剤を含む、方法。
- 請求項13に記載の方法であって、前記接着層の外面に剥離フィルムをさらに備える、方法。
- 請求項1から14のいずれか一項に記載の方法であって、前記ペイントフィルムアップリケの全体厚さが130ミクロンよりも薄い、方法。
- 請求項1から15のいずれか一項に記載の方法で形成されたペイントフィルムアップリケを使用する方法であって、モータ付き乗り物の表面を塗装するために用いられ、当該方法は、
請求項1から15のいずれか一項に記載のペイントフィルムアップリケを用意する工程と、
前記モータ付き乗り物の前記表面に前記ペイントフィルムアップリケを適用する工程と、
を備える、方法。 - 請求項1から16のいずれか一項に記載の方法であって、前記着色層が溶液流涎法により形成される、方法。
- 請求項17に記載の方法であって、前記着色層が有機溶媒溶液から流涎される、方法。
- 請求項17に記載の方法であって、前記着色層が水性溶から流涎される、方法。
- 請求項1から19のいずれか一項に記載の方法であって、前記in-situで重合されたキャリア層は、脂肪族ポリイソシアネート及び少なくとも3種のポリオールを含む成分の反応生成物を備え、前記ポリオールのうちの1種は数平均分子量が1400~2000であり、前記ポリオールのうちの1種はポリエーテルポリオールである、方法。
- 請求項1から19のいずれか一項に記載の方法であって、前記in-situで重合されたキャリア層は、脂肪族ポリイソシアネート及び少なくとも3種のポリオールを含む成分の反応生成物を備え、前記ポリオールのうちの1種は数平均分子量が900~1400であり、前記ポリオールのうちの1種はポリエーテルポリオールである、方法。
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2017
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- 2017-09-14 EP EP23214243.0A patent/EP4328280A3/en active Pending
- 2017-09-14 CN CN201780048041.XA patent/CN110139756A/zh active Pending
- 2017-09-14 KR KR1020187033764A patent/KR102432050B1/ko active IP Right Grant
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