阅读说明：本技术 成型用叠层体 (Laminate for molding ) 是由 福永泰隆 挂谷文彰 于 2019-08-05 设计创作，主要内容包括：本发明提供一种硬涂层的固化后的性状和、成型性优异、并且能够在未固化状态下将硬涂层的表面维持在良好状态的成型用叠层体。上述课题可以通过如下的成型用叠层体解决,其包括硬涂层和贴合在硬涂层表面的遮蔽膜,该遮蔽膜的作为硬涂层侧表面的粘合面基于OWRK法测定的表面自由能的值在贴合前为30.0(mN/m)以上,硬涂层具有固化性。(The invention provides a laminate for molding, which has excellent properties and moldability after curing of a hard coat layer and can maintain the surface of the hard coat layer in a good state in an uncured state. The above object can be achieved by a laminate for molding comprising a hard coat layer and a masking film bonded to the surface of the hard coat layer, wherein the value of the surface free energy of the adhesive surface of the masking film, which is the surface on the side of the hard coat layer, as measured by the OWRK method is 30.0(mN/m) or more before bonding, and the hard coat layer has curability.)

1. A laminate for molding, characterized in that:

comprises a hard coating and a shielding film attached to the surface of the hard coating,

a value of surface free energy of a pressure-sensitive adhesive surface of the masking film, which is a surface on the hard coat layer side, before the lamination is 30.0mN/m or more, the value of the surface free energy being calculated from values of an average contact angle of water and an average contact angle of diiodomethane based on an OWRK method,

the hard coat layer has curability.

2. The laminate for molding as set forth in claim 1, wherein:

the masking film comprises polyethylene.

3. The laminate for molding as set forth in claim 1 or 2, wherein:

the surface roughness Sa of the adhesive surface of the masking film is 0.1 [ mu ] m or less.

4. The laminate for molding as set forth in any one of claims 1 to 3, wherein:

the hard coating comprises inorganic oxide nanoparticles.

5. The laminate for molding as set forth in claim 4, wherein:

the inorganic oxide nanoparticles comprise silica having a copolymerizable group on the surface.

6. The laminate for molding as set forth in claim 5, wherein:

the average particle size of the silicon dioxide is 5-500 nm.

7. The laminate for molding as set forth in any one of claims 1 to 6, wherein:

the hard coat layer includes a (meth) acryl polymer.

8. The laminate for molding as set forth in any one of claims 1 to 7, wherein:

the hard coat layer contains a leveling agent.

9. The laminate for molding as set forth in claim 8, wherein:

the leveling agent further includes a fluorine-based additive or a silicone-based additive.

10. The laminate for molding as set forth in any one of claims 1 to 9, wherein:

the hard coat layer has energy ray curability.

11. The laminate for molding as set forth in any one of claims 1 to 10, wherein: the hard coat layer further includes a photopolymerization initiator.

12. The laminate for molding as set forth in any one of claims 1 to 11, wherein: and a base material layer laminated on a surface of the hard coat layer opposite to a masking film side adhesive surface to which the adhesive surface of the masking film is bonded.

13. A curable hard coat layer for forming a laminate for molding by bonding a masking film to a surface of the curable hard coat layer, the hard coat layer comprising:

a (meth) acryl polymer and inorganic oxide nanoparticles.

Technical Field

The present invention relates to a laminate for molding, and more particularly to a laminate for molding obtained by laminating a curable hard coat layer and a masking film.

Background

Resin film laminates having a hard coat layer have been used in various fields (see patent document 1). For example, such a laminate of resin films is used for a front panel, a back panel, an automotive interior material, and the like of a mobile device.

Documents of the prior art

Patent document

Patent document 1: japanese Kohyo publication 2017-508828

Disclosure of Invention

Technical problem to be solved by the invention

A hard coat layer for protecting the surface of a laminate of resin films needs to have hardness of a certain degree or more and high scratch resistance, while good moldability is required for producing a resin film laminate having a desired shape. Further, since the surface of the uncured hard coat layer is soft, it is necessary to maintain the surface in a smooth and good state. Moreover, it is difficult to make the hard coat layer satisfy these different properties at the same time.

Accordingly, an object of the present invention is to provide a laminate for molding which is excellent in properties after curing and moldability of a hard coat layer and can maintain a surface of the hard coat layer in a good state in an uncured state.

Technical solution for solving technical problem

The present inventors have found that a laminate for molding comprising a curable hard coat layer and a predetermined masking film bonded to the surface of the hard coat layer has excellent characteristics capable of solving the above problems, and have completed the present invention.

Namely, the present invention is as follows.

(1) A laminate for molding comprising a hard coat layer and a masking film bonded to the surface of the hard coat layer,

the value of the surface free energy of the adhesive surface of the masking film, which is the surface on the hard coat layer side, is 30.0(mN/m) or more before the lamination, the value of the surface free energy being calculated from the values of the average contact angle of water and the average contact angle of diiodomethane based on the OWRK method,

the hard coat layer has curability.

(2) The laminate for molding of (1), wherein the shielding film comprises polyethylene.

(3) The laminate for molding according to (1) or (2), wherein the masking film has a surface roughness Sa of 0.1 μm or less on the adhesive surface.

(4) The laminate for molding as described in any one of (1) to (3), wherein the hard coat layer contains inorganic oxide nanoparticles.

(5) The laminate for molding according to (4), wherein the inorganic oxide nanoparticles comprise silica having a copolymerizable group on the surface.

(6) The laminate for molding as described in (5), wherein the silica has an average particle diameter of 5 to 500 nm.

(7) The laminate for molding use according to any one of (1) to (6), wherein the hard coat layer contains a (meth) acryl polymer.

(8) The laminate for molding as described in any one of (1) to (7), wherein the hard coat layer contains a leveling agent.

(9) The laminate for molding as described in (8), wherein the leveling agent further contains a fluorine-based additive or a silicone-based additive.

(10) The laminate for molding use according to any one of (1) to (9), wherein the hard coat layer has energy ray curability.

(11) The laminate for molding use according to any one of (1) to (10), wherein the hard coat layer further contains a photopolymerization initiator.

(12) The laminate for molding use according to any one of (1) to (11),

and a base material layer laminated on a surface of the hard coat layer opposite to the masking film side adhesive surface, wherein the masking film side adhesive surface is adhered to the adhesive surface of the masking film.

(13) A curable hard coat layer for forming a laminate for molding by bonding a masking film to the surface of the curable hard coat layer, wherein the hard coat layer comprises a (meth) acryloyl polymer and inorganic oxide nanoparticles.

ADVANTAGEOUS EFFECTS OF INVENTION

The laminate for molding of the present invention contains a predetermined hard coat layer and a masking film bonded to the surface of the hard coat layer as described above. The laminate for molding has excellent properties and moldability of the hard coat layer after curing, and is characterized in that the surface of the hard coat layer is maintained in a good state in an uncured state.

The hard coat composition of the present invention is particularly suitable as a material for a resin film laminate used for applications such as mobile devices and automobile interior materials because of its excellent characteristics.

Drawings

Fig. 1 is a sectional view showing a specific example of a laminate for molding including a masking film and a hard coat layer.

Fig. 2 is a graph showing the surface shapes of the masking films of example 1 and comparative example 2 after 1 day from the attachment of the hard coat layer based on the processing data.

Fig. 3 is a view showing image data of an interface (surface on the hard coat layer side) between the hard coat layer and the masking film adhesive layer in a state where the masking films of example 1 and comparative example 1 are respectively attached to the hard coat surface.

Detailed Description

The present invention will be described in detail below. However, the present invention is not limited to the following embodiments, and can be implemented by being arbitrarily modified within the scope of the effect of the invention.

[ Molding laminate ]

The laminate for molding of the present invention comprises a curable hard coat layer and a masking film bonded to the surface of the hard coat layer. As described in detail later, the masking film has a high surface free energy of the adhesive surface to be bonded to the hard coat layer and has excellent wettability. In the molding laminate obtained by laminating such a masking film on a hard coat layer, even when the masking film is peeled off and removed thereafter, fine irregularities are not generated on the surface of the adhesive surface on the masking film side of the hard coat layer, and a smooth state can be maintained.

[ masking film ]

In the masking film, the surface in contact with the hard coat layer is an adhesive surface having a moderate adhesive force, and is bonded to the surface of the hard coat layer. The masking film may be a single layer of only an adhesive layer, but preferably has a 2-layer structure including a base material and an adhesive layer. The masking film having a 2-layer structure is laminated on the hard coat layer such that the adhesive surface of the adhesive layer is in contact with the hard coat layer. The masking film may have a multilayer structure further including a layer other than the base material and the adhesive layer. The masking film may have a single-layer structure, and the masking film having a single-layer structure may have an appropriate adhesive force on the adhesive surface, which is the hard-coat layer side surface.

The base material of the masking film is preferably molded from a thermoplastic resin, and more preferably contains a polyolefin resin. As the polyolefin resin contained in the masking film, for example, polyethylene, polypropylene, or the like can be used, and it may be a homopolymer or a copolymer. Among the polyolefin resins, polyethylene is preferred.

As the polyethylene, Low Density Polyethylene (LDPE), Linear Low Density Polyethylene (LLDPE), Very Low Density Polyethylene (VLDPE), Medium Density Polyethylene (MDPE), High Density Polyethylene (HDPE), and the like can be used, but low density polyethylene is preferable.

In addition, as the polyolefin copolymer, a copolymer of ethylene or propylene and a monomer copolymerizable therewith can be used. Examples of the monomer copolymerizable with ethylene or propylene include α -olefins, styrenes, dienes, cyclic compounds, and compounds containing an oxygen atom.

Examples of the α -olefin include 1-butene, 3-methyl-1-pentene, 4-methyl-1-pentene, 1-hexene, 1-heptene, 1-octene, 1-decene, 1-tetradecene, 1-hexadecene, 1-octadecene, and 1-eicosene. Examples of the styrene include styrene, 4-methylstyrene, and 4-dimethylaminostyrene. Examples of the diene include 1, 3-butadiene, 1, 5-hexadiene, 1, 4-hexadiene, and 1, 7-octadiene. Examples of the cyclic compound include norbornene and cyclopentene. Examples of the compound containing an oxygen atom include hexenol, hexenoic acid, and methyl octenoate. These copolymerizable monomers may be used alone or in combination of 2 or more. In addition, a copolymer of ethylene and propylene is also possible.

The copolymer may be any of alternating copolymerization, random copolymerization, and block copolymerization.

The polyolefin resin contained in the base material of the masking film may contain a modified polyolefin resin modified with a small amount of a carboxyl group-containing monomer such as acrylic acid, maleic acid, methacrylic acid, maleic anhydride, fumaric acid, itaconic acid, or the like. The modification can generally be carried out by copolymerization or graft modification.

The base material of the masking film preferably contains 80% by weight or more of a polyolefin resin based on the entire weight of the base material, more preferably 90% by weight or more of a polyolefin resin, and still more preferably 95% by weight or more of a polyolefin resin.

The adhesive layer of the masking film is preferably molded from an elastomer or a thermoplastic resin. Examples of the thermoplastic resin contained in the adhesive layer include polyolefin resins such as polypropylene and modified polyolefin. As the polyolefin resin contained in the masking film, for example, polyethylene, polypropylene, or the like can be used, and it may be a homopolymer or a copolymer. Among the polyolefin resins, polyethylene is preferred.

The adhesive layer of the masking film preferably contains 80 wt% or more of an elastomer or a thermoplastic resin, more preferably 90 wt% or more of an elastomer or a thermoplastic resin, and still more preferably 95 wt% or more of an elastomer or a thermoplastic resin, based on the entire weight of the adhesive layer.

The adhesive surface of the masking film, i.e., the adhesive surface contacting the surface of the hard coat layer, is adhered to the hard coat layer before the hard coat layer is adhered to the adhesive surfaceHas a surface free energy of 30.0(mN/m) or more. The value of the surface free energy can be determined by measuring the average contact angle of 1. mu.l of water and 1. mu.l of diiodomethane (CH) on the above adhesive surface based on the theta/2 method₂I₂) And from these average contact angle values, are calculated based on the OWRK method (Owens-Wendt-Rabel-Kaelble method). The value of the surface free energy of the adhesive surface is preferably 31.0(mN/m) or more.

The value of the average contact angle of the masking film on the adhesive surface in contact with the surface of the hard coat layer is preferably 64 ° or less, more preferably 60 ° or less, and still more preferably 58 ° or less, when the masking film is left to stand for 1 μ l of diiodomethane.

As described above, the masking film having the adhesive surface with a high surface free energy or a small contact angle of the static diiodomethane droplet is said to have high wettability. When the surface of the hard coat layer, which will be described in detail later, is coated with a masking film having high wettability, the surface of the hard coat layer can be easily maintained smooth without generating fine irregularities.

In addition, since the surface of the hard coat layer can be reliably protected even in an uncured soft state by such a masking film, the formability of the hard coat layer is easily improved.

In the masking film, the value of the surface roughness Sa of the adhesive surface that comes into contact with the hard coat layer in a state before the masking film is attached to the hard coat layer (not attached) is preferably 0.100 μm or less (ISO 25178). The value of the surface roughness Sa in the non-stuck state of the pressure-sensitive adhesive surface of the masking film is more preferably 0.090 μm or less, still more preferably 0.080 μm or less, and particularly preferably 0.070 μm or less.

The value of the adhesive force of the adhesive surface of the masking film is preferably 5(mN/25mm) or more and 5000(mN/25mm) or less, more preferably 9(mN/25mm) or more and 3000(mN/25mm) or less, with respect to the surface of the PMMA (polymethyl methacrylate resin layer).

In the laminate for molding, the thickness of the shielding film is preferably 10 to 100 μm, more preferably 20 to 80 μm.

[ hard coating layer ]

The hard coat layer contained in the molding laminate is a laminate obtained by molding a hard coat composition into a layer, and has curability that can be cured by irradiation with an energy ray or the like. The hard coat layer (hard coat composition) preferably contains a (meth) acryl polymer and inorganic oxide nanoparticles. The hard coating composition is excellent in moldability and tack-free (tack-free) properties before curing, and when the masking film is peeled off from the laminate for molding and removed for curing, a hard coating layer constituting the outermost layer of the cured laminate can realize high hardness and excellent scratch resistance.

The hard coating composition preferably contains 20 to 80 wt% of the (meth) acryl polymer and 80 to 20 wt% of the inorganic oxide nanoparticles, based on the total weight of the hard coating composition. More preferably, the hard coating composition contains 30 to 70 wt% of the (meth) acryl polymer and 70 to 30 wt% of the inorganic oxide nanoparticles, and even more preferably contains 40 to 60 wt% of the (meth) acryl polymer and 60 to 40 wt% of the inorganic oxide nanoparticles.

The thickness of the hard coat layer is preferably 1.0 μm to 10 μm. The thickness of the hard coat layer is, for example, 2.0 to 8.0. mu.m, or 3.0 to 7.0. mu.m.

Further, after the masking film was attached to the hard coat layer formed of the (meth) acryl polymer described later, 30kg/m was applied from the masking film at a temperature of 23. + -. 2 ℃ and a relative humidity of 50. + -. 5%²The Sa value of the hard coat layer surface after peeling off the masking film after 24 hours is preferably 0.0300 μm or less, more preferably 0.0200 μm or less, and still more preferably 0.0150 μm or less.

As conditions for peeling the masking film from the surface of the hard coat layer, the peeling angle, that is, the angle between the masking film in a state of being peeled and the surface of the hard coat layer was 90 degrees, and the peeling speed was 600 mm/min.

< (meth) acryl Polymer

The (meth) acryl polymer has a (meth) acrylic acid equivalent of 200 to 500 g/eq. The (meth) acryl polymer preferably has a (meth) acrylic acid equivalent of 220 to 450g/eq, more preferably 250 to 400 g/eq.

The (meth) acryl polymer has a weight average molecular weight of 5,000 to 200,000. The weight average molecular weight of the (meth) acryl polymer is preferably 10,000 to 150,000, more preferably 15,000 to 100,000, and still more preferably 20,000 to 50,000.

The value of the weight average molecular weight can be measured based on the description of paragraphs 0061 to 0064 of Japanese patent application laid-open No. 2007-179018. Details of the assay are shown below.

[ Table 1]

Measurement conditions for weight average molecular weight

Device for measuring the position of a moving object	"Aliance" manufactured by WATERS corporation "
		Chromatographic column	Shodex K-805L (2 root)
Detector	UV detector: 254nm
		Eluent	Chloroform

That is, first, a calibration curve showing the relationship between the elution time and the molecular weight of polycarbonate was prepared by a general calibration method using polystyrene as a standard polymer. Then, the elution profile (chromatogram) of the polycarbonate was measured under the same conditions as in the case of the calibration curve described above. Further, the weight average molecular weight (Mw) was calculated from the elution time (molecular weight) of the polycarbonate and the peak area (number of molecules) of the elution time. The weight average molecular weight is represented by the following formula (a), wherein Ni represents the number of molecules having a molecular weight Mi.

Mw＝∑(NiMi²)/∑(NiMi)····(A)

In the present specification, (meth) acrylic acid means any of acrylic acid and methacrylic acid.

As described above, the hard coating composition containing the (meth) acryl polymer having the (meth) acrylic equivalent and the weight average molecular weight in the predetermined ranges has good non-tackiness before curing and scratch resistance after curing, and also enables easy progress of curing and polymerization reaction.

The (meth) acryl polymer contained in the hard coat composition preferably has a repeating unit represented by the following formula (I).

Wherein in the formula (I), m is an alkylene group having 1 to 4 carbon atoms or a single bond, n is an alkyl group having 1 to 4 carbon atoms or hydrogen, p is a single bond or an alkylene group having 1 or 2 carbon atoms, and q is an alkyl group having 1 to 12 total carbon atoms which may have at least one substituent selected from the group consisting of an epoxy group, a hydroxyl group, an acryloyl group and a methacryloyl group or hydrogen.

The (meth) acryl polymer more preferably contains a repeating unit wherein m is an alkylene group having 1 or 2 carbon atoms, n is an alkyl group having 1 or 2 carbon atoms, p is a single bond or a methylene group, and q is an alkyl group having 1 to 6 total carbon atoms which may contain at least one substituent selected from the group consisting of a glycidyl group, a hydroxyl group and an acryl group, or hydrogen in the formula (I).

For example, in the formula (I), m is a methylene group, n is a methyl group, p is a single bond, and q is a methyl group, an alkyl group having 5 or less carbon atoms and containing a glycidyl group (epoxy group), an alkyl group having 8 or less carbon atoms and containing a hydroxyl group and an acryloyl group, or the like.

Specific examples of the repeating unit contained in the (meth) acryloyl polymer include repeating units represented by the following formulae (II-a), (II-b), and (II-c).

In the (meth) acryl-based polymer, the content of the repeating unit of the formula (II-a) is preferably 30 to 85 mol%, more preferably 40 to 80 mol%, based on the total mole number of the repeating unit of the formula (II-a), the repeating unit of the formula (II-b), and the repeating unit of the formula (II-c). The content of the repeating unit of the formula (II-b) is preferably 5 to 30 mol%, more preferably 10 to 25 mol%, based on the total mole number. The content of the repeating unit of the formula (II-c) is preferably 10 to 40 mol%, more preferably 10 to 35 mol%, based on the total mol number.

The molar ratio of the recurring unit of the formula (II-a), the recurring unit of the formula (II-b), and the recurring unit of the formula (II-c) is preferably 4.5 to 5.5: 1.5 to 2.5: 2.5 to 3.5, for example, 5: 2: 3.

The (meth) acryl polymer may be added with a pentaerythritol-based polyfunctional acrylate compound. As the polyfunctional acrylate compound having a plurality of acrylate groups, preferably 3 or more acrylate groups, for example, pentaerythritol tetraacrylate and dipentaerythritol hexaacrylate represented by the following formulae (III-a) and (III-b), respectively, and pentaerythritol triacrylate and the like can be used.

The polyfunctional acrylate compound is contained in an amount of preferably 70% by weight or less, more preferably 50% by weight or less, based on the total weight of the polyfunctional acrylate compound and the (meth) acryloyl polymer. In this way, by adding the polyfunctional acrylate compound to the hard coating composition and reacting with the acryloyl group, glycidyl group (epoxy group) and hydroxyl group contained in the side chain of the (meth) acryloyl polymer, a hard coating film having higher scratch resistance can be formed.

< inorganic oxide nanoparticles >

As the inorganic oxide nanoparticles contained in the hard coating composition, silica particles, alumina particles and the like can be used, and among these, it is preferable that the inorganic oxide nanoparticles contain silica particles. Further, the inorganic oxide nanoparticles contained in the hard coat are preferably treated with a surface treatment agent. By the surface treatment, the inorganic oxide nanoparticles can be dispersed in a stable state in the hard coat composition, particularly in the (meth) acryl polymer component.

As the surface treatment agent used for the inorganic oxide nanoparticles, a compound having a substituent capable of binding to the surface of the inorganic oxide nanoparticles and a substituent highly compatible with the component of the hard coat composition in which the inorganic oxide nanoparticles are dispersed, particularly with the (meth) acryl polymer, is suitably used. For example, silane compounds, alcohols, amines, carboxylic acids, sulfonic acids, phosphonic acids, and the like are used as the surface treatment agent.

The inorganic oxide nanoparticles preferably have a copolymerizable group on the surface. The copolymerizable group can be introduced by surface treatment of the inorganic oxide nanoparticles, and specific examples of the copolymerizable group include a vinyl group, a meth (acrylic) acid group, a radical polymerizable group, and the like.

The average particle diameter of the inorganic oxide nanoparticles is preferably 5 to 500nm, more preferably 10 to 300nm, and still more preferably 20 to 100 nm. The average particle diameter of the inorganic oxide nanoparticles is measured by a particle diameter measurement method using a dynamic light scattering method, for example, Zetasizer Nano ZS manufactured by Malvern Panalytical corporation.

< other ingredients in the hardcoat composition >

In the hard coat composition, it is preferable to further contain a leveling agent in addition to the above (meth) acryl polymer and inorganic oxide nanoparticles. As the leveling agent, for example, a fluorine-based additive, a silicone-based additive, or the like can be used.

As the fluorine-containing additive, MEGAFAC RS-56, RS-75, RS-76-E, RS-76-NS, RS-78, RS-90, FTERGENT 710FL, 220P, 208G, 601AD, 602A, 650A, 228P, FTERGENT 240 GFTX-218 (all of which are oligomers containing a fluorine-containing UV reactive group) manufactured by DIC, and the like can be used, and among these, FTERGENT 601AD and the like are preferable as the fluorine-containing additive.

Further, BYK-UV 3500 and BYK-UV 3505 (both acrylic group-containing polyether-modified polydimethylsiloxanes) manufactured by BYK-Chemie can be used as the silicone additive, and among these, BYK-UV 3500 and the like are preferably used as the silicone additive.

The hard coating composition preferably contains the leveling agent in an amount of 0.1 to 10 wt% based on the total weight of the hard coating composition, and the content of the leveling agent in the hard coating composition is more preferably 0.5 to 7 wt%, and still more preferably 1 to 5 wt%.

The curable hard coat composition may be energy ray-curable or thermosetting, preferably energy ray-curable, and more preferably ultraviolet-curable. Therefore, the hard coat composition preferably further contains a photopolymerization initiator. As the photopolymerization initiator, IRGACURE 184 (1-hydroxy-cyclohexyl-phenyl-ketone), IRGACURE 1173 (2-hydroxy-2-methyl-1-phenyl-propane-1-one), IRGACURE TPO (2,4, 6-trimethylbenzoyl-diphenyl-phosphine oxide), IRGACURE 819 (bis (2,4, 6-trimethylbenzoyl) -phenyl phosphine oxide), esacure one (oligo (2-hydroxy-2-methyl-1- [ 4- (1-methylvinyl) phenyl ] acetone), etc. can be used, and among these, IRGACURE TPO and the like are preferable as the photopolymerization initiator from the viewpoint of heat resistance.

The hard coat composition contains, for example, a photopolymerization initiator in an amount of 1 to 6 wt% based on the total weight of the hard coat composition. The content of the photopolymerization initiator in the hard coat composition is more preferably 2 wt% or more and 5 wt% or less, and still more preferably 3 wt% or more and 4 wt% or less.

The hard coat composition may contain other additives, for example, at least 1 additive selected from the group consisting of a heat stabilizer, an antioxidant, a flame retardant aid, an ultraviolet absorber, a mold release agent and a colorant. An antistatic agent, a fluorescent whitening agent, an antifogging agent, a flow improver, a plasticizer, a dispersant, an antibacterial agent, and the like may be added to the hard coat composition without significantly impairing desired physical properties.

In the hardcoat composition, the (meth) acryl-based polymer and the inorganic oxide nanoparticles are contained preferably at 60 mass% or more, more preferably at 80 mass% or more, and particularly preferably at 90 mass% or more. Therefore, the content of the components other than the above-described main two components in the hard coating composition is preferably less than 40% by mass, more preferably less than 20% by mass, and particularly preferably less than 10% by mass.

< production of hard coating >

The hard coat layer is produced by blending material substances such as the above-mentioned (meth) acryl-based polymer and inorganic oxide nanoparticles. For example, the (meth) acryl polymer is produced by mixing the respective components such as the (meth) acryl polymer with a tumbler and melt-kneading the mixture with an extruder. The form of the hard coat composition is not limited to pellet form, and may be flake, powder or block form.

The hard coat layer is produced by processing the hard coat composition into a layer (sheet) by a conventional method. For example, extrusion molding or cast molding is used. Examples of extrusion molding include a method in which pellets, flakes, or powder of the hard coating composition are melted and kneaded by an extruder, extruded from a T die or the like, and the resulting semi-molten sheet is cooled and solidified while being nipped by a roll to form a sheet.

< Property of hard coating >

(i) Non-stick property

The hard coat layer of the present invention is excellent in non-tackiness. In the laminate for molding in which such a hard coat layer is coated with a masking film, the uncured hard coat layer can maintain a predetermined shape even when it comes into contact with another substance such as a hand of an operator, and can prevent a part of the hard coat layer from adhering to the surface of the contacted substance. A laminate for molding having such excellent characteristics can be easily processed by curing after being molded into a shape suitable for various applications. Further, the laminate for molding in a state before curing can be easily stored or distributed while maintaining a predetermined shape.

On the other hand, a laminate having a hard coat layer mainly composed of a resin composition having poor non-tackiness, for example, an oligomer having a low molecular weight, is likely to have poor moldability because a step of curing the laminate is required before molding the laminate into a shape suitable for various applications.

(ii) Gloss (appearance) after peeling off the masking layer

The hard coat layer is processed into a film in an uncured state, and when a masking film is laminated and then peeled off, the generation of unevenness on the film surface can be suppressed, and good gloss can be maintained. As described in detail later, in such an evaluation test, it was confirmed that the surface of the hard coat layer after peeling off the masking film was smooth and maintained good gloss.

(iii) Formability (air pressure formability)

The hard coat layer of the laminate for molding of the present invention is excellent in moldability in an uncured state. The formability of the hard coat composition is evaluated, for example, as follows. That is, when the laminate obtained after applying and drying the hard coat composition on the surface of the base material layer is heated in a state of being placed on a mold having a convex portion and subjected to air pressure formability, it can be evaluated whether or not the sheet-like hard coat composition can appropriately stretch following the convex portion, whether or not cracks are generated, or the like.

Although details are omitted, it is confirmed in such an evaluation test that the hard coat layer can follow the convex portion and be stretched without generating cracks in the air pressure formability.

(iv) Scratch resistance

When the hard coat layer is cured in a state where the masking film is removed, high scratch resistance can be achieved. As described in detail later, when the laminate for molding having the hard coat layer was cured, it was confirmed that the scratch resistance of the surface of the hard coat layer was more excellent than those of the cured PMMA resin (polymethyl methacrylate resin) and the resin for lens.

(v) Hardness of

The hard coat layer cured in a state where the masking film is removed has high hardness. Specifically, JIS K5600-5-4: 1999 evaluation method of pencil hardness of B or more. In the surface of the cured hard coat layer, pencil hardness of F or more, particularly 2H or more is more preferably achieved.

(vi) Adhesion Property

The cured hard coat composition also has excellent adhesion. Specifically, a hard coating composition having an evaluation result of 0 determined by the evaluation method of JIS K5600-5-6 was obtained.

< substrate layer >

The laminate for molding of the present invention preferably further comprises a base material layer in contact with the surface of the hard coat layer opposite to the shielding film. The base material layer is laminated on the surface of the hard coat layer opposite to the masking film side adhesive surface, and the masking film side adhesive surface is bonded to the adhesive surface of the masking film.

The substrate layer of the laminate for molding preferably contains a resin, and more preferably contains a thermoplastic resin. The type of the thermoplastic resin is not particularly limited, and various resins such as Polycarbonate (PC) resin, acrylic resin such as polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), triacetyl cellulose (TAC), polyethylene naphthalate (PEN), Polyimide (PI), cycloolefin copolymer (COC), norbornene-containing resin, polyethersulfone, cellophane (cellophane), and aromatic polyamide can be used. Among these options, the thermoplastic resin of the substrate layer preferably contains at least a polycarbonate resin.

The type of the polycarbonate resin contained in the base layer is not particularly limited as long as it is a resin containing a- [ O-R-OCO ] -unit (R is an aliphatic group, an aromatic group, or a group containing both an aliphatic group and an aromatic group, and further having a linear structure or a branched structure) containing a carbonate bond in the molecular main chain, and a polycarbonate having a bisphenol skeleton or the like is preferred, and a polycarbonate having a bisphenol a skeleton or a bisphenol C skeleton is particularly preferred. As the polycarbonate resin, a mixture or copolymer of bisphenol a and bisphenol C can also be used. By using a bisphenol C-based polycarbonate resin, for example, a polycarbonate resin of only bisphenol C, a polycarbonate resin of a mixture or copolymer of bisphenol C and bisphenol a, the hardness of the base layer can be increased.

The viscosity average molecular weight of the polycarbonate resin is preferably 15,000 to 40,000, more preferably 20,000 to 35,000, and still more preferably 22,500 to 25,000.

The acrylic resin contained in the base layer is not particularly limited, and examples thereof include a homopolymer of polymethyl methacrylate (PMMA), various (meth) acrylates typified by Methyl Methacrylate (MMA), and a copolymer of PMMA or MMA with 1 or more other monomers, and a mixture of a plurality of these resins may be mentioned. Among these, (meth) acrylates containing a cyclic alkyl structure, which are excellent in low birefringence, low hygroscopicity and heat resistance, are preferable. Examples of the (meth) acrylic resin include, but are not limited to, ACYPET (manufactured by Mitsubishi corporation), DELPET (manufactured by Asahi Kasei corporation), and PARAPET (manufactured by Cola corporation).

When a laminate in which the acrylic resin is laminated on the surface layer of a polycarbonate resin is used as a substrate, the hardness of the surface layer of the substrate layer is preferably increased.

The base material layer may contain an additive as a component other than the thermoplastic resin. For example, at least 1 additive selected from the group consisting of a heat stabilizer, an antioxidant, a flame retardant aid, an ultraviolet absorber, a mold release agent and a colorant, and the like. In addition, an antistatic agent, a fluorescent whitening agent, an antifogging agent, a flowability improver, a plasticizer, a dispersant, an antibacterial agent, and the like may be added to the base layer.

The base layer preferably contains 80 mass% or more, more preferably 90 mass% or more, and particularly preferably 95 mass% or more of a thermoplastic resin. The thermoplastic resin of the base layer preferably contains 80 mass% or more, more preferably 90 mass% or more, and particularly preferably 95 mass% or more of a polycarbonate resin.

The thickness of the base material layer is not particularly limited, and is preferably 0.1mm to 1.0 mm. The thickness of the substrate layer is, for example, 0.2mm to 0.8mm, or 0.3mm to 0.7 mm.

The laminate film is configured as shown in fig. 1, for example. In the laminate 10 for molding illustrated in fig. 1, the outermost masking film 12 is laminated on the hard coat layer 16. Therefore, the surface of the hard coat layer 16 on the side of the masking film 12 is protected by the masking film. The hard coat layer 16 is laminated on the surface on the PMMA layer side of the base material layer having the polymethyl methacrylate layer (PMMA resin layer) 20 and the polycarbonate layer (PC resin layer) 22.

< production of Molding laminate >

The laminate for molding including the base material layer was produced as follows. First, a material such as a resin composition is processed into a layer (sheet-like) by a conventional method to produce a base layer. For example, extrusion molding or cast molding is used. Examples of extrusion molding include a method in which pellets, flakes, or powder of a resin composition is melted and kneaded by an extruder, extruded from a T die or the like, and the resulting semi-molten sheet is cooled and solidified while being nipped by a roller to form a sheet.

Then, the coating composition produced as described above is applied to the outer surface of a single layer or a base material layer having a plurality of layers to form a hard coat layer.

The masking film is bonded to the surface of the laminate of the base layer and the hard coat layer on the hard coat layer side or the surface of the single hard coat layer to produce a laminate for molding.

The cured film can be obtained by removing the masking film from the laminate for molding and then curing the same. In this way, the molding laminate has a curable hard coat layer, and a cured film can be obtained by curing the hard coat layer of the molding laminate.

As is clear from the properties of the hard coat composition after curing, the surface of the cured film on the hard coat layer side has excellent properties. That is, on the surface of the cured film on the hard coat layer side, a high pencil hardness, preferably based on JISK 5600-5-4: 1999, pencil hardness of B or more, high scratch resistance, and excellent adhesion, for example, adhesion of class 0 as evaluated in JISK 5600-5-6 can be realized.

Examples

The present invention will be described in more detail with reference to the following examples. However, the present invention is not limited to the following examples, and can be implemented by arbitrarily changing the examples without departing from the spirit and scope of the present invention.

[ production of a laminate ]

First, nano-silica particles (organic silica sol MEK-AC-2140Z manufactured by Nissan chemical industries, Ltd.: average particle diameter: 10 to 15nm) were mixed with an ultraviolet-curable acryl polymer (ART CURE RA-3602 MI manufactured by Kokusan Kaisha) at a weight ratio of the acryl polymer to the nano-silica particles of 60: 40. Further, a photopolymerization initiator IRGACURE TPO (3 wt% based on the solid content) and a leveling agent BYK-UV 3500 (1 wt% based on the solid content) manufactured by BYK-Chemie were added to obtain a mixed solution.

MEK as a diluting solvent was added to the obtained mixed solution, and the coating composition prepared to have a solid content of 30 wt% was applied to the PMMA side of the PC/PMMA film as the base material layer.

In the coating step, the coated coating solution was dried at 120 ℃ for 5 minutes using a #16 wire bar. A hard coat layer of about 7 μm thickness was formed from the dried coating solution.

As a masking film having a base material and an adhesive layer shown in table 2 below, the following materials were prepared. Namely:

a laminate of a base material of PE (polyethylene) and an adhesive layer of modified PO (polyolefin) (example 1: PAC-3-50 THK manufactured by Sun A. Kaken Co., Ltd., thickness 50 μm);

a laminate of a base material of PET (polyethylene terephthalate) and an adhesive layer of PU (polyurethane) (example 2: PU4050 manufactured by Sun a. kaken co., ltd., thickness 50 μm);

a laminate of a PP (polypropylene) base material and an adhesive layer of PP (example 3: MX-107-N manufactured by JASMO Co., Ltd., thickness: 30 μm);

a laminate of a PP base material and an elastomer adhesive layer (comparative example 1: FUTAMURA CHEMICAL CO., FSA-050M manufactured by LTD., thickness 30 μ M); and

laminate of a PP (polypropylene) base material and a PE adhesive layer (comparative example 2: TORAY ADVANCED FILM CO., R033KS manufactured by LTD., thickness 45 μm).

For the surfaces of these masking film, hard coat layer and base material layer, 1. mu.l of water and 1. mu.l of diiodomethane (CH) were added₂I₂) The average contact angle of the liquid droplet(s) of (1) was measured by using a measuring instrument MSA of KRUSS, inc. Further, the surface free energy value was calculated from the values of the average contact angles by the OWRK method (Owens-Wendt-Rabel-Kaelble method). These results are shown in table 2 below.

Further, the masking films of the examples and comparative examples were bonded to the surface of the hard coat layer opposite to the substrate, and 30kg/m was applied from the masking film at a temperature of 23. + -. 2 ℃ and a relative humidity of 50. + -. 5%²For 24 hours, and the surface of the hard coat layer was observed after 1 week had elapsed. For surface observation, a white interference microscope (VS-1530, Hitachi technologies, Ltd.) and an optical microscope (ECLIPSE LV100ND, manufactured by Nikon Co., Ltd.) were used. The value of the surface roughness Sa (according to ISO 25178) was measured by a scanning white interference microscope VS1530 manufactured by hitachi height, ltd. In contrast to the examples in which no air was mixed into the space between the masking film and the hard coat layer during lamination, or the amount of air mixed into the space was small, the comparative examples showed significant air mixing. Therefore, it is considered that a difference occurs in the surface shape (appearance) of the hard coat layer after the masking film is peeled off.

That is, as shown in the following table 2 and fig. 2, the surface of the hard coat layer after peeling the masking film of the example was smooth without substantial unevenness and was excellent in gloss, whereas the surface of the hard coat layer after peeling the masking film of the comparative example was observed with fine unevenness and was poor in gloss. As shown in fig. 3, in the example, when the masking film was attached to the hard coat layer, the interface between the hard coat layer and the masking film adhesive layer was in close contact with each other, and high adhesion was achieved, whereas in the comparative example, a gap was observed between these layers.

[ Table 2]

Description of the symbols

10: a laminate for molding; 12: a masking film; 16: a hard coating layer; 20: a polymethyl methacrylate layer (PMMA resin layer); 22: polycarbonate layer (PC resin layer).