TRANSFER FILM, METHOD FOR PRODUCING A FILM-COATED ARTICLE AND FILM-COATED ARTICLE

Abstract

A transfer film, a method for producing a film-coated article and a film-coated article.

Claims

1. A transfer, comprising a carrier ply and a transfer ply, which contains at least one decorative element, arranged on the carrier ply, wherein the transfer ply, adjoining the carrier ply, has at least one upper layer, which is not yet completely cured at least in areas, wherein the at least one decorative element is arranged on the side of the at least one upper layer facing away from the carrier ply, and wherein the carrier ply is at least one carrier layer made of a polyester, a polyolefin or a combination thereof.

2. The transfer film according to claim 1, wherein the at least one upper layer not yet completely cured at least in areas has a thickness of from 0.5 m to 15 m.

3. The transfer film according to claim 1, wherein the at least one upper layer not yet completely cured at least in areas comprises or consists of at least one binder which is selected from the group which consists of polyurethane resins, polyurethane dispersions, acrylic resins, methacrylic resins, phenolic resins, epoxy resins, polyureas, melamine resins, aminoplasts, polyester resins, alkyd resins, polyamide resins, vinyl ester resins and mixtures thereof.

4. The transfer film according to claim 1, wherein a first adhesion-promoter layer is arranged between the at least one upper layer not yet completely cured at least in areas and the at least one decorative element.

5. The transfer film according to claim 4, wherein the first adhesion-promoter layer comprises or consists of at least one acrylic resin.

6. The transfer film according to claim 1, wherein the at least one decorative element is arranged in at least one decorative layer, which comprises, in each case independently of one another, a UV-crosslinked varnish or a thermoplastically deformable layer and which is, in each case independently of one another, unpigmented or pigmented or dyed.

7. The transfer film according to claim 1, wherein the at least one decorative layer containing at least one decorative element is selected from the group which consists of transparent and/or colored varnish layers.

8. The transfer film according to claim 1, wherein the transfer film has at least one detachment layer with a layer thickness of from 0.1 nm to 50 nm, which is arranged between the carrier layer and the at least one upper layer.

9. The transfer film according to claim 1, wherein the transfer film has at least one varnish layer with a layer thickness of from 0.5 m to 10 m, which is arranged on the surface of the transfer ply facing away from the carrier ply.

10. The transfer film according to claim 9, wherein the at least one varnish layer comprises or consists of at least one adhesive which is selected from the group which consists of physically curing adhesives, chemically curing adhesives, pressure-sensitive adhesives or mixture thereof.

11. The transfer film according to claim 1, wherein the carrier ply is arranged on the at least one upper layer with an adhesiveness from a range of from 2 cN to 50 cN.

12. A method for producing a film-coated article using a transfer film according to claim 1, wherein the transfer film comprises a carrier ply and a transfer ply, which contains at least one decorative element, arranged on the carrier ply, wherein the method comprises the following steps: a) joining a substrate to at least one surface of the transfer ply facing away from the carrier ply, and b) removing the carrier ply from the transfer ply bonded to the substrate, c) applying at least one protective layer to a surface of the transfer ply lying opposite the substrate, wherein the transfer ply, adjoining the carrier ply, has at least one upper layer, which is not yet completely cured at least in areas, wherein the at least one decorative element is arranged on the side of the at least one upper layer of the transfer ply facing away from the carrier ply, and wherein the application of the at least one protective layer to the at least one upper layer of the transfer ply in step c) is effected by at least partial flooding and/or dousing of the at least one upper layer with at least one solvent-containing, polyurethane-containing composition and subsequent curing.

13. The method according to claim 12, wherein the at least one solvent-containing, polyurethane-containing composition is selected from the group which consists of polyurethane-containing dispersions, polyurethane-containing resins, polyurethane solutions, compositions comprising polyurethane precursors (2C PUR systems) and mixtures thereof.

14. The method according to claim 12, wherein the application of the at least one protective layer to the at least one upper layer in step c) is effected by open flooding, flooding in a casting die or flooding in a 2C die.

15. The method according to claim 12, wherein before and/or during and/or after the application of the at least one protective layer in step c), the at least one protective layer is modified and/or structured.

16. The method according to claim 12, wherein in step a) the joining of a substrate to at least one surface of the transfer ply of the transfer film facing away from the carrier ply is effected by adhesive bonding, hot stamping, lamination or combinations thereof onto at least one surface of a substrate which is selected from the group which of paper, plastic, wood, composite, glass, metal and combinations thereof.

17. The method according to claim 12, wherein in step a), during the joining of a substrate to at least one surface of the transfer ply of the transfer film facing away from the carrier ply, the surface of the transfer ply facing away is at least partially covered with at least one plastic injection-molding composition, wherein the transfer film is arranged in at least one injection mold and the at least one injection mold is filled with at least one plastic injection-molding composition, wherein the plastic injection-molding composition comprises a thermoplastic, a thermosetting plastic or a mixture thereof.

18. A film-coated article, comprising a substrate and at least one transfer ply, which contains at least one decorative element, at least partially arranged on at least one surface of the substrate, wherein the side of the transfer ply facing away from the substrate is formed by at least one upper layer, on which at least one protective layer, which comprises at least one plastic based on a polyurethane, with a thickness from a range of from 0.2 mm to 5 mm is arranged, wherein the at least one protective layer adheres to the at least one upper layer with an adhesiveness, determined according to the method described in DIN EN ISO 4624: 2016-08, from a range of from 2.5 MPa to 5 MPa.

19. The film-coated article according to claim 18, wherein the substrate is selected from the group which consists of paper, plastic, wood, composite, glass, metal and combinations thereof.

20. The transfer film according to claim 8, wherein the at least one detachment layer comprises or consists of at least one wax.

21. The transfer film according to claim 11, wherein the carrier ply is arranged on the at least one upper layer with an adhesiveness from a range of from 5 cN to 35 cN.

22. The method according to claim 12, wherein the subsequent curing is carried out at a temperature of from 25 C. to 180 C.

23. The method according to claim 15, wherein the at least one protective layer is modified and/or stretched by placing particles in/on the at least one upper layer after step b) and/or through the use of die structures during the application in step c) and/or through subsequent lasering, overprinting and/or overstamping of the at least one protective layer.

24. The film-coated article according to claim 18, wherein the at least one protective layer adheres to the at least one upper layer with an adhesiveness from 2.5 MPa to 10 MPa.

Description

[0206] In the following the invention is explained with reference to several embodiment examples utilizing the attached drawings by way of example. There are shown in:

[0207] FIG. 1 shows a schematic representation of a transfer film

[0208] FIG. 2 shows a schematic representation of a transfer film

[0209] FIG. 3 shows a schematic representation of a transfer film

[0210] FIG. 4 shows a schematic representation of a transfer film

[0211] FIG. 5 shows a schematic representation of a film-coated item.

[0212] FIG. 6 shows a schematic representation of a film-coated item.

[0213] FIG. 7 shows a schematic representation of a film-coated item.

[0214] FIG. 8 shows a schematic representation of a film-coated item.

[0215] The abbreviation wt.-% used in the present patent application denotes the specification of content percent by weight.

[0216] A transfer film 1 according to the invention comprises a carrier ply 10, 10 and a transfer ply 13, 13, 13, which contains at least one decorative element, arranged on the carrier ply 10, 10, wherein the transfer ply 13, 13, 13, adjoining the carrier ply 10, 10, has at least one upper layer 15, which is not yet completely cured at least in areas, wherein the at least one decorative element is arranged on the side of the at least one upper layer 15 facing away from the carrier ply 10, 10, and wherein the carrier ply 10, 10 is at least one carrier layer 11 made of a polyester, a polyolefin or a combination thereof, in particular made of PET, preferably with a layer thickness of from 10 m to 75 m, further preferably from 20 m to 40 m.

[0217] Preferably, the at least one upper layer 15 not yet completely cured at least in areas has a thickness of from 0.5 m to 15 m, preferably from 1 m to 12 m.

[0218] Preferably, the at least one decorative element is arranged in at least one decorative layer 14, which comprises, in each case independently of one another, a UV-crosslinked varnish or a thermoplastically deformable layer and which is, in each case independently of one another, unpigmented or pigmented or dyed.

[0219] Further preferably, the layer thickness of the at least one decorative layer 14 is, in each case independently of one another, from 0.1 m to 15 m, further preferably from 4 to 8 m.

[0220] In the preferred embodiment of a transfer film 1 according to the invention represented in FIG. 1, the at least one decorative element is arranged in at least one decorative layer 14. The at least one decorative layer 14 is arranged on the side of the at least one upper layer 15 of the transfer ply 13 facing away from the carrier ply 10, 10.

[0221] The at least one decorative layer 14 can comprise one or more layers which are arranged over the whole surface or partially in the one transfer ply 13, 13, 13 and which are preferably selected from: transparent and/or colored varnish layer, in particular comprising one or more dyes and/or pigments, replication layer with a molded optically active surface structure, reflective layer, in particular opaque reflective layer, transparent reflective layer, metallic reflective layer or dielectric reflective layer, optically variable layer, adhesion-promoter layer, adhesive layer, hot-melt adhesive layer, heat-sealing adhesive layer, cold adhesive layer, interference multilayer system, volume hologram layer, liquid crystal layer, in particular cholesteric liquid crystal layer, electrically conductive layer, antenna layer, electrode layer, magnetic layer, magnetic storage layer, barrier layer, and/or combinations of two or more of the above layers.

[0222] For example, at least one varnish layer 16 with a layer thickness of from preferably 0.5 m to 10 m, further preferably from 1 m to 5 m, can be arranged on the surface of the transfer ply 13, 13, 13 facing away from the carrier ply 10, 10.

[0223] In the preferred embodiment of a transfer film 1 according to the invention represented in FIG. 2, at least one varnish layer 16 is arranged on the surface of the transfer ply 13 facing away from the carrier ply 10.

[0224] In the preferred embodiment represented in FIG. 2, the at least one decorative layer 14 is arranged between the at least one upper layer 15 of the transfer ply 13 and the at least one varnish layer 16.

[0225] Preferably, the at least one varnish layer 16 comprises or consists of at least one adhesive which is selected from the group which consists of physically curing adhesives, chemically curing adhesives, pressure-sensitive adhesives or mixture thereof.

[0226] Preferably, a first adhesion-promoter layer 17, which preferably has a layer thickness of from 0.1 m to 10 m, further preferably from 1 m to 4 m, can be arranged between the at least one upper layer 15 not yet completely cured at least in areas and the at least one decorative layer 14.

[0227] Preferably, the first adhesion-promoter layer 17 comprises or consists of at least one acrylic resin.

[0228] In the preferred embodiment of a transfer film 1 according to the invention represented in FIG. 3, a first adhesion-promoter layer 17 is arranged between the at least one upper layer 15 not yet completely cured at least in areas and the at least one decorative layer 14, wherein furthermore at least one varnish layer 16 can be arranged on the surface of the transfer ply 13 facing away from the carrier ply 10.

[0229] Preferably, the transfer film 1 can have at least one detachment layer 12, preferably with a layer thickness of from 0.1 nm to 50 nm, further preferably from 1 nm to 20 nm, which is arranged between the carrier layer 11 and the at least one upper layer (15).

[0230] Further preferably, the at least one detachment layer 12 comprises or consists of at least one wax.

[0231] In the preferred embodiment of a transfer film 1 according to the invention represented in FIG. 4, the carrier ply 10 is formed by at least one carrier layer 11 and at least one detachment layer 12 arranged thereon. The transfer ply 13 arranged on the carrier ply 10 is preferably formed by at least one upper layer 15 arranged on the detachment layer 12 and at least one decorative layer 14 arranged thereon.

[0232] Preferably, the carrier ply 10, 10 is arranged on the at least one upper layer 15 with an adhesiveness, preferably determined with a Z006 measuring instrument from Zwick, from a range of from 2 cN to 50 cN, preferably from a range of from 5 cN to 35 cN.

[0233] During the measurement of the adhesiveness of the carrier ply 10, 10 to the at least one upper layer 15 with a Z006 measuring instrument from Zwick, in a first step a coated test piece is preferably produced by strongly adhesive application of a transfer film in a width of 3.5 cm to a plastic plate by means of hot stamping.

[0234] During the measurement, in a second step the carrier ply is preferably peeled off the test piece vertically over a length of 100 mm. The required forces in the area of the length of from 10 mm to 90 mm of the applied carrier film are preferably measured with a Z006 measuring instrument from Zwick GmbH & Co. KG (Ulm, DE).

[0235] To measure the adhesiveness, the above-named Z006 measuring instrument is preferably combined with a horizontal substrate receiver. The substrate receiver has a movable slide, to which a test substrate is attached. The transfer film 1 is applied to the test substrate, in particular by means of hot stamping. The carrier ply 10, 10 of the applied transfer film 1 is preferably deflected from the horizontal into the vertical by means of a deflection roller and attached to the above-named measuring instrument. During the measurement and of the force of the measuring instrument acting vertically as uniformly as possible on the carrier ply 10, 10, the slide with the test substrate is moved or pulled correspondingly such that it is possible to peel the carrier ply 10, 10 off the transfer ply 13, 13, 13 applied to the test substrate.

[0236] A film-coated article 2 according to the invention, produced by a method according to one of claims 12 to 17 using a transfer film 1 according to one of claims 1 to 11, comprises a substrate S and at least one transfer ply 13, 13, 13, which contains at least one decorative element, at least partially arranged on at least one surface of the substrate S, wherein the side of the transfer ply 13, 13, 13 facing away from the substrate S is formed by at least one, preferably cured, upper layer 15, on which at least one protective layer 20, which comprises at least one plastic based on a polyurethane, with a thickness from a range of from 0.2 mm to 5 mm is arranged, wherein the at least one protective layer 20 adheres to the at least one upper layer 15 with an adhesiveness, determined according to the method described in DIN EN ISO 4624: 2016-08, preferably with a PosiTest AT Series pull-off adhesion tester from DeFelsko Corporation (Ogdensburg, N.Y., USA) using a 20 mm dolly, from a range of from 2.5 MPa to 5 MPa, in particular from 2.5 MPa to 10 MPa.

[0237] The adhesiveness can be determined according to the methods described in DIN EN ISO 4624: 2016-08 (BeschichtungsstoffeAbreiversuch zur Bestimmung der Haftfestigkeit, issue date: 2016-08 [Paints and varnishesPull-off test for adhesion]) and DIN EN ISO 16276-1: 2007-08 (Korrosionsschutz von Stahlbauten durch BeschichtungssystemeBeurteilung der Adhasion/Kohasion (Haftfestigkeit) einer Beschichtung and Kriterien fr deren AnnahmeTeil 1: AbreiBversuch, issue date: 2007-08 [Corrosion protection of steel structures by protective paint systemsAssessment of, and acceptance criteria for, the adhesion/cohesion (fracture strength) of a coatingPart 1: Pull-off testing]), for example through the use of a PosiTest AT adhesion tester from DeFelsko Corporation (Ogdensburg, N.Y., USA), which, by means of hydraulic pressure, preferably measures the force which is required to detach a specified test area of a coating from the substrate.

[0238] Preferably, the substrate S is selected from the group which consists of paper, plastic, wood, composite, glass, metal and combinations thereof.

[0239] In the preferred embodiment of a film-coated article 2 according to the invention represented in FIG. 5, the transfer ply 13 has a cured upper layer 15 and at least one decorative layer 14, which is partially arranged on at least one surface of the substrate S, wherein the side of the transfer ply 13 facing away from the substrate S is formed by at least one, preferably cured, upper layer 15, on which at least one protective layer 20, which comprises at least one plastic based on a polyurethane, with a thickness from a range of from 0.2 mm to 5 mm is arranged.

[0240] The protective layer 20 is furthermore likewise arranged on the substrate S.

[0241] The transfer ply 13 has been joined to a plastic-containing substrate S by partial hot stamping of a transfer film 1 represented in FIG. 1 or FIG. 4, wherein, after the joining, the respective carrier ply 10 or 10 has been removed from the transfer ply 13 arranged on the substrate S.

[0242] The application of the at least one protective layer 20 to the at least one upper layer 15 of the transfer ply 13 is then effected by flooding and/or dousing of the at least one upper layer 15 of the transfer ply 13 with at least one solvent-containing, preferably flowable, polyurethane-containing composition and subsequent curing, preferably at a temperature from a range of from 60 C. to 160 C.

[0243] In the preferred embodiment of a film-coated article 2 according to the invention represented in FIG. 6, the transfer ply 13 has a cured upper layer 15 and at least one decorative layer 14, which is arranged on at least one surface of the substrate S over the whole surface, wherein the side of the transfer ply 13 facing away from the substrate S is formed by at least one, preferably cured, upper layer 15, on which at least one protective layer 20, which comprises at least one plastic based on a polyurethane, with a thickness from a range of from 0.2 mm to 5 mm is arranged.

[0244] The protective layer 20 is arranged only on transfer ply 13.

[0245] The transfer ply 13 has been joined to a plastic-containing substrate S by hot stamping over the whole surface of a transfer film 1 represented in FIG. 1 or FIG. 4, wherein, after the joining, the respective carrier ply 10 or 10 has been removed from the transfer ply 13 arranged on the substrate S.

[0246] The application of the at least one protective layer 20 to the at least one upper layer 15 of the transfer ply 13 is then effected by flooding and/or dousing of the at least one upper layer 15 of the transfer ply 13 with at least one solvent-containing, preferably flowable, polyurethane-containing composition and subsequent curing, preferably at a temperature from a range of from 60 C. to 160 C.

[0247] In the preferred embodiment of a film-coated article 2 according to the invention represented in FIG. 7, the transfer ply 13 has at least one cured upper layer 15 and at least one decorative layer 14, which is arranged on at least one surface of the substrate S over the whole surface, wherein the side of the transfer ply 13 facing away from the substrate S is formed by at least one, preferably cured, upper layer 15, on which at least one protective layer 20, which comprises at least one plastic based on a polyurethane, with a thickness from a range of from 0.2 mm to 5 mm is arranged.

[0248] The upper layer 15 has a thickness of from 0.5 m to 15 m, preferably from 1 m to 12 m.

[0249] The joining of the substrate S to at least one surface of the transfer ply 13 of the transfer film facing away from the carrier ply was effected by covering the whole surface, formed by decorative layer 14, of the transfer ply 13 of the transfer film 1 represented in FIG. 1 or FIG. 4 with at least one plastic injection-molding composition, which comprises a thermoplastic, a thermosetting plastic or a mixture thereof.

[0250] After the joining, the respective carrier ply 10 or 10 has been removed from the transfer ply 13 arranged on the substrate S.

[0251] The application of the at least one protective layer 20 to the at least one upper layer 15 of the transfer ply 13 is then effected by flooding and/or dousing of the at least one upper layer 15 of the transfer ply 13 with at least one solvent-containing, preferably flowable, polyurethane-containing composition and subsequent curing, preferably at a temperature from a range of from 60 C. to 160 C.

[0252] In the preferred embodiment of a film-coated article 2 according to the invention represented in FIG. 8, the transfer ply 13 has at least one cured upper layer 15, at least one decorative layer 14 and at least one varnish layer 16, which is arranged on at least one surface of the substrate S over the whole surface, wherein the side of the transfer ply 13 facing away from the substrate S is formed by at least one, preferably cured, upper layer 15, on which at least one protective layer 20, which comprises at least one plastic based on a polyurethane, with a thickness from a range of from 0.2 mm to 5 mm is arranged.

[0253] The upper layer 15 has a thickness of from 0.5 m to 15 m, preferably from 1 m to 12 m.

[0254] The joining of the substrate S to at least one surface of the transfer ply 13 of the transfer film 1 facing away from the carrier ply was effected by laminating the surface, formed by varnish layer 16, of the transfer ply 13 of the transfer film 1 represented in FIG. 2 onto at least one surface of a substrate S over the whole surface.

[0255] The application of the at least one protective layer 20 to the at least one upper layer 15 of the transfer ply 13 is then effected by flooding and/or dousing of the at least one upper layer 15 of the transfer ply 13 with at least one solvent-containing, preferably flowable, polyurethane-containing composition and subsequent curing, preferably at a temperature from a range of from 60 C. to 160 C.

[0256] The preferred embodiment of a film-coated article 2 according to the invention represented in FIG. 8 has an undercut.

[0257] With the method according to the invention, decorative undercuts can be coated in a simple manner with at least one decoration and subsequently in a simple manner with at least one protective layer.

[0258] To produce upper layer 15 of the transfer films 1 represented in FIG. 1 to FIG. 4 the following resin composition can be used, for example: 20 wt.-% to 90 wt.-% of at least one binder, for example polyurethane,

5 wt.-% to 25 wt.-% of at least one co-binder, for example acrylate copolymer,
1 wt.-% to 10 wt.-% of at least one of the above-named crosslinkers,
0 wt.-% to 10 wt.-% of at least one filler, for example aerosil,
0 wt.-% to 10 wt.-% of at least one of the above-named additives,
10 wt.-% to 50 wt.-% of at least one solvent, for example water, in each case relative to the total weight of the resin composition.

LIST OF REFERENCE NUMBERS

[0259] 1 transfer film [0260] 2 film-coated article [0261] S substrate [0262] 10, 10 carrier ply [0263] 11 carrier layer [0264] 12 detachment layer [0265] 13, 13, 13 transfer ply [0266] 14 decorative layer [0267] 15 upper layer [0268] 16 varnish layer [0269] 17 first adhesion-promoter layer [0270] 20 protective layer