TRANSFER FOIL, METHOD FOR PRODUCING A TRANSFER FOIL AND METHOD FOR PRODUCING A PLASTIC ARTICLE DECORATED USING A TRANSFER FOIL

Abstract

A The invention relates to a transfer film (10), which has a carrier film (12) having a master structure varnish (18) and a transfer ply (14), arranged on the carrier film (12) and detachable from the carrier film (12), including a topcoat (16), wherein the master structure varnish (18) is arranged on the carrier film (12) on its side facing the transfer ply (14) and has a master structure and wherein a master structure is molded on the carrier film (12) on its side facing the transfer ply (14) and wherein the topcoat (16) includes a structuring which has a structure complementary to the master structure.

Claims

1. A transfer film, which has a carrier film comprising a master structure varnish and a transfer ply, arranged on the carrier film and detachable from the carrier film, comprising a topcoat; wherein the master structure varnish is arranged on the carrier film on its side facing the transfer ply and has a master structure and wherein the topcoat comprises a structuring which has a structure complementary to the master structure.

2. The transfer film according to claim 1, wherein the master structure varnish and/or the topcoat has a relief structure, at least in areas.

3. The transfer film according to claim 2, wherein the relief structure has a design and/or one or more of the following profile shapes: rectangular profiles, sinusoidal profiles, sawtooth profiles, hemispherical profiles or blazed structures.

4. The transfer film according to claim 2, wherein the relief structure is formed as or comprises a matte structure, a diffractive structure, a refractive structure and/or a macrostructure.

5. The transfer film according to claim 2, wherein the relief structure comprises a microstructure.

6. The transfer film according to claim 1, wherein the relief structure comprises a macrostructure.

7. The transfer film according to claim 1, wherein the carrier film has a carrier layer, wherein the carrier layer is arranged on the side of the carrier film facing away from the transfer ply.

8. The transfer film according to claim 7, wherein the carrier layer is formed from ABS, ABS/PC, PET, PC, PMMA, PE and/or PP and/or wherein the layer thickness of the carrier layer is selected from a range of from 5 ?m to 100 ?m.

9. The transfer film according to claim 1, wherein, the master structure varnish a structure depth from a range of from 0.2 ?m to 30 ?m.

10. The transfer film according to claim 1, wherein, the master structure varnish has components curable by UV radiation and/or a thermoplastic varnish.

11-13. (canceled)

14. The transfer film according to claim 1, wherein the topcoat is formed transparent and/or has, a transmittance of at least 25%.

15. The transfer film according to claim 1, wherein, the topcoat has a stretchability of at least 50%%.

16. The transfer film according to claim 1, wherein, the topcoat has a temperature resistance of up to 250? C.

17. The transfer film according to claim 1, wherein, a detachment layer is arranged between the topcoat and the master structure varnish and/or wherein the topcoat and/or the master structure varnish have additives which reduce the separating force which is necessary in order to detach the master structure varnish from the topcoat.

18. (canceled)

19. The transfer film according to claim 1, wherein, the transfer ply has a promoter layer, wherein the promoter layer is arranged on the side of the topcoat facing away from the carrier film.

20. The transfer film according to claim 1, wherein, a promoter layer, is arranged in the carrier film between the master structure varnish and the carrier layer.

21. The transfer film according to claim 19, wherein the promoter layer of the transfer ply has components selected individually or in combination from: crosslinkable acrylates, polyester resins, alkyd resins as well as their modifications, amino resins, amido resins, phenolic resins.

22. The transfer film according to claim 19, wherein the promoter layer of the transfer ply has a layer thickness in the range of from 0.1 ?m to 10 ?m.

23. The transfer film according to claim 1, wherein the transfer film, has at least one decorative layer, at least one metalization, at least one replication layer and/or at least one adhesive layer or primer layer.

24. The transfer film according to claim 1, wherein, the layers of the transfer ply arranged on the side of the topcoat facing away from the carrier film, the promoter layer, the at least one adhesive layer or primer layer, the at least one replication layer, the at least one metalization and/or the at least one color layer, have at least 80% of the stretchability of the topcoat.

25. A method for producing a transfer film, which has a carrier film comprising a master structure varnish and a transfer ply, arranged on the carrier film and detachable from the carrier film, comprising a topcoat, wherein a master structure, is introduced into or generated in the master structure varnish and wherein the topcoat is applied to the master structure, wherein a structure complementary to the master structure of the carrier film is molded into the topcoat.

26. The method according to claim 25, wherein the master structure varnish is applied to a carrier layer.

27. (canceled)

28. The method according to claim 25, wherein the master structure varnish is applied to the carrier layer over the whole surface or partially.

29. The method according to claim 25, wherein a further varnish is applied at least in areas to the carrier layer in areas where no master structure varnish is applied.

30. (canceled)

31. The method according to claim 25, wherein the master structure varnish is crosslinked and/or cured, during the production of the transfer film.

32. The method according to claim 25, wherein further layers, are applied to the topcoat and/or wherein a promoter layer is printed on the carrier layer.

33. The method according to claim 25, wherein at least one metalization is applied to the transfer ply.

34. The method according to claim 25, wherein the topcoat is crosslinked and/or cured, during the production of the transfer film.

35. (canceled)

36. A method for producing a plastic article or film article decorated with a transfer ply of a transfer film, with one or more of the following steps, which are preferably carried out in the following order: providing a transfer film comprising a carrier film comprising a master structure varnish and a transfer ply, arranged on the carrier film and detachable from the carrier fil comprising a topcoat, wherein the master structure varnish is arranged on the carrier film on its side facing the transfer ply and has a master structure and wherein the topcoat comprises a structuring which has a structure complementary to the master structure, peeling the carrier film, together with the master structure, off the transfer ply of the transfer film, arranging the transfer film in an injection mold, back-injection molding the transfer film with a plastic injection-molding material, obtaining a decorated plastic article or a film article.

37. The method according to claim 36, wherein the method comprises the further step: applying, the transfer film to a substrate.

38. The method according to claim 36, wherein the structure depth of the transfer film is reduced, by at most 30%.

39. (canceled)

40. The method according to claim 36, wherein the method comprises the further step: heating the transfer film.

41. The method according to claim 36, wherein the method comprises the further step: fixing the transfer film, in the injection mold.

42. The method according to claim 37, wherein the method comprises the further step: temporarily storing and/or rolling up the transfer film comprising the substrate.

43. The method according to claim 36, wherein the method comprises the further step: deforming the transfer film.

44. The transfer film according to claim 20, wherein the promoter layer of the carrier film has components selected individually or in combination from: crosslinkable acrylates, polyester resins, alkyd resins as well as their modifications, amino resins, amido resins, phenolic resins.

Description

[0194] In the following, the invention is explained by way of example with reference to several embodiment examples with the aid of the accompanying drawings. The embodiment examples shown are therefore not to be understood as limitative.

[0195] FIG. 1 shows a schematic sectional representation of a transfer film.

[0196] FIG. 2 shows a schematic sectional representation of a transfer film.

[0197] FIG. 3 shows a schematic sectional representation of a film article.

[0198] FIG. 4 shows a schematic sectional representation of a plastic article decorated with a transfer ply.

[0199] FIG. 5 shows a schematic sectional representation of a plastic article decorated with a transfer ply.

[0200] FIG. 6 shows a schematic sectional representation of a transfer film.

[0201] FIG. 7 shows a schematic sectional representation of a transfer film.

[0202] FIG. 8 shows a schematic sectional representation of a film article.

[0203] FIG. 9 shows a schematic sectional representation of a film article.

[0204] FIG. 10 shows a schematic sectional representation of a plastic article.

[0205] FIG. 1 shows a schematic sectional representation of a transfer film 10. The transfer film 10, in particular insert-molding film, IMD film, hot-stamping film, laminating film and/or as an IML film, has a carrier film 12 and a transfer ply 14 arranged on the carrier film 12 and detachable from the carrier film 12. The transfer ply 14 comprises a topcoat 16. A master structure is molded on the carrier film 12 on its side facing the transfer ply 14, wherein the topcoat 16 comprises a structuring which has a structure complementary to the master structure.

[0206] The master structure varnish 18 in FIG. 1 advantageously has the master structure.

[0207] Further, the carrier film 12 shown in FIG. 1 preferably has a carrier layer 20 and the master structure varnish 18 arranged on the carrier layer 20 in the direction of the transfer ply 14. The carrier layer 20 is preferably formed from ABS, ABS/PC, PET, PC, PMMA, PE and/or PP and its layer thickness advantageously lies in a range of from 5 ?m to 100 ?m, in particular from 20 ?m to 80 ?m.

[0208] The replicated master structure varnish 18 is arranged over the whole surface and single-layered on the plane spanned by the carrier layer 20.

[0209] The master structure varnish 18 in FIG. 1 preferably comprises components curable by UV radiation and/or a thermoplastic varnish.

[0210] The UV-curable master structure varnish 18 can be constructed from the following components selected individually or in combination from: monomeric or oligomeric polyester acrylates, polyether acrylates, urethane acrylates, epoxy acrylates, amine-urethane acrylates.

[0211] For example, in FIG. 1 a thermoplastic varnish which is suitable as master structure varnish 18 can be a varnish with the following composition:

TABLE-US-00004 Constituent: Proportion by weight: Methyl ethyl ketone 200 to 600, preferably 300 to 500 Ethyl acetate 100 to 400, preferably 200 to 300 Butyl acetate 50 to 300, preferably 100 to 200 Polymethyl methacrylate 50 to 250, preferably 100 to 200 (softening point approx. 170? C.) Cellulose nitrate 50 to 250, preferably 100 to 200

[0212] The replicated master structure varnish preferably has a layer thickness in the range of from 0.1 ?m to 100 ?m, in particular from 0.5 ?m to 50 ?m, preferably from 1.0 to 30 ?m.

[0213] The master structure varnish 18 in FIG. 1 advantageously has a structure depth from a range of from 0.2 ?m to 30 ?m, preferably from 3 ?m to 20 ?m.

[0214] This is because, through such a structure depth, a particularly good haptic and/or good optically variable effect of the master structure varnish 18 can be achieved.

[0215] The master structure varnish 18 in FIG. 1 preferably has a stretchability of at least 50%, preferably of at least 100%. In particular in the case of a necessary deformation of the master structure varnish in a production method and/or application method, the sufficient stretchability of the master structure varnish is advantageous. In particular in the insert-molding method, the carrier film with the master structure varnish is removed before the deformation of the transfer film, with the result that a stretchability of the master structure varnish plays only a subordinate role for this use.

[0216] The topcoat 16 in FIG. 1 is preferably arranged on the transfer film 10 such that it forms the topmost layer of the transfer ply 14 on the side of the transfer ply 14 facing the carrier film 12. In other words, the topcoat 16 can form the outermost layer on the decorated plastic article, and in particular no further protective varnish layer needs to be arranged on the topcoat 16.

[0217] The topcoat 16 in FIG. 1 preferably has a layer thickness in the range of from 0.1 ?m to 60 ?m, preferably from 0.5 ?m ?m to 40 ?m, preferably from 1.0 ?m to 30 ?m.

[0218] Further, the topcoat 16 is preferably formed transparent and/or has, in particular in the wavelength range of from 380 nm to 780 nm, a transmittance of at least 25%, preferably of at least 35%, further preferably of at least 85%.

[0219] Furthermore, it is possible for the topcoat 16 to be dyed in FIG. 1, in particular for the topcoat 16 to be dyed by means of dye pigments, and/or for the pigmentation level of the topcoat 16 to be less than 15%, preferably less than 10%, further preferably less than 5%. It is also possible for the topcoat 16 to be colorless and/or for the pigmentation level of the topcoat 16 to be 0%. Thus, it is possible for the topcoat 16 to be and/or to form an in particular unpigmented clear varnish layer.

[0220] The topcoat 16 in FIG. 1 can be designed such that it has a gloss value in a range of from 1 to 98, preferably in a range of from 10 to 90.

[0221] Advantageously, no formation of glossy spots occurs during use of the transfer film 10, for example during shaping, in particular deep-drawing. In other words, the gloss value of the shaped transfer film 10 lies in a range of from 90% to 110%, preferably from 95% to 105%, of the gloss value of the unshaped transfer film 10, in particular in areas of surface with comparatively large strains of the topcoat and/or the transfer ply of the transfer film, in particular in the case of strains of the topcoat of between approx. 50% and approx. 200%, preferably between 50% and 200%.

[0222] Preferably, the topcoat 16 has a stretchability of at least 50%, preferably of at least 150%, in particular preferably of at least 200%.

[0223] It is advantageous if the topcoat 16 has a temperature resistance of up to 250? C., preferably of up to 200? C.

[0224] Furthermore, it is advantageous if the topcoat 16 in FIG. 1 is formed from long-chain polymers. The polymers can be formed crosslinked. The crosslinking and/or curing is preferably based on an application of thermal energy and/or UV radiation.

[0225] The topcoat 16 is preferably formed from polymers selected individually or in combination from: polymethyl acrylates, polymethyl methacrylates, polyvinylidene flouride, copolymers of polymethyl acrylates and polyvinylidene fluoride, copolymers of polymethyl methacrylate and polyvinylidene flouride.

[0226] In addition, the topcoat 16 can have been and/or be formed from aqueous polymer dispersions, preferably from aqueous polyurethane dispersions, based on components selected individually or in combination or as hybrid dispersions from: polyether, polyester, polycarbonate, natural castor oil polyols, natural linseed oil polyols, acrylate dispersions, styrene/acrylate dispersions, vinyl acetate dispersions.

[0227] In addition, the topcoat 16 can be formed from polymers selected individually or in combination from: be formed from polyol, from polyurethane (PU), from copolymers of polyurethane (PU) and polyol, and/or from copolymers of polyurethane (PU) and polyacrylates. The polyurethanes (PU) are preferably formulated into a topcoat 16 via a cobinder, for example via polyols and/or via melamine resins, or with an isocyanate binder.

[0228] The topcoat 16 and/or individual components of the topcoat 16 can be both thermally dried and/or curable by means of chemical crosslinking, in particular by means of polyisocyanate crosslinking and/or by means of aziridine crosslinking and/or by UV curing or UV crosslinking.

[0229] Polyisocyanates preferably comprise components which comprise at least two isocyanate groups, in particular wherein the isocyanate groups are at least one group selected from diisocyanate monomer, diisocyanate oligomer, diisocyanate-terminated prepolymer, diisocyanate-terminated polymer, polyisocyanate monomer, polyisocyanate oligomer, polyisocyanate-terminated prepolymer, and/or polyisocyanate-terminated polymer, and/or mixtures thereof.

[0230] It is further possible here for the diisocyanate-comprising component to comprise at least one component selected individually or in combination from: polyurethane oligomer, or polyurea oligomer, polyurethane prepolymer, polyurea prepolymer, polyurethane polymer, polyurea polymer polymer.

[0231] The components which comprise at least two isocyanate groups further preferably comprise at least one group selected individually or in combination from: hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI), methylene diphenyl diisocyanate (MDI), toluene diisocyanate (TDI), phenylene diisocyanate, naphthalene diisocyanate (NDI), diphenyl sulfone diisocyanate, ethylene diisocyanate, propylene diisocyanate, dimers of these diisocyanates, trimers of these diisocyanates, triphenylmethane triisocyanate, polyphenylmethane polyisocyanate (polymerized MDI).

[0232] The components having hydroxyl groups used in particular for the polyisocyanate crosslinking, in particular hydroxyl-functional acrylic components, are preferably selected individually or in combination from: hydroxy monoacrylate, hydroxy diacrylate, hydroxy polyacrylate, hydroxyl-functional aliphatic polyether urethane monoacrylate, hydroxyl-functional aliphatic polyester urethane monoacrylate, hydroxyl-functional aromatic polyether urethane monoacrylate, hydroxyl-functional aromatic polyester urethane monoacrylate, hydroxyl-functional polyester monoacrylate, hydroxyl-functional polyether monoacrylate, hydroxyl-functional epoxy monoacrylate, hydroxyl-functional acrylated acrylic monoacrylate, hydroxyl-functional aliphatic polyether urethane diacrylate, hydroxyl-functional aliphatic polyester urethane diacrylate, hydroxyl-functional aromatic polyether urethane diacrylate, hydroxyl-functional aromatic polyester urethane diacrylate, hydroxyl-functional polyester diacrylate, hydroxyl-functional polyether diacrylate, hydroxyl-functional epoxy diacrylate, acrylated acrylic diacrylate, hydroxyl-functional aliphatic polyether urethane polyacrylate, hydroxyl-functional aliphatic polyester urethane polyacrylates, hydroxyl-functional polyether polyacrylate, hydroxyl-functional epoxy polyacrylate, hydroxyl-functional acrylated acrylic polyacrylate.

[0233] Melamine resins preferably comprise resins which are obtained by reacting melamine with aldehydes, in particular formaldehyde, acetaldehyde, isobutyraldehyde and glyoxal.

[0234] It is further possible for such resins to be partially or completely modified, for example by etherification of the methylol groups obtained with mono- or polyhydric alcohols. In other words, as melamine resins, in particular those which can be obtained by reacting melamine with aldehydes and optionally can be partially or completely modified are suitable.

[0235] In particular, formaldehyde, acetaldehyde, isobutyraldehyde and glyoxal are suitable as aldehydes.

[0236] Melamine formaldehyde resins are preferably reaction products of the reaction of melamine with aldehydes, e.g. the above-named aldehydes, in particular formaldehyde. Where appropriate, the methylol groups obtained are preferably modified by etherification with mono- or polyhydric alcohols.

[0237] Further, it is also advantageous that the topcoat 16 of UV-curable monomers and/or oligomers is selected individually or in combination from the group polyurethanes, polyacrylates, polymethacrylates, polyester resins, polycarbonates, phenolic resins, epoxy resins, polyureas, and/or melamine resins, in particular further preferably is selected from the group polymethyl methacrylate (PMMA), polyester, polycarbonate (PC), polyvinylidene fluoride (PVDF).

[0238] The topcoat 16 in FIG. 1 is particularly resistant to chemical and/or mechanical loads due to the above-named polymers, in particular due to the polyvinylidene fluoride. This provides the advantage in particular that in the case of the transfer ply 14 a further protective varnish layer can be dispensed with, in particular which would additionally have been applied to the topcoat 16, with the result that the topcoat 16 preferably forms the exposed visible face of the decorated plastic article 50. In other words, the topcoat 16 preferably has a high chemical resistance of its surface, preferably a substantially chemically inert surface.

[0239] Thus, the topcoat 16 is preferably formed particularly resistant to solvents, such as for example isopropanol and methyl ethyl ketone (MEK), to aggressive substances, such as for example sunscreen, hand cream, fuel, insect repellent (diethyltoluamide (DEET), e.g. Autan?), engine oil, brake fluid, coolant, polish, bitumen and tar remover, bird droppings, tree resin and/or cellulose thinner, to weathering, such as for example sunlight, rain and/or dew, to foodstuffs, such as for example coffee, to cleaning agents and/or to mechanical stresses as well as to high thermal loads.

[0240] Further, the transfer ply 14, wherein the topcoat 16 forms the visible face, has a good adhesive strength in the cross-cut test.

[0241] FIG. 2 shows a schematic sectional representation of a further transfer film 10. The transfer film 10 in FIG. 2 is based on the structure of the transfer film 10 in FIG. 1. Thus, the transfer film 10 likewise has a carrier film 12 and a transfer ply 14 arranged on the carrier film 12 and detachable from the carrier film 12. The transfer ply 14 comprises a topcoat 16. A master structure is molded on the carrier film 12 on its side facing the transfer ply 14, wherein the topcoat 16 comprises a structuring which has a structure complementary to the master structure.

[0242] However, the transfer film 10 in FIG. 2 has still further layers. Thus, the transfer film 10, in particular the transfer ply 14, can have at least one decorative layer 28, in particular at least one color layer and/or at least one metalization 30 and/or at least one adhesive layer or primer layer 32 and/or at least one replication layer. The at least one decorative layer 28, in particular at least one color layer and/or at least one adhesive layer or primer layer 32 and/or at least one replication layer, are preferably printed.

[0243] Further, the transfer ply 14 can have a promoter layer 24, in particular an adhesion-promoter layer. The at least one decorative layer 28 is arranged on the topcoat 16 on the side facing away from the master structure varnish 18.

[0244] The promoter layer of the transfer ply 24 is preferably arranged between the at least one decorative layer 28 and the topcoat 16 in the transfer ply 14.

[0245] The carrier film 12 can further have a promoter layer 26, in particular an adhesion-promoter layer, which is arranged between master structure varnish 18 and carrier layer 20.

[0246] The promoter layers of the transfer ply 24 or of the carrier film 26 ensure in particular that a very good adhesions are produced between the topcoat 16 and the other layers of the transfer ply 14, or between the carrier layer 20 and the master structure varnish 26.

[0247] In FIG. 2, as promoter layer of the transfer ply 24 and/or of the carrier film 26, components are preferably applied which are selected individually or in combination from: crosslinkable acrylates, in particular polyacrylates, polyester resins, alkyd resins as well as their modifications, amino resins, amido resins, phenolic resins. The promoter layer of the transfer ply 24 and/or of the carrier film 26 thus has and/or consists of the above components. All crosslinkers known in the state of the art can be used for crosslinking the above components. Suitable crosslinkers comprise for example isocyanates, melamines, alcohols and/or aziridines, or mixtures thereof.

[0248] A crosslinking of the promoter layer of the transfer ply 24 and/or of the carrier film 26 can be initiated in particular by UV radiation and/or by application of thermal energy and/or by chemical reaction. A first crosslinking step is preferably effected by means of thermal energy and/or chemical reaction. In an optional further process step, which can also take place with a time delay, a further and additional crosslinking can be effected by means of UV radiation. In particular, a crosslinking is effected by means of application of thermal energy and/or chemical reaction before the deformation of the transfer film and an optional additional crosslinking is effected by means of UV radiation after the deformation of the transfer film 10, preferably as one of the last process steps.

[0249] Ideally, the promoter layer of the transfer ply 24 in FIG. 2 has a layer thickness in the range of from 0.1 ?m to 10 ?m, preferably in the range 0.3 ?m to 5 ?m, preferably from 0.5 ?m to 4 ?m. The promoter layer of the carrier film 26 preferably has a layer thickness in the range of from 0.1 ?m to 5 ?m, preferably from 0.3 ?m to 3 ?m, particularly preferably from 0.5 ?m to 2 ?m.

[0250] The layer thickness of the at least one decorative layer 28 is preferably between 0.1 ?m and 30 ?m, in particular between 0.5 ?m and 15 ?m.

[0251] The at least one decorative layer 28 in FIG. 2 can have at least one partial or whole-surface color layer for generating a pattern and/or a motif. The at least one color layer can, in particular in the case of partial application, also be in register with the structure of the topcoat 16, in particular with respect to reflection, absorption and/or refractive index of the topcoat 16.

[0252] The at least one decorative layer 28 can further have at least one replication layer, into which diffractively and/or refractively acting micro- or macrostructures are molded. The at least one replication layer is preferably provided with a reflective layer, which can consist of a metalization and/or an HRI layer with a high refractive index (HRI=High Refractive Index). Here, the at least one reflective layer can be opaque, semitransparent or transparent.

[0253] One or more of the following structures can be molded in at least one replication layer: a diffractive structure, a zero-order diffraction structure, a blazed grating, a macrostructure, in particular a lens structure or microprism structure, a mirror surface, a matte structure, in particular an anisotropic or isotropic matte structure.

[0254] The structures in at least one replication structure can represent a pattern and/or a motif, which in particular also be arranged in register with the color layers of the decorative layer 28 and/or in register with the structure of the master structure varnish 18.

[0255] The at least one decorative layer 28 can further have at least one metalization 30. The at least one metalization 30 is preferably produced by means of vapor deposition. Cr, In, Sn, Cu and/or Al are particularly suitable as metal. Through the use of a layer made of metal, for example a microembossing film with metallic visual appearance is obtained.

[0256] The at least one vapor-deposited metalization 30 can be applied over the whole surface and either preserved over the whole surface or else structured with known demetalization methods such as etching, lift-off or photolithography and thereby be only partially present. However, the at least one metalization 30 can also consist of a printed layer made of metallic pigments in a binder. The printed metallic pigments can be applied over the whole surface or partially and have different colorings in different areas of surface. The at least one metalization 30 can represent a pattern and/or motif, which in particular also be arranged in register with the at least one color layer of at least one decorative layer 28 and/or with the structures of the at least one replication layer.

[0257] The at least one decorative layer 28 can further have at least one adhesive layer or primer layer 32. The at least one adhesive layer or primer layer 32 faces the plastic body to be decorated or the plastic injection-molding material 51. In other words, it is the bottommost layer of the transfer ply 14 viewed from the carrier film 12.

[0258] The at least one adhesive layer or primer layer 32 preferably has a layer thickness from a range of from 0.1 ?m to 10 ?m, in particular from 0.1 ?m to 3 ?m, and can also have several sublayers.

[0259] The layers of the transfer ply 14 arranged on the side of the topcoat 16 facing away from the carrier film 12, in particular the at least one decorative layer 28, the at least one replication layer, the promoter layer 24, the at least one adhesive layer or primer layer 32, the at least one metalization 30 and/or the at least one color layer, must in each case have at least 80% of the stretchability of the topcoat 16. In other words, the respective layer has a stretchability of at least 40%, preferably of at least 120%, preferably of at least 160%.

[0260] In the embodiment shown in FIG. 2, a detachment layer 22 is arranged between the topcoat 16 and the master structure varnish 18. This detachment layer 22 can support a reliable detachment of the transfer ply 14 from the carrier film, wherein the separating plane is located between topcoat 16 and master structure varnish 18.

[0261] In order to guarantee a clean detachment of the topcoat 16 from the master structure, the separating force between topcoat 16 and master structure preferably lies in a range of from 3 N/m to 40 N/m, preferably from 10 N/m to 30 N/m.

[0262] The detachment layer 22 preferably has a layer thickness in a range of from 0.001 ?m to 2 ?m, in particular from 0.05 ?m to 1 ?m.

[0263] The detachment layer 22 can have and/or consist of a wax. Such a wax can be for example a carnauba wax, a montanic acid ester, a polyethylene wax, a polyamide wax or a PTFE wax, or mixtures thereof. In particular, surface-active substances, such as for example silicones, or thin layers of melamine-formaldehyde-resin-crosslinked varnishes, are also suitable as detachment layer 22.

[0264] Further, the structure of the master structure layer 18 and/or the complementary structure in FIG. 2 can be formed as a relief structure, preferably as a non-random relief structure.

[0265] By a non-random relief structure is preferably meant a relief structure which is formed in a targeted manner and does not occur because of random surface roughnesses of material surfaces. Thus, non-random relief structures are recognizable in particular by the fact that they are reproducible in a targeted manner and can be present identically in several end products. If for example a relief structure with a desired profile shape is for example generated on an industrial scale in an endless carrier film, then a correspondingly structured stamp or cylinder, which has a finite length, is usually used for this. Because of the continuous use of the structured tool on the endless carrier film, the molded relief structures repeat at regular distances on the carrier film and are thus recognizably non-random relief structures, even if at first glance a random relief structure appears to be present locally.

[0266] A non-random relief structure is furthermore recognizable for example by the fact that particular profile shapes, which usually do not or only very rarely feature, occur massed, periodically or quasiperiodically. While a rather undefined and rounded profile shape is to be expected of a random relief structure, such as for example a surface roughness and/or introduced particles, non-random relief structures can comprise or consist of functional surfaces such as for example exact and geometrically formed profile shapes such as rectangular profiles, sinusoidal profiles, sawtooth profiles, hemispherical profiles or blazed structures. Further, non-random relief structures can also comprise or consist of a design, in particular technical designs, such as for example carbon fibers, waves, polygons, etc., and/or organic designs, such as for example wood grains. Furthermore, non-random relief structures display for example binary profiles or profiles with profile depth staggered in the manner of a staircase, in particular with constant profile depth, such as in particular the binary profiles described in DE 10054503 B4. A special case for a staircase-like profile is for example a rectangular profile wherein the local profile depths can adopt only discrete levels. The distances between two neighboring depressions preferably lie in a range of from 0.25 ?m to 100 ?m, preferably from 0.5 ?m to 50 ?m. The profile depth, relative to an average level, is preferably less than 15 ?m, preferably less than 10 ?m, particularly preferably less than 7 ?m and in particular preferably values from DE 102012105571 A1. Microscopically fine, non-random relief structures with locally varying structure depth are disclosed for example in EP 0992020 B1. The non-random relief structure can also be a microstructure diffracting achromatically in a directed manner, such as is described in DE 102018123482 A1.

[0267] It is advantageous if the master relief structure is designed such that the complementary relief structure comprises a microstructure, in particular a microstructure the dimensions of which lie below the resolution limit of the unaided human eye.

[0268] Further, the master relief structure can be designed such that the complementary relief structure comprises a macrostructure, in particular a macrostructure the dimensions of which lie above the resolution limit of the unaided human eye.

[0269] A microstructure can advantageously have an optical effect which simulates the presence of a macrostructure.

[0270] The complementary relief structure can be formed as a matte structure, as a diffractive structure and/or as a refractive structure and/or as a macrostructure. Further, several of the above-named structures can also be present next to each other and/or be superimposed with each other.

[0271] Preferred matte structures have an average distance in the range of from 300 nm to 5000 nm, a roughness average, Ra, in the range of from 20 nm to 2000 nm, preferably in the range of from 50 nm to 500 nm. The correlation length, I.sub.c, preferably lies in the range of from 200 nm to 50000 nm, in particular in the range of from 500 nm to 10000 nm.

[0272] Preferred diffractive structures have typical numbers of lines in the range of from 300 lines/mm to 2000 lines/mm and typical structure depths in the range of from 50 nm to 800 nm. For achromatic effects, however, very coarse grating structures with numbers of lines in the range of from 10 lines/mm to 300 lines/mm and structure depths in the range of from 0.5 ?m to 10 ?m can also be used.

[0273] Optically variable effects on the basis of the previously named structures can be realized for example by varying one or more structure parameters. For example by varying the grating period, the average distance, the angle of inclination of the micromirrors, the structure depth and/or the azimuthal angle.

[0274] Through the above-named properties of the master structure varnish 18, of the topcoat 16, as well as the surface structures introduced into these varnishes, defined and reproducible images, motifs and/or structures can be transferred to plastic articles to be decorated. This provides the advantage in particular over so-called soft touch varnishes, which have only a partial or whole-surface undefined, non-reproducible surface roughness.

[0275] FIG. 3 shows a schematic sectional representation of a film article 40 decorated with the transfer film 10. The film article 40 was obtained by applying the transfer ply 14 to a substrate 33. The structure of the transfer film 10 substantially equates to the transfer film 10 in FIG. 2. Thus, the transfer film 10 has a carrier film 12 and a transfer ply 14 arranged on the carrier film 12 and detachable from the carrier film 12. The transfer ply 14 comprises a topcoat 16. A master structure is molded on the carrier film 12 on its side facing the transfer ply 14, wherein the topcoat 16 comprises a structuring which has a structure complementary to the master structure. The transfer ply 14 also has a promoter layer 24, preferably adhesion-promoter layer, at least one decorative layer 28 and an adhesive layer or primer layer 32. The carrier film 12 moreover has a detachment layer 22 on the master structure varnish 18 as well as a promoter layer 26, in particular adhesion-promoter layer, arranged between master structure varnish 18 and carrier film 20.

[0276] The substrate 33 can be selected for example from PC, ABS/PC, PP, TPU and/or PMMA, or blends and/or coextrudates thereof, and preferably have a thickness in the range of from 50 ?m to 500 ?m, preferably from 100 ?m to 350 ?m. Further, the carrier layer 20 has been peeled off the transfer ply 14, with the result that the topcoat 16 represents the exposed visible face.

[0277] The film article 40 shown in FIG. 3 can also be stored temporarily and/or rolled up before further processing steps.

[0278] FIG. 4 shows a schematic sectional representation of a plastic article 50 decorated with a transfer ply 10. The plastic article 50 is preferably produced by means of an insert-molding method. To produce the plastic article 50, for example a transfer film 10 such as described in FIG. 2 can be used. Thus, the transfer film 10 used has a carrier film 12 and a transfer ply 14 arranged on the carrier film 12 and detachable from the carrier film 12. The transfer ply 14 also comprises a structured topcoat 16. Further, the transfer ply 14 has a promoter layer 24, preferably adhesion-promoter layer, at least one decorative layer 28 and an adhesive layer or primer layer 32.

[0279] To produce the plastic article 50 shown in FIG. 4, the transfer film 10 is applied to a substrate 33, for example a substrate 33 such as described in FIG. 3, to obtain a film body 40. The carrier film 12 with the master structure varnish 18 is preferably peeled off before the back-injection molding. Further, the transfer film 12 can also be die-cut and/or laser-cut before the back-injection molding. Further, the transfer film 10 can be deformed, in particular deep-drawn, during the method. In particular, the deforming can be carried out in an injection mold and/or in a separate device by means of a deep-drawing tool.

[0280] To produce the plastic article 50, the film article 40 is arranged in an injection mold after the die-cutting and/or laser-cutting and then back-injection molded with a plastic injection-molding material 51, to obtain a decorated plastic article 50. Here, in particular, the film article 40 with the transfer ply 14 of the transfer film 10 is aligned such that the side of the film article 40 facing away from the transfer ply 14 of the transfer film 10 faces the hollow space of the cavity of the injection mold.

[0281] The structures introduced into the topcoat 16 are for the most part preserved during the method, in particular during the deforming and/or during the back-injection molding. In other words, the structure shape and/or the structure cross section and/or the structure depth is substantially preserved, preferably the structure depth is reduced by at most 30%, preferably by at most 20%. In particular, the reduction of the structure depth is only effected locally, in particular in areas of surface with comparatively large strains of the topcoat 16 and/or the transfer ply 14 of the transfer film 10, in particular in the case of strains of the topcoat 16 of between approx. 50% and approx. 200%, in particular between 50% and 200%.

[0282] A plastic article 50 is obtained, wherein the topcoat 16 represents the outer layer and the surface has the structure complementary to the master structure layer 18. Plastic articles 50 decorated in such a way are preferably used as decorative components for motor vehicles, for ships, for aircraft or also in telecommunications devices or household appliances.

[0283] FIG. 5 shows a schematic sectional representation of a plastic article 50, decorated with a transfer ply 10, which is preferably produced by means of an IMD method. The transfer film 10 used to produce the plastic article 50 substantially equates to the transfer film 10 in FIG. 2 and has a carrier film 12 and a transfer ply 14 arranged on the carrier film 12 and detachable from the carrier film 12. The transfer ply 14 comprises a structured topcoat 16. Further, the transfer ply 14 has a promoter layer 24, preferably adhesion-promoter layer, at least one decorative layer 28 and an adhesive layer or primer layer 32.

[0284] To produce the plastic article 51, the transfer film 10 comprising carrier film 12 and transfer ply 14 is arranged in an injection mold. Here, in particular, the transfer film 12 is aligned such that the side of the transfer ply 14 facing away from the topcoat 16 is aligned in the direction of the hollow space of the cavity of the injection mold. The transfer film 10 is preferably heated in the injection mold and in particular fixed by means of vacuum, with the result that it rests against the wall of the injection mold. The transfer film 10 is then is back-injection molded with a plastic injection-molding material 51. After the demolding, the carrier film 12 can be peeled off, to obtain a decorated plastic article 50.

[0285] FIGS. 6 and 7 show a schematic sectional representation of a further transfer film 10. The structure is similar to the structure of the transfer film 12 in FIG. 2. Thus, the transfer film 10 has a carrier film 12 and a transfer ply 14 arranged on the carrier film 12 and detachable from the carrier film 12. The transfer ply 14 comprises a topcoat 16. A master structure is molded on the carrier film 12 on its side facing the transfer ply 14, wherein the topcoat 16 comprises a structuring which has a structure complementary to the master structure. The transfer ply 14 also has a promoter layer 24, preferably adhesion-promoter layer, at least one decorative layer 28 and an adhesive layer or primer layer 32. The carrier film 12 has a promoter layer 26, in particular adhesion-promoter layer, arranged between master structure varnish 18 and carrier layer 20.

[0286] In the schematic transfer film 10 shown in FIGS. 6 and 7, no detachment layer 22 is arranged between the master structure varnish 18 and the topcoat 16. Instead, the master structure, thus the master structure varnish 18, and/or the topcoat 16 has additives, such as for example silicones, aliphatic hydrocarbons, which prevent too strong an adhesion between the topcoat 16 and the master structure. In other words, the additives reduce the required separating force which is necessary in order to detach the master structure varnish 18 from the topcoat 16. Further, the adhesive layer or primer layer 32 is in contact with a metalization 30 arranged on the side facing carrier layer.

[0287] In order to guarantee a clean detachment of the topcoat 16 from the master structure, the separating force between topcoat 16 and master structure preferably lies in a range of 3 N/m and 40 N/m, preferably from 10 N/m to 30 N/m.

[0288] The transfer films 10 of FIGS. 6 and 7 differ from each other to the effect that the master structure varnish 18 in FIG. 7 is arranged on the carrier layer 20 over the whole surface, while the master structure varnish 18 in FIG. 6 is arranged on the carrier layer 20 only partially. In the areas of the carrier layer 20 where no master structure varnish 18 is arranged, a further varnish 19, in particular a varnish 19 with a surface that is not raised, preferably with a smooth and/or unstructured surface, is applied preferably at least in areas. The topcoat 16 of the transfer ply 14 in particular comprises only structuring in the areas in which the master structure varnish 18 has been applied. In the areas in which the further varnish 19 is arranged, the topcoat 16 is preferably smooth and/or unstructured.

[0289] A schematic sectional representation of a film article 40 is shown in FIG. 8. The structure of the transfer ply 14 shown in FIG. 8 substantially equates to the transfer ply 14 shown in FIG. 7. Thus, the transfer ply 14 comprises a structured topcoat 16, a promoter layer 24, preferably adhesion-promoter layer, and an adhesive layer or primer layer 32. In this embodiment example, however, the transfer ply 14 has no decorative layer 28, in particular no metalization 30, arranged between the adhesive layer or primer layer 32 and the promoter layer 24. The transfer ply 14 in FIG. 8 appears transparent due to its design, in particular in the wavelength range of from 380 nm to 780 nm.

[0290] The transfer film 14 shown in FIG. 8 is arranged on a substrate 33 and the carrier film 12 in the representation shown has already been peeled off.

[0291] The substrate 33 preferably has a thickness in the range of from 50 ?m to 500 ?m, preferably from 100 ?m to 350 ?m. In particular, the transfer ply 14 is applied in such a way that, with the side facing away from the topcoat 16, the transfer ply 14 is in contact with the substrate 33. The substrate 33 can be selected for example from PC, ABS/PC, PP, TPU and/or PMMA, or blends and/or coextrudates thereof. The substrate 33 in FIG. 8 is advantageously designed transparent, preferably with a transmittance of at least 25%, preferably with a transmittance of at least 35%, further preferably with a transmittance of at least 85%, in particular in the wavelength range of from 380 nm to 780 nm.

[0292] The embodiment example shown in FIG. 8 of the transfer ply 14 arranged on the substrate 33 and with the carrier film 12 peeled off can already represent a film article 40 in its end state. Such a film article 40 can be used for example for display applications. The complementary structures of the topcoat 16 here are preferably antireflective structures, in order to suppress the reflectance of surfaces and/or increase their transmittance. In particular, the introduced structures are not arranged on the side of the display which is in contact with the user, but are arranged on the side facing away from the user. The structures are thus protected by the substrate 33 from mechanical loads in particular.

[0293] A schematic sectional representation of a film article 40 is shown in FIG. 9. The structure of the transfer ply 14 shown in FIG. 9 substantially corresponds to the transfer ply 14 shown in FIG. 7. Thus, the transfer ply 14 comprises a structured topcoat 16, a promoter layer 24, preferably adhesion-promoter layer, and an adhesive layer or primer layer 32 adhesive layer or primer layer 32 attached between topcoat 16 and promoter layer 24.

[0294] The transfer ply 14 shown in FIG. 9 was first applied to a substrate 33, for example a substrate 33 such as described in FIG. 8. The carrier film 12 of the transfer film 10 was then removed, with the result that the transfer ply 14 of the topcoat 16 remains on the transparent substrate 33 and the structure of the topcoat 16 of the transfer ply 14 forms the visible face.

[0295] Thus, the topcoat 16 can be provided with a metalization 30. Cr, In, Sn, Cu and/or Al are particularly suitable as metal. The topcoat 16 is preferably provided with a metalization 30 with a layer thickness in the range of from 5 nm to 200 nm, in particular from 10 nm to 100 nm. The application of the metalization 30 can be effected by means of vapor deposition. Further, the metalization 30 can be applied homogeneously or with a gradient. In other words, the layer thickness of the metalization 30 can remain constant and/or decrease or increase in a top view onto the plane formed by the topcoat 16 in the x and/or y direction. In particular, a transfer ply 14 comprising a structured topcoat 16 with a metallic visual appearance is obtained here.

[0296] In addition, after the carrier film 12 of the film with the master structure has been removed from the transfer ply 14, further layers such as for example a decorative layer 28, in particular a partial or whole-surface color layer, and/or a promoter layer 24, in particular adhesion-promoter layer, can also be applied to the layer forming the visible face. In particular, the application of the decorative layer 28 and/or the promoter layer 24 is effected after the application of a metalization 30.

[0297] An adhesive layer or primer layer 32a can then be applied to the decorative layer 28. The adhesive layer or primer layer 32a is selected such that it is suitable for the plastic injection-molding material 51 of a subsequent injection-molding process and thus joined in particular to the plastic injection-molding material 51.

[0298] The film article 40 obtained, in particular consisting of substrate 33, transfer ply 14, the metalization 30, decorative layer 28, promoter layer 24 and/or adhesive layer or primer layer 32a, can then be deformed, in particular deep-drawn and/or die-cut and/or back-injection molded. Here, the film article 40 is arranged in the injection mold such that the substrate 33 rests against the wall of the injection mold. The plastic injection-molding material 51, not represented in more detail in FIG. 9, is applied to the outer free side of the film article 40, thus to the side facing away from the wall, in particular to the primer layer 32a. The structuring of the topcoat 16 is thus embedded between the substrate 33 and the plastic injection-molding material 51. The structuring is thus protected by the substrate 33 from external influences. Furthermore, an additional optical depth effect is obtained through the structure shown in FIG. 9 of the film article 40.

[0299] Still further layers can then be applied to the free side of the substrate 33 facing away from the plastic injection-molding material 51. In particular, these can be protective layers, which improve the mechanical and/or chemical resistance of the substrate 33. These protective layers can be wet painted and/or be applied by means of transfer methods and/or by means of laminating methods.

[0300] The substrate 33 can be single-layered or multi-layered and in particular have a self-supporting layer 33a, which consists of materials selected individually or in combination from ABS, ABS/PC, PET, PC, PMMA, PE, PP. The substrate can likewise of PET.

[0301] The substrate 33 can have further layers on the self-supporting layer 33a, selected individually or in combination from adhesion-promoter layer, metal layer, color layer, functional layer, replication layer, decorative layer, protective layer.

[0302] In the embodiment shown in FIG. 10 the substrate 33 has a self-supporting layer 33a, to which a protective layer 33b is applied. A detachment layer 33c, which allows a detachment of the protective layer 33b from the self-supporting layer 33a, is preferably arranged between the self-supporting layer 33a and the protective layer 33b. In particular, an adhesion-promoter layer 33d is arranged on the side of the protective layer 33b facing away from the self-supporting layer 33a, in order to improve an adhesion of a layer applied thereto or of a layer pack applied thereto.

[0303] FIG. 10 now shows that the transfer ply 14 is applied to the protective layer 33b or to the adhesion-promoter layer 33d. Similarly to FIG. 9, still further layers 34, in particular a decorative layer 28, in particular a partial or whole-surface color layer, and/or a promoter layer 24, in particular adhesion-promoter layer, can now be applied to the free outer side of the transfer ply 14. In particular, the application of the decorative layer 28 and/or the promoter layer 24 is effected after the application of a metalization 30.

[0304] The film article 40 obtained, in particular consisting of self-supporting layer 33a, protective layer 33b, optionally adhesion-promoter layer 33c, optionally detachment layer 33d, transfer ply 14, metalization 30, decorative layer 28, promoter layer 24 and/or adhesive layer or primer layer 32, can then be deformed, in particular deep-drawn and/or die-cut and/or back-injection molded. Here, the film article 40 is arranged in the injection mold such that the substrate 33 rests against the wall of the injection mold. The plastic injection-molding material 51, not represented in more detail in FIG. 10, is applied to the outer free side of the film article 40. A plastic article 50 is obtained.

[0305] After the deep-drawing and/or die-cutting and/or back-injection molding, the self-supporting layer 33a can be peeled off the protective layer 33b. The optionally present detachment layer 33d can remain on the self-supporting layer 33a or remain on the protective layer 33b.

[0306] The protective layer 33b preferably has a layer thickness in the range of from 0.1 ?m to 60 ?m, preferably from 0.5 ?m to 40 ?m, preferably from 1.0 ?m to 30 ?m.

[0307] Preferably, the protective layer 33b is formed transparent and/or has, in particular in the wavelength range of from 380 nm to 780 nm, a transmittance of at least 25%, preferably of at least 35%, further preferably of at least 85%.

[0308] It is advantageous if the protective layer 33b has a temperature resistance of up to 250? C., preferably of up to 200? C.

[0309] The protective layer 33b is preferably formed from polymers selected individually or in combination from: polymethyl acrylates, polymethyl methacrylates, polyvinylidene flouride, copolymers of polymethyl acrylates and polyvinylidene fluoride, copolymers of polymethyl methacrylate and polyvinylidene flouride.

[0310] In addition, the protective layer 33b can have been and/or be formed from aqueous polymer dispersions, preferably from aqueous polyurethane dispersions, based on components selected individually or in combination or as hybrid dispersions from: polyether, polyester, polycarbonate, natural castor oil polyols, natural linseed oil polyols, acrylate dispersions, styrene/acrylate dispersions, vinyl acetate dispersions.

[0311] These aqueous polymer dispersions can be formulated as a one-component (1C) binder system, wherein a thermal drying is carried out in order to generate a dry layer, but no chemical crosslinking of the molecular groups takes place in the process.

[0312] These aqueous polymer dispersions can be formulated as a one-component (1C) binder system, wherein a chemical crosslinking of the molecular groups takes place because reactive molecular groups of the polymers crosslink with each other, initiated by means of UV radiation.

[0313] Alternatively, these aqueous polymer dispersions can be formulated as a two-component (2C) system, wherein in addition to the polymer or polymers as one component there is a second component for crosslinking the reactive groups of the polymers, wherein the second component is in particular selected individually or in combination from isocyanates, carbodiimides, aziridines. In the case of a two-component system, a further chemical crosslinking of the polymers can additionally take place by means of UV radiation.

[0314] In addition, the protective layer 33b can be formed from polymers selected individually or in combination from: polyol, polyurethane (PU), copolymers of polyurethane (PU) and polyol, copolymers of polyurethane (PU) and polyacrylate. The polyurethanes (PU) are preferably formulated into a topcoat via a cobinder, for example via polyols and/or via melamine resins, or with an isocyanate binder.

[0315] The protective layer 33b and/or individual components of the protective layer 33b can be both thermally dried and/or curable by means of chemical crosslinking, in particular by means of polyisocyanate crosslinking and/or by means of aziridine crosslinking and/or by means of carbodiimide crosslinking and/or by UV curing or UV crosslinking.

[0316] Of course, the listed embodiment variants, in particular with respect to the layer structure or arrangement of the transfer film 10, can be combined with each other as desired and do not represent a limitation.

LIST OF REFERENCE NUMBERS

[0317] 10 transfer film [0318] 12 carrier film [0319] 14 transfer ply [0320] 16 topcoat [0321] 18 master structure varnish [0322] 19 varnish [0323] 20 carrier layer [0324] 22 detachment layer [0325] 24 promoter layer [0326] 26 promoter layer [0327] 28 decorative layer [0328] 30 metalization [0329] 32 adhesive layer or primer layer [0330] 32a adhesive layer or primer layer [0331] 33 substrate [0332] 33a self-supporting layer [0333] 33b protective layer [0334] 33c adhesion-promoter layer [0335] 33d detachment layer [0336] 34 further layers [0337] 40 film article [0338] 50 plastic article [0339] 51 plastic injection-molding material