DE102012220595A1 - Producing decorative material comprising thin metal film and paint layer applied on metal film, by providing metal film with specified thickness, and providing a layer composite comprising carrier film coated with the paint layer - Google Patents

Abstract

Producing a decorative material comprising a thin metal film having a thickness of 10-100 mu m, preferably 30-50 mu m, and a paint layer subsequently applied on the thin metal film, comprises (a) providing the metal film with the specified thickness, (b) providing a layer composite comprising a carrier film that is coated with the paint layer and has a thickness of 15-100 mu m, preferably 20-50 mu m, and (c) contacting the paint layer of a layer composite with the metal film of the surface. Independent claims are included for: (1) the decorative material produced by the method, comprising the metal film with a thickness of 10-100 mu m, preferably 30-50 mu m and the paint layer applied on the film; and (2) producing a coated article comprising contacting the decorative material surface with the article, and pressing metal film side of the decorative material onto the article.

Description

The invention relates to a method for producing a decorative material and a decorative material produced according to the method. Furthermore, the invention relates to the decorative material coated articles and their preparation.

There is a large market for painted metal sheets and metal foils, especially for painted aluminum sheets and aluminum foils. Such sheets and films are used in particular as decorative material, for example in the automotive sector or in construction. In the latter case, metal foils, in particular aluminum foils, are often used as vapor barriers.

A painting of the films is often desirable for optical reasons, to protect against corrosion in general appropriate. Technically, the painting of very thin metal foils, especially very thin aluminum foils, but often very difficult. Resistant paints generally have to be dried and / or cured at higher temperatures. Metal foils only a few microns thick can easily warp under these conditions. Furthermore, many coating compositions contain chemically highly reactive components that can attack oxidation-sensitive metals such as aluminum.

The object of the present invention was to provide a solution to this technical problem.

This object is achieved by the method for producing a decorative material having the features of claim 1. Preferred embodiments of the method according to the invention are specified in the dependent claims 2 to 4. A decorative material produced by the method is the subject of claim 5. Preferred embodiments of the decorative material according to the invention are given in the dependent claims 6-8. The method according to claim 9, in which the decorative material according to the invention finds application, is encompassed by the invention. Preferred embodiments of this method can be found in the dependent claims 10 to 12. The wording of all claims is hereby incorporated by reference into the content of this description.

• (a) Bereitstellen einer Metallfolie mit einer Dicke zwischen 10 µm und 200 µm, bevorzugt zwischen 10 µm und 100 µm, besonders bevorzugt zwischen 10 µm und 80 µm, insbesondere zwischen 30 µm und 50 µm.
• (b) Bereitstellen eines Schichtverbunds umfassend eine Trägerfolie, die mit einer Lackschicht beschichtet ist, bevorzugt mit einer zwischen 15 µm und 150 µm, besonders bevorzugt zwischen 15 µm und 80 µm, insbesondere zwischen 20 µm und 50 µm, dicken Lackschicht.
• (c) Flächiges Inkontaktbringen der Lackschicht des Schichtverbunds mit der Metallfolie.

A method according to the invention is used to produce a decorative material which comprises a thin metal foil and a lacquer layer applied thereon. It includes the following steps:

• (A) providing a metal foil having a thickness between 10 .mu.m and 200 .mu.m, preferably between 10 .mu.m and 100 .mu.m, more preferably between 10 .mu.m and 80 .mu.m, in particular between 30 .mu.m and 50 .mu.m.
• (B) providing a layer composite comprising a carrier film which is coated with a lacquer layer, preferably with a between 15 microns and 150 microns, more preferably between 15 microns and 80 microns, in particular between 20 microns and 50 microns, thick paint layer.
• (c) surface contacting of the lacquer layer of the layer composite with the metal foil.

The layer composite used is in the filed by the Applicant WO 2009/024310 A1 , the contents of which are hereby incorporated in their entirety into the content of the present description.

From the automotive industry, it has long been known, for the coating of body or interior parts instead of conventional coatings paint films (laminations comprising a carrier film and a paint layer applied thereto) to use. Such paint films can be prepared by large-area coating of plastic films by means of conventional painting and subsequent drying. A major advantage of using these paint films lies in the fact that in their application, in contrast to Spruchackierverfahren virtually no solvent emissions occur.

For a long time it has been the state of the art to not or only partially to harden the lacquer layer of paint films during their production. Even sticky layers of paint were covered by protective films. Only after application of the paint films was then complete curing of the paint layer, such as described in the EP 0 819 520 A2 ,

The WO 2009/024310 A1 on the other hand, relates to paint films in which the carrier film can be detached from a lacquer layer located thereon, even if this is already fully cured thermally and / or with UV. The paint layers of such paint films must not be cured after their application, they are preferably already fully cured (under a fully cured paint is too understand that the varnish substantially no longer thermally or by actinic radiation crosslinkable groups.). Preferably, the carrier film only serves as a "transfer medium", by means of which a lacquer is transferred to a substrate.

The present invention makes of the properties of in the WO 2009/024310 A1 layer composite use described. This can be laminated on metal foils of the specified thickness, without the need for subsequent curing. The known from the prior art problems are thus avoided elegantly.

In addition, it has been found that the decorative material produced has excellent characteristics regarding its Umformability at low temperatures. Surprisingly, it can adapt very well in the temperature range between 0 ° C and 50 ° C to the profile of a substrate to be coated. The cold formability of the decorative material allows a particularly simple contour-locked application, for example by bonding at room temperature (20 ° C). This opens up completely new fields of application, which usually do not develop with conventional decorative films.

Like in the WO 2009/024310 A1 described, it is the carrier film of the composite layer to a single or multilayer film. All films with release properties, in particular with release properties against polyurethane-based adhesives and coatings, are suitable in principle. Both thermoformable and non-thermoformable films can be used.

The carrier film preferably consists essentially of plastic, in particular of fluoropolymers such as ethylene-tetrafluoroethylene (ETFE), polyethylene terephthalate, polyolefin, polycarbonate, acrylonitrile-butadiene-styrene (ABS), acryl-styrene-acrylonitrile (ASA), acrylonitrile-butadiene-styrene / Polycarbonate (ABS / PC), acrylic styrene-acrylonitrile / polycarbonate (ASA / PC), polyacrylate, polystyrene, polycarbonate / polybutylene terephthalate (PC / PBT) and / or polymethyl methacrylate.

Particularly preferably, a layer composite used in a method according to the invention has a carrier film made of a polyolefin film.

The carrier film preferably has a thickness in the range between 10 μm and 1500 μm, in particular between 10 μm and 200 μm. The carrier film is usually transparent.

As a lacquer layer, the layer composite used preferably comprises a first lacquer layer based on polyurethane. Particular preference is given to using a lacquer prepared from an aqueous polyurethane dispersion. Particularly suitable are polyester-based polyurethane dispersions and those in the WO 2009/024310 A1 comprising lacquers comprising a double bond-containing, OH-functional component A, a double bond-containing, NCO-functional component B and optionally a double bond-containing component C, where component A is preferably a polyol and components B and C are preferably urethane acrylates. Regarding preferred features and properties of such paints is based on the content of WO 2009/024310 directed.

The first lacquer layer can be pigmented or present as a clearcoat. In addition to the first lacquer layer, the layer composite may have at least one second lacquer layer. The at least one second paint can basically be chosen freely. Of course, it should be chemically compatible with the first paint.

The second lacquer is preferably a pigmented liquid lacquer (base lacquer) and the first lacquer is a clear lacquer, the second lacquer preferably being arranged between the carrier foil and the first lacquer layer. The at least one basecoat film is preferably a film having color and / or effect properties. Particularly preferably, the basecoat is a water-based paint.

The optionally consisting of several layers of paint layer, with which the carrier film is coated, is preferably fully cured. Alternatively, it may also be only partially cured, but it is then preferred that it can be completely cured non-thermally, in particular exclusively by radiation.

The above information regarding the thickness of the lacquer layer refers to its state after complete curing.

In preferred embodiments, the metal foil is made of a metal selected from the group consisting of aluminum, iron, copper, nickel, tin and zinc or an alloy of one of these metals.

In a particularly preferred embodiment, the metal foil is an aluminum foil.

It should be noted at this point that although the claims of the present application are directed to a metal foil as a substrate to be coated, the present invention is not limited to the use of such. Rather, it is also possible to use sheet-like composite materials instead of the metal foil, preferably with the same thickness as the metal foil.

The composites may be, for example, embedded in a plastic matrix fabrics, felts or fibers, the latter in particular selected from the group of glass fibers, carbon fibers, plastic fibers, aramid fibers and combinations thereof, act.

In particular, a composite material used in the context of the present invention may be a so-called organic sheet. These are understood in general fiber-reinforced thermoplastic materials, which are suitable because of their high strength and rigidity at a low density as a lightweight material.

Both the metal foil and optionally the composite material are preferably provided as a quasi-endless band (running web material). The paint-side application of the layer composite is preferably carried out in the course of a continuous process. The layer composite can also be provided as a quasi-endless band. The dimensions of the straps used can basically be adjusted individually. Their length may for example be between 1 m and 1000 m, their width for example between 5 mm and 1 m.

In preferred embodiments of the method according to the invention, the carrier film of the layer composite remains as a protective film on the lacquer layer. This protects the lacquer layer both from contamination and from damage during storage and transport. If necessary, it is deducted only after further processing of the decorative material.

Before the two-dimensional contacting of the lacquer layer of the layer composite with the metal foil, an adhesion promoter, preferably based on polyvinyl chloride (PVC), can be applied to the lacquer layer and / or to the metal foil.

Alternatively or additionally, it is also possible to treat the surface of the metal foil mechanically and / or chemically and / or physically in order to improve the adhesion of the lacquer layer thereon. In the case of an aluminum foil, for example, its surface can be oxidized anodically.

• – eine Metallfolie mit einer Dicke zwischen 10 µm und 200 µm, bevorzugt einer Dicke zwischen 10 µm und 100 µm, besonders bevorzugt zwischen 10 µm und 80 µm, insbesondere zwischen 30 µm und 50 µm,
• – eine auf die Folie aufgebrachte Lackschicht bevorzugt eine Lackschicht mit einer Dicke zwischen 15 µm und 150 µm, besonders bevorzugt zwischen 15 µm und 80 µm, insbesondere zwischen 20 µm und 50 µm, und
• – gegebenenfalls die oben erwähnte haftvermittelnde Schicht, die zwischen der Lackschicht und der Folie angeordnet ist.

According to the above statements, the decorative material according to the invention comprises

• A metal foil having a thickness between 10 μm and 200 μm, preferably a thickness between 10 μm and 100 μm, particularly preferably between 10 μm and 80 μm, in particular between 30 μm and 50 μm,
• A lacquer layer applied to the foil preferably comprises a lacquer layer with a thickness of between 15 μm and 150 μm, more preferably between 15 μm and 80 μm, in particular between 20 μm and 50 μm, and
• If appropriate, the abovementioned adhesion-promoting layer which is arranged between the lacquer layer and the film.

In analogy to the lacquer layer of the layer composite, in preferred embodiments the lacquer layer comprises the mentioned first and second lacquer layer, ie in particular at least one base lacquer layer and a clear lacquer layer, wherein the base lacquer layer is preferably arranged between the clear lacquer layer and the metal foil. In this case, the basecoat film preferably has a thickness between 5 .mu.m and 40 .mu.m, in particular between 10 .mu.m and 30 .mu.m. The clearcoat film preferably has a thickness between 10 μm and 40 μm, in particular between 20 μm and 30 μm.

In a particularly preferred embodiment, the decorative material on the lacquer layer as a removable protective layer on the carrier film of the composite layer, as already mentioned.

• • eine Metallfolie der angegebenen Dicke,
• • die Lackschicht sowie
• • die Schutzfolie bzw. Trägerfolie.

In preferred embodiments, a decorative material according to the invention has the following layer sequence:

• A metal foil of the specified thickness,
• • the paint layer as well
• • the protective foil or carrier foil.

• • eine Metallfolie der angegebenen Dicke,
• • eine Basislackschicht,
• • eine Klarlackschicht sowie
• • die Schutzfolie bzw. Trägerfolie.

In a further preferred embodiment, a decorative material according to the invention has the following layer sequence:

• A metal foil of the specified thickness,
• A basecoat layer,
• • a clear coat as well
• • the protective foil or carrier foil.

• • eine Aluminiumfolie der angegebenen Dicke,
• • gegebenenfalls eine haftvermittelnde Schicht,
• • eine pigmentierte Basislackschicht,
• • eine Klarlackschicht sowie
• • die Schutzfolie bzw. Trägerfolie.

An inventive decorative material is particularly preferred if it has the following sequence of layers.

• An aluminum foil of the specified thickness,
• Optionally an adhesion-promoting layer,
• A pigmented basecoat film,
• • a clear coat as well
• • the protective foil or carrier foil.

Preferably, the decorative material tape or web-shaped, in particular as a wound tape or wound web.

The decorative material according to the invention is a semi-finished product or a semi-finished product intended for industrial further processing. The production method according to the invention described below is used in particular for this purpose.

The inventive method for producing a coated article is characterized in a first approximation by making use of the decorative material according to the invention.

In order to produce the coated article, according to the invention, the decorative material can be contacted with the object surface-wide, in particular the metal foil side of the decorative material can be pressed onto the article.

If it is a profiled object, the contact is made for the purpose of conformal connection of the decorative material with the surface of the article preferably under cold forming. The high flexibility of the decorative material allows a sheathing of profiles with very small radii.

Alternatively, it is possible to form the article by film-side injection molding or foam back of the decorative material.

In preferred embodiments, the decorative material is first brought by cold forming in the desired final shape. This can be done by conventional methods such as deep drawing, vacuum deep drawing, pressing, blow molding or high-pressure molding. The preforms of the decorative material thus produced can then be placed in an injection mold and back-injected or foamed in a known manner.

The inventive method is particularly suitable for coating window frames, facade elements, blinds, furniture, plastic parts, especially in the automotive sector, as well as products in the field of consumer electronics, appliances, sanitary facilities, air conditioning and heating systems.

In particular, when the metal foil is an aluminum foil, the decorative material according to the invention can be used excellently for coating window frames or facade elements.

Any article made by a process of the invention or using the decorative material of the present invention is encompassed by the present invention.

Further features of the invention will become apparent from the example in conjunction with the subclaims. In this case, individual features can be implemented individually or in combination with one another in one embodiment of the invention. The described preferred embodiments are merely illustrative and for a better understanding of the invention and are in no way limiting.

example

Provision of a layer composite comprising a carrier film which is coated with a lacquer layer

To produce such a layer composite, a tape-shaped carrier film of polyethylene terephthalate having a layer thickness of about 100 μm was provided. On top of this, a pigmented base coat (Wörwag Hydrobasislack Brillantsilber 105628) was applied first as a varnish layer, then a clearcoat having the following composition: Urethane acrylate binder (solid) with glass transition temperature of 2 ° C; Double bond density: 4 mol / kg 30% by weight 3 Polyol, double bond, binder (solid), OH content: 5.7%; Double bond density: 3.5 eq / kg 10% by weight Irgacure 184 (photoinitiator) 1% by weight Irgacure 819 (photoinitiator) 0.40% by weight Tinuvin 400 (sunscreen) 0.70% by weight Tinuvin 292 (sunscreen) 0.70% by weight Tego Glide 435 (surface additive) 2% by weight Byk 051 (surface additive) 2% by weight solvent 23.2% by weight Urethane acrylate, NCO-containing. Binder (solid), NCO content: 5.4%; Double bond density: 1.5 val / kg 3 30% by weight

The basecoat and the clearcoat were fully cured in one step. The basecoat layer had a layer thickness of about 35 .mu.m, the clearcoat layer has a layer thickness of about 25 .mu.m.

The clearcoat film was covered with a temporary protective film, then wound the composite of carrier film, temporary protective film and the paint layers located therebetween and stored as a roll until further use.

Providing an aluminum foil as a metal foil to be coated

It was a band-shaped aluminum foil provided with a thickness of 70 microns, also in the form of a coil. The dimensions of the aluminum foil corresponded to those of the laminar composite.

Production of decorative material according to the invention

After removal of the temporary protective film, the layer composite was contacted with the aluminum foil in a laminating device. For this purpose, the layer composite was pressed under light pressure with its paint side ahead of the aluminum foil. A 10 μm thick layer of a PVC-based adhesion promoter had previously been sprayed onto the aluminum foil.

After the coating, the carrier film of the layer composite remained as a protective layer on the lacquer layer of the composite. The resulting decorative material with a brilliant silver color was wound up on a roll for further processing.

Coating of a substrate by contact connection

For coating a window frame profile with the decorative material, a thin layer (5 to 15 μm) of a bonding agent was applied to this. In a next step, the decorative material was laminated at room temperature with the metal foil on the profile. The carrier layer was peeled off after lamination.

Injection of the decorative material

To produce a plastic molded part, which is formed by injecting the decorative material according to the invention, the mold cavity of an injection molding machine was lined with the decorative material produced. The lining was carried out at room temperature in a vacuum by contour-fitting pressing of the decorative material to the wall of the mold cavity. The protective layer remained in the process on the wall facing lacquer layer. After closing the injection molding machine, a polyurethane-based plastic was injected into the cavity by means of Reactive Injection Molding (RIM). The mold life was between 2 and 3 min. Subsequently, the finished plastic molded part firmly connected to the decorative material was ejected and the protective layer was removed from the paint surface.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• WO 2009/024310 A1 [0007, 0010, 0011, 0013, 0017]
• EP 0819520 A2 [0009]
• WO 2009/024310 [0017]

Claims (12)

A method for producing a decorative material comprising a thin metal foil having a thickness between 10 μm and 100 μm, preferably between 30 μm and 50 μm, and a lacquer layer applied thereto, comprising the steps (a) providing a metal foil of the indicated thickness, (b) providing a layer composite comprising a carrier film which is coated with a lacquer layer, preferably with a lacquer layer between between 15 μm and 100 μm, in particular between 20 μm and 50 μm, (c) surface contacting of the lacquer layer of the layer composite with the metal foil. A method according to claim 1, characterized in that the metal foil consists of a metal from the group consisting of aluminum, iron, copper, nickel, tin and zinc, in particular of aluminum. Method according to claim 1 or claim 2, characterized in that the lacquer layer of the layer composite is present hardened. Method according to one of claims 1 to 3, characterized in that prior to contacting the lacquer layer and / or on the metal foil, an adhesion promoter, in particular based on polyvinyl chloride (PVC), is applied. Decorative material, produced by a process according to one of claims 1 to 4, comprising A metal foil having a thickness between 10 μm and 100 μm, preferably between 30 μm and 50 μm, and - A coat of paint applied to the film. Decorative material according to claim 5, characterized in that the lacquer layer comprises at least one base lacquer layer and a clear lacquer layer, wherein the base lacquer layer is preferably arranged between the clear lacquer layer and the metal foil. Decorative material according to one of claims 5 or 6, characterized in that between the lacquer layer and the metal foil an adhesion-promoting layer and / or on the lacquer layer, the carrier film is arranged as a protective film. Decorative material according to one of claims 5 to 7, characterized in that it is present in tape or web form, in particular as a wound tape or wound web. A process for producing a coated article, wherein for the production of a decorative material according to any one of claims 5 to 8 is used and wherein it is preferred that the decorative material is contacted flat with the object, in particular the metal foil side of the decorative material is pressed onto the article. A method according to claim 9, characterized in that the article is formed by film-side injection molding or foam back of the decorative material. Method according to one of claims 9 or 10, characterized in that the decorative material is cold-formed prior to application to the article or during the formation of the article. Method according to one of claims 9 to 11, characterized in that it is the object to a window frame, a facade element or a blind.