Decorative film for film insert molding and method for manufacturing same

A method for manufacturing a decorative film for film insert molding, the method comprising:

• a lamination step of laminating a fluorine-based resin layer containing 100 to 80 parts by mass of a fluorine-based resin and 0 to 20 parts by mass of a methacrylic acid ester-based resin, and an acrylic-based resin layer containing 50 to 0 parts by mass of a fluorine-based resin and 50 to 100 parts by mass of a methacrylic acid ester-based resin, by a co-extrusion method;
• a pressure-bonding step of pressure-bonding, with a heating roll, a decorative layer containing a thermoplastic resin to a surface of the acrylic-based resin layer of a laminate obtained in the lamination step, the surface being on the side not in contact with the fluorine-based resin layer;
• and
• a surface unevenness structure forming step of pressure-bonding a surface unevenness heating roll to a surface of the fluorine-based resin layer immediately after the pressure-bonding step, the surface being on the side not in contact with the acrylic-based resin layer, and thereby forming a surface unevenness structure on the surface.

A molded body, having:

• a fluorine-based resin layer containing 100 to 80 parts by mass of a fluorine-based resin and 0 to 20 parts by mass of a methacrylic acid ester-based resin;
• an acrylic-based resin layer containing 50 to 0 parts by mass of a fluorine-based resin and 50 to 100 parts by mass of a methacrylic acid ester-based resin;
• a decorative layer containing a thermoplastic resin;
• and
• a base material layer containing a thermoplastic resin
• laminated therein in this order,
• wherein the fluorine-based resin layer has a thickness of 10 to 200 μm, and
• surface unevenness is formed on a surface of the fluorine-based resin layer, the surface being on the side not in contact with the acrylic-based resin layer.

A method for manufacturing a molded body, the method comprising:

• a softening step of heating a decorative film for film insert molding in a mold to soften the decorative film, the decorative film having:
• a fluorine-based resin layer containing 100 to 80 parts by mass of a fluorine-based resin and 0 to 20 parts by mass of a methacrylic acid ester-based resin;
• an acrylic-based resin layer containing 50 to 0 parts by mass of a fluorine-based resin and 50 to 100 parts by mass of a methacrylic acid ester-based resin;
• and a decorative layer containing a thermoplastic resin, laminated therein in this order, the fluorine-based resin layer having a thickness of 10 to 200 μm, and surface unevenness being formed on a surface of the fluorine-based resin layer, the surface being on the side not in contact with the acrylic-based resin layer;
• a forming step of forming the decorative film softened in the softening step, into a final shape under vacuum pressure or with compressed air;
• and
• an injection step of pouring a thermoplastic resin for forming a base material layer into the mold after the forming step, cooling the thermoplastic resin to solidify, and thereby obtaining a molded body having the decorative film for film insert molding and the base material layer integrated therein.

A laminated film, utilized for manufacturing a decorative film for film insert molding,

• the laminated film having:
• a fluorine-based resin layer containing 100 to 80 parts by mass of a fluorine-based resin and 0 to 20 parts by mass of a methacrylic acid ester-based resin;
• and
• an acrylic-based resin layer containing 50 to 0 parts by mass of a fluorine-based resin and 50 to 100 parts by mass of a methacrylic acid ester-based resin,
• laminated therein, and the fluorine-based resin layer having a thickness of 10 to 200 μm,
• wherein during the manufacture of the decorative film, the decorative film is manufactured by pressure-bonding a decorative layer containing a thermoplastic resin to the laminated film with a heating roll, and immediately after the pressure-bonding, forming a surface unevenness structure on a surface of the fluorine-based resin layer, the surface being on the side not in contact with the acrylic-based resin layer, by pressure-bonding a surface unevenness heating roll to the surface.