# US 11,993,057 B2 · Film to hold a metal layer, metallic decorative sheet intermediate product, metallic decorative sheet, extruded laminate product, metallic molded product, injection molded product, method for producing a metallic molded product, method for producing injection molded product, and method for producing an extruded laminate product

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- Number: US 11,993,057 B2
- Document ID: US11993057B2
- Status: Granted
- Kind: B2
- Application number: 16/959,579
- Filed: 2019-01-09
- Published: 2020-12-10
- Granted: 2024-05-28
- Earliest claimed: 2018-01-12
- Assignees: Wavelock Advanced Technology Co., Ltd.
- Applicants: Wavelock Advanced Technology Co., Ltd.
- Inventors: Chikatsu Akisada; Tetsuya Kurosawa; Ryuta Takeuchi
- Web page: https://patentgrep.com/patent/US11993057B2

## CPC

- B32B 15/09: comprising polyesters
- B29C 45/1418: {the inserts being deformed or preformed, e.g. by the injection pressure}
- B29C 45/14262: {Clamping or tensioning means for the insert}
- B29C 45/14688: {Coating articles provided with a decoration}
- B29C 45/14811: {Multilayered articles (B29C45/14827 takes precedence)}
- B32B 1/00: Layered products having a non-planar shape
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 27/08: of synthetic resin
- B32B 27/281: {comprising polyimides}
- B32B 27/302: {comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers}
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 27/308: {comprising acrylic (co)polymers}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/322: {comprising halogenated polyolefins, e.g. PTFE}
- B32B 27/34: comprising polyamides
- B32B 27/36: comprising polyesters
- B32B 27/365: {comprising polycarbonates}
- B32B 27/40: comprising polyurethanes
- B32B 37/12: characterised by using adhesives
- C08J 7/06: with compositions not containing macromolecular substances
- B29K 2667/00: Use of polyesters {or derivatives thereof} for preformed parts, e.g. for inserts
- B29K 2667/003: {PET, i.e. poylethylene terephthalate}
- B29K 2705/00: Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
- B29L 2009/003: {comprising a metal layer}
- B32B 2250/03: 3 layers
- B32B 2250/24: All layers being polymeric
- B32B 2255/10: on synthetic resin layer or on natural or synthetic rubber layer
- B32B 2255/205: Metallic coating
- B32B 2307/30: having particular thermal properties
- B32B 2307/412: Transparent
- B32B 2307/732: Dimensional properties
- B32B 2451/00: Decorative or ornamental articles
- B32B 2509/00: Household appliances
- B32B 2605/003: Interior finishings
- C08J 2367/02: Polyesters derived from dicarboxylic acids and dihydroxy compounds; (C08J2367/06 takes precedence)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

An objective of the present invention is to provide a film to hold a metal layer, a metallic decorative sheet intermediate product, a metallic decorative sheet, a metallic molded product, and a method for producing a metallic molded product which prevent the occurrence of the whitening phenomena or the like of the metallic molded product which occur during production of the metallic molded products by using a metallic decorative sheet, as well as enables molding in a wider temperature range. A film to hold a metal layer comprises a thermoplastic resin having a melting point of 230° C. to 250° C. is provided, wherein the film to hold a metal layer has transparency.

## Claims

### Claim 1

A metallic decorative sheet intermediate product, comprising:
a metal layer; and
a film layer to hold the metal layer comprising a film to hold the metal layer, wherein the film holds the metal layer, wherein the film to hold the metal layer comprises: a thermoplastic resin that is a modified polyethylene terephthalate resin having a melting point of 235° C. to 243° C., wherein the film to hold the metal layer has transparency,
a second adhesive layer including one resin or a mixture of two or more resins selected from polyurethane-based, polyvinyl acetate-based, ethylene vinyl acetate copolymer-based, epoxy-based, and silicone-based resins,
wherein the metal layer, the film layer to hold the metal layer and the second adhesive layer are laminated in sequence, and
wherein the thickness of the metal layer is 10 nm to 100 nm, and
wherein the metal layer has a sea-island structure in which islands of metal particle have gaps apart from each other,
wherein the metal layer is vacuum-deposited on one side of the film layer to hold the metal layer,
wherein the film to hold the metal layer is a film that is softened and drawn down by heating, and wherein a temperature difference between a temperature at which the film to hold the metal layer recovers from drawdown and a temperature at which the film to hold the metal layer starts to hang down due to melting is from 95° C. to 120° C.,
wherein the temperature difference is determined for the film to hold the metal layer by performing a clamping step and a heating step and then measuring changes in a surface temperature of the film to hold the metal layer and the hanging state of the film to hold the metal layer,
wherein the clamping step includes cutting the film to hold the metal layer into 350 mm×300 mm, and the film to hold the metal layer is sandwiched from above and below by a clamping frame of a vacuum-compressed air forming machine, and four sides of the film to hold the metal layer is gripped so as not to cause loosening by their own weight,
wherein the heating step is performed after the clamping step, the film to hold the metal layer is moved to a heating section of the vacuum-compressed air forming machine, and heaters each having nine heat generating bodies are arranged above and below the film to hold the metal layer, and then the film to hold the metal layer is heated uniformly, and wherein
during the heating step, the film to hold the metal layer is observed in a horizontal direction to evaluate the behavior of hanging of the sheet due to heating.

### Claim 2 (depends on 1)

The metallic decorative sheet intermediate product according to claim 1, wherein a total luminous transmittance of the film to hold a metal layer is 85% or more.

### Claim 3 (depends on 1)

The metallic decorative sheet intermediate product according to claim 1, wherein a haze of the film to hold a metal layer is 2.0% or less.

### Claim 4 (depends on 1)

The metallic decorative sheet intermediate product according to claim 1, comprising:
a first laminate with
the film layer to hold the metal layer,
the metal layer and
a first adhesive layer
laminated in this sequence.

### Claim 5 (depends on 1)

The metallic decorative sheet intermediate product according to claim 1, comprising:
a second laminate with the second adhesive layer,
the film layer to hold the metal layer,
the metal layer,
a first adhesive layer and
a base film layer
laminated in this sequence.

### Claim 6 (depends on 1)

The metallic decorative sheet intermediate product according to claim 1, comprising:
a third laminate with
a protection film layer having transparency,
the second adhesive layer,
the film layer to hold the metal layer,
the metal layer, and
a first adhesive layer
laminated in this sequence.

### Claim 7 (depends on 1)

The metallic decorative sheet intermediate product according to claim 1, wherein a total luminous transmittance of the film to hold the metal layer is 85% or more.

### Claim 8 (depends on 1)

The metallic decorative sheet intermediate product according to claim 1, wherein a haze of the film to hold the metal layer is 2.0% or less.

### Claim 9 (depends on 1)

The metallic decorative sheet intermediate product according to claim 1, wherein the thermoplastic resin is polyethylene terephthalate modified with neopentyl glycol.

### Claim 10 (depends on 1)

A metallic decorative sheet comprising the metallic decorative sheet intermediate product according to claim 1 comprising:
a fourth laminate with:
a protection film layer having transparency,
the second adhesive layer,
the film layer to hold the metal layer,
the metal layer,
a first adhesive layer and
a base film layer
laminated in this sequence.

### Claim 11 (depends on 10)

An extruded laminate product comprising a metallic decorative sheet according to claim 10 and
a resin sheet,
wherein the resin sheet is laminated on the protective film layer and/or the base film layer.

### Claim 12 (depends on 10)

A metallic molded product comprising a molded product of the metallic decorative sheet according to claim 10.

### Claim 13 (depends on 12)

An injection molded product comprising:
the metallic molded product according to claim 12; and
a resin layer,
wherein the resin layer is injected and molded on a surface of the base film layer of the metallic molded product.

### Claim 14 (depends on 10)

A method for producing a metallic molded product, comprising:
a molding step of fitting the metallic decorative sheet according to claim 10 having a surface temperature of 160° C. to 215° C. to a mold to obtain a molded product.

### Claim 15 (depends on 14)

The method for producing a metallic molded product according to claim 14, wherein the metallic decorative sheet is fitted to the mold by vacuum and/or compressed air.

### Claim 16 (depends on 14)

The method for producing a metallic molded product according to claim 14, comprising, before the molding step,
a clamping step of clamping the metallic decorative, and
a heating step of heating the metallic decorative sheet after the clamping step.

### Claim 17 (depends on 14)

A method for producing an injection molded product, comprising:
an injection molding step of using an injection molding die to inject a resin between a surface of the base film layer of a metallic molded product obtained with the method for producing the metallic molded product according to claim 14 and the injection molding die in order to form a resin layer so that a molded product is obtained in which the metallic molded product is integrated with the resin layer.

### Claim 18 (depends on 10)

The method for producing an extruded laminate product, comprising:
a laminating step of laminating a molten resin sheet on the protection film layer and/or the base film layer of the metallic decorative sheet according to claim 10.