Textured hardcoat films
Textured hardcoat films are disclosed for preferable use in film insert moulding. Texture in the hardcoat film is created through the use of a textured protective overlayer, which can impart texture to the curable coating of the hardcoat film. This process preferably avoids the need to alter the composition of the curable coating to allow for texture and preferably produces a hardcoat film with a matte and reduced-glare finish. An apparatus and a method embodying the invention are disclosed.
1. A method of producing a molded decorative article comprising the steps of:
(i) providing a hardcoat film comprising:
a polymeric film substrate having a first side and a second side;
a curable coating having a first side and a second side, wherein the first side of the curable coating is disposed on the second side of the polymeric film substrate; and
a protective overlayer having a first side and a second side, wherein the first side of the protective overlayer is disposed on the second side of the curable coating;
wherein at least the first side of the protective overlayer is textured; and
wherein the texture of the first side of the protective overlayer is imparted to the second side of the curable coating;
(ii) printing an image on the hardcoat film;
(iii) removing the protective overlayer;
(iv) forming the hardcoat film into a three-dimensional pattern by using one or more of heat and vacuum to set or thermoset the hardcoat film into the three-dimensional pattern;
(v) curing the curable coating;
(vi) cutting the hardcoat film; and
(vii) injection molding a plastic part on the first side of the polymeric film substrate.
2. The method according to claim 1 , wherein the step of removing the protective overlayer occurs either before or after the step of forming the hardcoat film into a three-dimensional pattern.
3. The method according to claim 1 wherein the curable coating is curable with ultraviolet radiation and wherein the step of curing the curable coating is performed using ultraviolet radiation.
4. The method according to claim 1 wherein the texture of the second side of the curable coating reduces glare.
5. The method according to claim 1 wherein the texture of the second side of the curable coating is soft or smooth to the touch.
6. The method according to claim 1 wherein a second protective overlayer having a first side and a second side is removed from the hardcoat film prior to the step of providing a hardcoat film with the protective overlayer, and wherein the second side of the second protective overlayer is not textured and is disposed on the second side of the curable coating prior to the step of providing a hardcoat film with the protective overlayer.
7. The method according to claim 1 wherein the polymeric film substrate is polycarbonate, polyester, or PMMA.
8. The method according to claim 1 wherein steps (i) through (vii) are performed in order.
9. The method according to claim 1 , wherein the curable coating is partially thermal cured prior to step (iv).
10. The method according to claim 1 , wherein the hardcoat film is formed into a three-dimensional pattern by vacuum forming to create the three-dimensional formed shape and is thereafter fully cured by exposure to UV radiation.
11. The method according to claim 1 , wherein only a portion of the protective overlayer is textured, wherein the texture is imparted to only a corresponding portion of the curable layer.
12. A method of producing a molded decorative article comprising the steps of:
(i) providing a hardcoat film comprising:
a polymeric film substrate having a first side and a second side;
a curable coating having a first side and a second side, wherein the first side of the curable coating is disposed on the second side of the polymeric film substrate; and
a protective overlayer having a first side and a second side, wherein the first side of the protective overlayer is disposed on the second side of the curable coating;
wherein at least the first side of the protective overlayer is textured; and
wherein the texture of the first side of the protective overlayer is imparted to the second side of the curable coating;
(ii) printing an image on the hardcoat film;
(iii) removing the protective overlayer;
(iv) forming the hardcoat film into a three-dimensional pattern by vacuum forming to create the three-dimensional formed shape;
(v) curing the curable coating by exposure to UV radiation;
(vi) cutting the hardcoat film; and
(vii) injection molding a plastic part on the first side of the polymeric film substrate.