UV-curable resin composition for vacuum forming and replica film of real material comprising the same

1. A UV-curable resin composition comprising:

a prepolymer comprising a urethane-containing oligomer;

an acrylate monomer; and

a photoinitiator,

wherein the photoinitiator comprises a firstphotoinitiator and a second photoinitiator,

wherein the first photoinitiator comprises 1-hydroxy cyclohexyl phenyl ketone and the second photoinitiator comprises diphenyl(2,4,6-trimethylbenzoyl)phosphine oxide (TPO),

wherein the prepolymer is present in an amount of about 20 to 50% by weight, the acrylate monomer comprises an amount of about 15 to 30% by weight of isobornyl acrylate, an amount of about 15 to 30% by weight of 2-hydroxypropyl acrylate and an amount of about 1 to 10% by weight of hydroxyl pivalate neopentyl glycol diacrylate, and

the photoinitiator comprises an amount of about 1% by weight to 5% by weight of the first photoinitiator and an amount of about 0.5% by weight to 1% by weight of the second photoinitiator,

wherein the weight percentage (% by weight) is based on the total weight of the UV-curable resin composition in each case.

2. The UV-curable resin composition according to claim 1 , wherein the urethane-containing oligomer is obtained or obtainable by reacting:

isocyanate comprising one or more selected from the group consisting of toluene diisocyanate (TDI), naphthalene-1,5-diisocyanate, p-phenylene diisocyanate, tolidine diisocyanate, 4,4′-diphenyl methane diisocyanate, 4,4′-methylene dicyclohexyl diisocyanate, 4,4′-methylene dicyclohexyl diisocyanate, hexamethylene diisocyanate, hexamethylene diisocyanate, dicyclohexylmethane diisocyanate and isophorone diisocyanate;

a polyol comprising one or more selected from the group consisting of polyether polyol, polyester polyol, polycarbonate polyol and acryl polyol; and

a reactive monomer.

3. The UV-curable resin composition according to claim 2 , wherein the reactive monomer comprises one or more selected from the group consisting of 2-hydroxyethyl acrylate, 4-hydroxybutyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl acrylate and pentaerythritol triacrylate.

4. The UV-curable resin composition according to claim 1 , wherein the urethane-containing oligomer has a weight average molecular weight of about 2,000 g/mol to 5,000 g/mol.

5. The UV-curable resin composition according to claim 1 , wherein the acrylate monomer comprises one or more selected from the group consisting of isobornyl acrylate, 2-hydroxypropyl acrylate and hydroxyl pivalic acid neopentyl glycol diacrylate.

6. The UV-curable resin composition according to claim 1 , wherein the acrylate monomer comprises isobornyl acrylate, 2-hydroxypropyl acrylate, and hydroxyl pivalic acid neopentyl glycol diacrylate.

7. The UV-curable resin composition according to claim 1 , further comprising an additive selected from UV stabilizers, heat-resistant stabilizers and combinations thereof.

8. A replica film of a real material comprising:

a base layer;

a resin layer provided on the base layer, and

a printing layer provided on the resin layer,

wherein the resin layer comprises a first surface adjacent to the base layer and a second surface adjacent to the printing layer and comprises the UV-curable composition according to claim 1 .

9. The replica film according to claim 8 , wherein the resin layer comprises a surface pattern.

10. The replica film according to claim 8 , wherein the replica film has bendability corresponding to a curvature radius of about 1 mm to 10 mm and an elongation of about 200% or greater.

11. A vehicle part comprising the replica film according to claim 8 .

12. A method of producing a replica film of a real material, comprising:

forming a resin layer comprising the UV-curable resin composition according to claim 1 on a base layer;

forming a surface pattern on a surface of the resin layer; and

forming a laminate of the resin layer.

13. The method according to claim 12 , wherein the resin layer has a thickness of about 100 to 250 μm.

14. The method according to claim 12 , wherein the laminate is formed by applying vacuum at a temperature of about 130 to 150° C.

15. The method according to claim 12 , wherein the replica film has bendability corresponding to a curvature radius of about 1 mm to 10 mm and an elongation of about 200% or greater.