Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Reexamination Certificate
2000-10-26
2003-04-08
Lorengo, J. A. (Department: 1734)
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
C156S231000, C156S232000, C156S233000, C156S235000, C156S240000, C156S247000, C156S289000, C156S273500, C427S148000, C428S195100, C428S344000, C428S438000, C428S542200, C428S913300, C428S914000
Reexamination Certificate
active
06544369
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to thin film-like material and process of producing it. More Specifically, the present invention relates to thin film-like material that can bear various designs having unique effects, that can be incinerated as it is or made into regenerated paper if a base material is made of paper, and that can have a printable surface, and process of producing it by transfer process.
2. Prior Art
Thin film-like material that is a laminated member made of, for example, a paper or resin web and sheet as a base material, and a thin metal layer formed on a surface of the base material, for example, by vacuum deposition process is broadly used in various kinds of wrapping paper interior wall paper, book covers, Christmas cards, and various kinds of labels. Al deposited paper is a typical example of the thin film-like material.
There is also known thin film-like material that has a mirror surface with metallic luster. (Note that for convenience sake, “mirror surface” will be also referred to as “surface having a mirror pattern”), a surface having a mat pattern with metallic luster, a surface having a hairline pattern with metallic luster, a surface having an embossed pattern, a surface having a hologram pattern or the like, even if it includes a paper or resin web and sheet as a base mate real. There is also thin film-like material in which more than one of the above patterns are combined on the same plane with metallic luster.
Thin film-like material as described above is usually produced as follows:.
First, in the case of thin film-like material having a mirror surface, resin is applied thin on a base material, and metal such as Al is deposited directly on the resin by vacuum deposition process or sputtering process to form a thin metal layer. Here, in order that the formed metal thin layer may generate mirror-surface luster with a metallic tone, the metal thin layer needs to have a thickness of 50 nm or more, usually.
Thin fllm-like material having a mat pattern Is usually produced by preparing a metal web and sheet having a mat pattern formed on one side, and sticking a base material to the opposite side of the metal web and sheet by applying adhesive between to form a laminated structure.
Thin film-like material having a hairline pattern is produced by preparing a metal web and sheet having a hairline pattern formed on one side, and sticking a base material to the opposite side of the metal web and sheet by applying adhesive between to form a laminated structure. Alternately, it can be produced as follows: A resin web and sheet having a hairline pattern formed on a surface is prepared. Release agent is applied on the surface having a hairline pattern, and then metal is deposited on the applied release agent, for example, by vacuum deposition process to form a metal thin layer. After hot melt adhesive is applied on the thin metal layer, a base material is stacked on it and both are subjected to hot stamping. Then, the metal thin layer is transferred to the base material side by removing the metal web and sheet from the resin web and sheet.
Thin film-like material having an embossed pattern is produced by sticking a metal web and sheet and a base material together to form a laminated structure, and then embossed finish having a minute height is applied on the metal web and sheet.
If the metal web and sheet used in producing the above-described thin film-like materials having a mat pattern, a hairline pattern and an embossed pattern is too small in thickness, the metal web and sheet may wrinkle or tear while it is handled. Therefore, a metal web and sheet of about 6 to 20 &mgr;m in thickness is usually used.
Thin film-like material having a hologram pattern is generally produced as follows: release agent is applied on one side of, for example, a resin web and sheet. A protective layer is formed on it, and a thermoplastic resin layer is formed on the protective layer. Then, a hologram pattern is sculptured on the surface of the thermoplastic resin layer by pressure heating process, and then, for example, aluminum is deposited on it. Then, the resin web and sheet thus prepared is stuck on a base material with the Al deposited surface being placed on it, and then the resin web and sheet is removed.
In recent years, general consumers tend to think more of individuality. They tend to want goods with a design having a more individual and novel effect.
This means that manufacturers are required to provide goods with a design having a discriminative effect in contrast to other goods.
The easiest way to impart a design having a new effect to the above-described thin film-like material having a surface pattern of various kinds is to print a desired pattern on the patterned surface to produce a combination of the original pattern and the printed pattern. For example, the combination is such that the original pattern has disappeared due to the printed pattern at some portions and remains visible at the other portions.
However, the above way has a problems. The original surface pattern of the thin film-like material is formed on a thin metal layer as described above. The pattern formed on the thin metal layer does not disappear easily even if a new pattern is printed thereon. Therefore, a satisfactory change of effect of design is not always obtained.
Further, the conventional thin film-like material using a metal web and sheet contains large amount of metal, because the metal web and sheet is large in thickness (about 6 to 20 &mgr;m). Therefore, the thin film-like material is hard to incinerate as it is. Further, in order to reuse the thin film-like material by making it into regenerated paper, the thin film-like material needs to be separated into the base material and metal web and sheet, for example, by being soaked in alkali solvent capable of dissolving the adhesive so that only the base material may be subjected to regeneration.
Further, in the conventional thin film-like material produced by depositing, for example, aluminum directly on a base material by vacuum deposition process, minute roughness of the surface of the base material reappear on the deposited aluminum as they are. Therefore, in order to produce thin film-like material having a mirror-like surface, a base material whose surface has fairly high smoothness needs to be used. For example, when a base material of woven or nonwoven fabric, or a base material having a rough surface is used thin film-like material having a mirror surface is hard to obtain. To sum up, the kinds of base material that can be used to produce the thin film-like material having a mirror surface are limited.
Further, a mirror surface can be formed using a base material of paper, to be sure. The luminance of the formed mirror surface depends on layer forming conditions, but the glossiness of the formed mirror surface is about 700% when it is measured in accordance with a method stipulated as method 5 of JIS-Z-8741. It is very difficult to raise the glossiness, for example, over 1000%.
OBJECTS AND SUMMARY OF THE INVENTION
An object of the present invention is to provide thin film-like material on which unique patterns of various kinds that would meet the recent demand can be formed easily and which can have a design having an effect that has never been produced, and process of producing it.
Another object of the present invention is to provide thin film-like material on which a desired pattern can be formed easily regardless of the kind of a base material, which uses only a very small amount of metal and therefore can be incinerated as it is, which can have a mirror surface that exhibits a glossiness of much higher than 1500% when measurement is performed in accordance with the above-mentioned method, and which can be broken and turned into regenerated paper when a base material is made of paper; and process of producing that thin film-like material.
in order to attain the above objects, the present invention provides
thin film-like material having a laminated structure in which an
Kitamura Yoshinori
Matsumoto Shigenobu
Japan Tobacco Inc.
Lorengo J. A.
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