JP2002120347A - Decorative material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorative material having laminated constitution of a woody resin molded object having a good woody feeling and good processability such as cutting or nailing and a decorative sheet excellent in design effect, capable of being easily recycled without separating woody resin molded object and the decorative sheet. SOLUTION: The decorative material is formed by laminating the decorative sheet 1 based on a thermoplastic resin same to the thermoplastic resin 3 contained in a woody resin foamed molded object 2 to the surface of the woody resin foamed molded object 2 containing the thermoplastic resin 3 and a woody filler 4 and having cells 5 present therein.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative material used for building interior materials such as flooring materials, wall materials and ceiling materials, fittings, and surface materials of home electric appliances.

[0002]

2. Description of the Related Art Conventionally, decorative materials for the above-mentioned various uses include:
2. Description of the Related Art In many cases, a natural veneer, a decorative paper or a decorative sheet formed by printing on a paper or a synthetic resin sheet, and the like are bonded to a wood substrate such as a plywood or a fiber board. However, these decorative materials suffer from physical properties such as warping, insect erosion, and corrosion due to moisture absorption and release of the wooden base material, and are difficult to recycle. Has been disposed of by landfill or incineration.

[0003] Further, as a decorative material using a substrate other than wood, there is also used a decorative resin bonded to a surface of a synthetic resin substrate by deformed extrusion or the like. There is no such a drawback as described above due to the use of the wood base material, and the appearance is like a wood due to the attachment of the decorative sheet of the wood grain design. However, there is a problem that there is no woody texture in terms of specific gravity, rigidity, etc., and that various processes such as cutting and nailing are difficult, and there is a disadvantage that it can be used only in a limited portion.

In recent years, many attempts have been made to provide a wood resin molded article containing a thermoplastic resin and a wood filler for applications such as building interior materials, flooring materials, fittings, and surface materials of home appliances. . However, these woody resin molded articles have excellent recyclability, workability such as cutting and nailing, and a woody feel when used alone, and the surface thereof is of a monotonous color colored with a woody filler. Therefore, there is a disadvantage that the design is inferior.

[0005] Therefore, it is conceivable to impart a desired excellent design by attaching a surface material such as a natural veneer, a decorative paper or a decorative sheet to the surface of the above-mentioned woody resin molded article. However, in the decorative material in which various surface materials are attached to the surface of the wood resin molded body in this manner, the separation of the surface material from the wood resin molded body which is the main body of discarded scrap materials and waste materials is technically difficult. However, since it is economically difficult, there is a concern that a problem may occur that the recyclability of the woody resin molded product is not sufficiently utilized.

On the other hand, the inventors of the present invention have proposed a method in which the surface of a woody resin molded product containing a thermoplastic resin and a woody filler is
We have already proposed a decorative material in which a decorative sheet mainly composed of a thermoplastic resin similar to the thermoplastic resin contained in the woody resin molded product is laminated (Japanese Patent Application No. 2000-178362). This cosmetic material has good wood texture, workability such as cutting and nailing,
In addition, it has an excellent advantage of having both excellent design and recyclability.

However, in the above decorative material, the woody resin molded body as the base material is inferior in adhesiveness to a normal woody base material such as plywood or fiber board, and is widely used for ordinary wood. When a decorative sheet is stuck using an adhesive containing a volatile component that is not 100% solids, such as an aqueous emulsion adhesive or a solvent adhesive,
A long curing period is required after bonding because the volatile components in the adhesive do not easily come off between the non-breathable woody resin molded product and the decorative sheet and stay in the adhesive for a long time. In addition, there is a problem that adhesion failure such as wrinkles, displacement, and swelling is likely to occur during curing, and it is difficult to adhere the woody resin molded article to the decorative sheet.

[0008]

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems in the prior art, and the objects thereof are to provide a feeling of wood, cutting and nailing. It is a decorative material with a laminated structure of a woody resin molded body with good workability and a decorative sheet with excellent design, and can be easily recycled without the need to separate the woody resin molded body and the decorative sheet. Another object of the present invention is to provide a decorative material having excellent adhesion between a woody resin molded product and a decorative sheet.

[0009]

Means for Solving the Problems The cosmetic material of the present invention contains a thermoplastic resin and a wood-based filler, and is contained on the surface of the foamed wood-based resin foamed article in the wood-based resin foamed article. A decorative material characterized by being laminated with a decorative sheet mainly composed of the same thermoplastic resin as the thermoplastic resin to be produced.

[0010] In particular, in the above-mentioned decorative material, the foamed wooden resin article has at least a portion containing a wood-based filler or entirely contains a wood-based filler. Material.

[0011] In particular, the above-mentioned decorative material is characterized in that the wood-based filler has an average particle size of 1 to 200 µm.

Particularly, in the above-mentioned decorative material, the mixing ratio of the wood-based filler in the portion containing the wood-based filler is 10 to 100 parts by weight of the thermoplastic resin.
It is a cosmetic material characterized by being 500 parts by weight.

[0013] In particular, in the above-mentioned decorative material, the foamed wooden resin article has a foamed part in a part thereof or is entirely foamed.

[0014] In particular, in the above-mentioned decorative material, the wooden resin foam molded article has an expansion ratio of 1.1 to 10.0 times.

[0015] In particular, in the above decorative material, the thermoplastic resin is a polyolefin resin.

[0016] In particular, in the above-mentioned decorative material, the decorative sheet has a wood grain design.

[0017] In particular, the decorative material is characterized in that the decorative sheet has transparency.

[0018]

BEST MODE FOR CARRYING OUT THE INVENTION As shown in FIG. 1, the decorative material of the present invention contains a thermoplastic resin 3 and a wood-based filler 4 and is a foamed wood resin (bubble 5 exists inside). A decorative material characterized in that a decorative sheet 1 mainly composed of a thermoplastic resin of the same type as the thermoplastic resin 3 contained in the woody resin foam molded article 2 is laminated on the surface of the foam molded article 2. .

As described above, in the decorative material of the present invention, the decorative sheet 1 and the wood-based resin foam molded body 2 are mainly composed of the same thermoplastic resin. It can be reused as a material of the woody resin foamed molded article 2 without separating it from the resin foamed molded article 2, and there is no molding failure at the time of molding at the time of recycling. There is no damage or reduction in strength.

Moreover, since the wood resin foam molded body 2 is made porous and has a porous shape containing bubbles 5 therein, the adhesion between the decorative sheet 1 and the wood resin foam molded body 2 can be achieved by using an aqueous emulsion type adhesive or the like. Even if an adhesive containing a general-purpose volatile component for wood, such as a solvent-type adhesive, is used, the volatile component in the adhesive is diffused through the bubbles 5 inside the foamed wooden resin article 2, and the adhesive Can be quickly dried and solidified, so that it can be efficiently and stably manufactured without requiring a long time for curing after bonding and without generating wrinkles, displacement, or swelling during curing. What you can do,
After the bonding, the adhesive enters the air bubbles in the vicinity of the bonding surface of the wood resin foam molded body 2, and thus has an advantage such that the adhesive force is improved by the anchoring effect.

In addition to the above, foaming of the wood-based resin foam molded article 2 can be achieved by improving the heat insulating property to prevent a cold feel or dew condensation, or by imparting an appropriate elasticity (cushioning property). There are also advantages such as improvement in safety at the time of collision and walking feeling as a floor material, and improvement in workability and economy due to weight reduction.

In particular, when the decorative sheet 1 has a wood grain design, the woody resin foam molded article 2 contains the woody filler 4, so that the woody mouth can be seen by cutting or grooving. Because of the texture, there is no sense of incongruity with the wood grain design on the surface. In addition, the printing ink for giving the wood grain design to the decorative sheet 1 is similar in color to the wood material. Wood resin foam molding 1
Even if mixed in, there is an advantage that there is no unnatural feeling in color.

The material of the wood-based filler 4 used in the present invention is not particularly limited as long as it is a powdery, granular or short-fiber filler basically produced from natural wood. It can be arbitrarily selected from conventionally known ones, but in general, wood is broken by a cutter mill or the like, and this is pulverized by a ball mill or an impeller mill or the like into a fine powder (wood). Powder) can be suitably used.

When the amount of the wood-based filler 4 is more than 100 parts by weight based on 100 parts by weight of the thermoplastic resin, the dispersibility in the resin is particularly important. From this viewpoint, it is preferable to use the granular wood-based filler 4 having relatively few cilia. As the wood-based filler 4 having less cilia, specifically, a polishing powder mainly obtained by polishing a particle board or the like is preferably used.

The average particle size of the wood-based filler 4 is not particularly limited, but is generally preferably 1 to 200 μm, more preferably 5 to 100 μm. If the average particle size is less than 1 μm, it is difficult to handle, and especially when the amount of the wood-based filler 4 is large, poor dispersion in the resin may cause a decrease in mechanical strength. There is. On the other hand, if it is larger than 200 μm, the uniformity, flatness and mechanical strength of the molded product are likely to be reduced.

The amount of the wood-based filler 4 is not particularly limited in the present invention, but is generally about 10 to 500 parts by weight based on 100 parts by weight of the thermoplastic resin 3. It is possible to select appropriately within the range,
Since the optimum blending amount varies depending on the use of the cosmetic material, it is desirable to appropriately design the amount according to the use.

Specifically, for example, when a polyolefin resin is used as the thermoplastic resin 3, after forming into a flat plate by a compression molding method or the like, cutting, V-cutting, or the like is performed. In order to obtain a resin having excellent post-processability, the amount of the wood-based filler 4 is 50 to 500 parts by weight, more preferably 100 to 500 parts by weight, based on 100 parts by weight of the thermoplastic resin 3. It is desirable. On the other hand, for applications molded by, for example, a profile extrusion method or an injection molding method, the wood-based filler 4 is added in an amount of 10 to 100 parts by weight of the thermoplastic resin 3 in order to improve moldability and homogeneity. It is desirable that the amount be 200 parts by weight, more preferably 15 to 150 parts by weight.

In the present invention, the thermoplastic resin 3 used for the wood resin foam molded article 2 includes, for example, a polyolefin resin, a polystyrene resin, a polycarbonate resin,
Polyester resins, polyamide resins, polyvinyl alcohol resins, acrylic resins, polyvinyl chloride resins, cellulose derivatives, etc., can be appropriately selected from conventionally known various thermoplastic resins. Considering problems such as the generation of harmful substances such as dioxins and dioxins, and the outflow of environmental hormones during landfills, it is desirable to use non-halogen resins, among which the weather resistance and heat resistance of components, chemicals and solvents It is most desirable to use a polyolefin-based resin in order to satisfy performances such as resistance to odor.

The polyolefin resin used here includes polyethylene, polypropylene, polybutene,
Polyisoprene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, ethylene-α olefin copolymer, propylene-α olefin copolymer, ethylene-ethyl acrylate copolymer, and acid-modified products thereof (adhesion For the purpose of improvement, an unsaturated carboxylic acid or an anhydride thereof is graft-polymerized), an ionomer (a metal hydrate of an olefin-unsaturated carboxylic acid copolymer) or the like can be appropriately selected. May be mixed.

However, in the case of a mixture of a plurality of types, in order to obtain a wood-based resin foam molded article 2 which can maintain sufficient physical properties as a base material for a decorative material even after recycling, it is as good as possible in compatibility with each other. It is desirable to select and combine things. Alternatively, in the case of mixing resins having poor compatibility, the incorporation of a compatibilizer is also effective. For example, mixing or lamination of polyethylene and polypropylene, and in the case where incompatible resins are mixed, these are made compatible. It is more desirable to blend an ethylene-propylene copolymer or the like. Particularly, in order to enhance the adhesiveness between the resins and increase the internal strength, the compounding ratio of the acid-modified resin is increased (about 20 to 50% by weight of the entire resin), and the resin itself is made polar and the It is desirable to enhance the adhesiveness with the filler 4.

In the foam molding of the wood resin foam molded article 2, it is desirable that the thermoplastic resin 3 contained therein has a high melt tension in order to improve foamability. When using a resin of a type having a relatively low tension, a known method such as the use of a resin into which long-chain branching is introduced by electron beam crosslinking, adjustment of the molecular weight distribution, or addition of an additive that increases the melt tension. It is desirable to use a resin whose melt tension is adjusted to be higher as necessary.

In the present invention, the technique for foaming the wood resin foam molded article 2 is not particularly limited, and any conventionally known various resin foaming techniques can be arbitrarily used. Specifically, for example, there is a mechanical foaming method of mechanically introducing bubbles 5 by vigorously stirring a molten thermoplastic resin 3 in air, and a method of more easily obtaining a stable foamed state. In many cases, a foaming technique using a foaming agent as an additive to the thermoplastic resin 3 is used. The foaming method using such a foaming agent is generally a chemical foaming method using a chemical foaming agent having a property of generating a gas by thermal decomposition or a chemical reaction, and a low boiling point as a foaming agent introduced into a resin. It is classified into a physical foaming method in which a liquid is heated and vaporized.

Examples of the chemical foaming agent include inorganic foaming agents such as sodium bicarbonate, ammonium carbonate, ammonium bicarbonate, ammonium nitrite, sodium borohydride, light metals, and azide compounds; and azo, nitroso, and hydrazide compounds. And the like, and these can be used in any combination. In particular, physical foaming is mainly used for foaming at a high expansion ratio exceeding 2 times, and carbon dioxide or aliphatic hydrocarbon is mainly used as a foaming agent. Also, in physical foaming, a chemical foaming agent is often used in combination in order to adjust the cell shape of the foam.

If the expansion ratio of the foamed wooden resin article 2 is too low, various effects due to foaming are poor. On the other hand, if it is too high, the mechanical strength is reduced, and it cannot withstand the load or stress applied to the decorative material. In some cases, the adhesive strength with the decorative sheet may be reduced as a result of a decrease in the surface strength. Therefore, although it depends on the application, it is generally 1.1 to 10.0 times, and more preferably 1.3 to 8.0 times. It is desirable to be within the range of twice.

In addition to the above-mentioned wood-based filler 4 and the foaming agent, the wood-based resin foam molded body 2 may further comprise a heat stabilizer, an acid neutralizer, an ultraviolet absorber, a light stabilizer, a pigment or a dye, if necessary. Various types of coloring agents, organic or inorganic fillers other than wood, antistatic agents, lubricants, nucleating agents, flame retardants, antiblocking agents, light scattering agents for translucency, gloss adjusting agents, etc. One or more selected from additives can be added.

Among these additives, hindered phenol-based, sulfur-based, phosphorus-based and the like as heat stabilizers, metal stearate, hydrotalcite and the like as acid neutralizers.
Fillers such as benzotriazole, benzoate, benzophenone, and triazine as ultraviolet absorbers, hindered amines as light stabilizers, halogen-based flame retardants, phosphorus-based flame retardants, and chlorine-based flame retardants as flame retardants As calcium carbonate, silica, titanium oxide, barium sulfate, zinc oxide, alumina, talc, mica, magnesium silicate, potassium titanate, magnesium sulfate, aluminum hydroxide, magnesium hydroxide, iron oxide, carbon black, metal powder, etc. As the lubricant, a hydrocarbon-based lubricant,
Fatty acids, higher alcohols, fatty acid amides, metal soaps, esters, etc., nucleating agents such as metal carboxylate, sorbitol, phosphate metal salts, etc .; pigments such as condensed azo, insoluble azo, quinacridone Organic pigments such as isoindolinone, anthraquinone, imidazolone and phthalocyanine; inorganic pigments such as carbon black, cobalt blue, titanium oxide, zinc oxide and iron oxide; titanium oxide-coated mica; and pearl pigments such as bismuth oxide chloride. Yes, these additives can be used in any combination.

In the present invention, the wood resin foam molded article 2
May contain the wood-based filler 4 as a whole, or if the processability such as the recyclability, wood texture, cutting property, nailing property, and adhesive property, which are the objects of the present invention, is not impaired, for example, A layer not containing the wood-based filler 4 may be present, such as a skin layer (a thin layer on the surface) made of a thermoplastic resin similar to the thermoplastic resin 3 contained in the portion containing the wood-based filler 4. Absent.

In the present invention, the wood resin foam molded article 2 may be foamed as a whole, or may have the object of the present invention such as recyclability, wood texture, cutting property, nailing property, adhesive property and the like. If the processability of the foam is not impaired, a non-foamed layer such as a skin layer (surface thin layer) made of a thermoplastic resin similar to the thermoplastic resin 3 contained in the foamed portion exists. It doesn't matter.

The presence of the skin layer which does not contain the wood-based filler 4 or is not foamed as described above is caused by the wood-based semi-dotted 4
To prevent the air bubbles 5 due to heat or foam from being exposed on the surface of the wood-based resin foam molded body 2 and smooth the surface,
In particular, it also has an effect of improving the stain resistance and the water resistance in a portion where the decorative sheet 1 is not bonded. However, in view of the object of the present invention described above, in the present invention, it is desirable that at least the surface portion of the wood resin foam molded body 2 at the portion where the decorative sheet 1 is bonded is a foamed portion.

The mode of existence of the portion not containing the wood-based filler 4 and the portion which is not foamed is not limited to the above-described skin layer. Arbitrary structures such as streaks, meshes, and layers can be adopted. In addition, even in a portion containing the wood-based filler 4 or in a foamed portion, it is not always necessary that the wood-based filler 4 is uniformly blended in the entirety or the whole is foamed uniformly. A plurality of types of portions having different compounding ratios and expansion ratios of the filler 4 may be formed in, for example, a sea-island shape, a streak shape, a mesh shape, a layer shape, or the like.

The wood resin foam molded body 2 is made of a thermoplastic resin 3
A wood resin foamable composition obtained by adding and kneading the wood-based filler 4 and a foaming agent to the foamed resin composition is molded into an appropriate shape by an appropriate molding method and foamed. The method of kneading the wood-based filler 4 and the thermoplastic resin 3 is not particularly limited, but a method of kneading with a Banbury mixer and pelletizing with a pelletizer or a method of mixing and pelletizing with a twin-screw extruder is generally used. It is a target. Further, the wood-based filler 4 may be kneaded with the thermoplastic resin 3 simultaneously with the molding of the thermoplastic resin 3. Although the foaming agent can be kneaded at the time of pelletization, it is desirable to add the foaming agent at the time of molding in order to prevent an unexpected foaming accident before molding.

When the decorative material of the present invention is recycled, the crushed product is added with a wood-based filler 4, a thermoplastic resin 3, and other various additives, if necessary, and pelletized again. In this case, the method is not particularly limited.

The method for producing the wood resin foam molded article 2 is not particularly limited, either. For example, various well-known methods such as a compression molding method, an extrusion molding method, a profile extrusion molding method, an injection molding method, an injection compression molding method, and a transfer molding method. What is necessary is just to select suitably from the molding method according to the shape and dimension of a molded product. The shape thereof can be freely selected, for example, a flat plate shape, a three-dimensional shape, a hollow shape, a rib shape, and the like. In the profile extrusion molding method, adopting the Celka method is particularly effective for improving the surface properties.
In addition, plate-shaped ones that are molded with high expansion ratio by gas foaming,
In order to enhance the uniformity of the foamed state, it is particularly effective to use a circular die and extrude it into a cut-out plate.

The decorative material of the present invention is formed by laminating a decorative sheet 1 for imparting a desired and appropriate design on the surface of the above-mentioned foamed wooden resin article 2. What is essential is that the decorative sheet 1 is mainly composed of a thermoplastic resin similar to the thermoplastic resin 3 contained in the woody resin foam molded article 2, thereby improving the recyclability of the decorative material of the present invention. It is secured.

It should be noted that in the present invention, it is important that the same type of thermoplastic resin can be recycled without significant change in physical properties even when mixed with each other. As the thermoplastic resin to be used, the same type of thermoplastic resin is selected and used from various thermoplastic resins similar to those listed as examples of the thermoplastic resin 3 contained in the woody resin foam molded article 2 described above. be able to.

Specifically, for example, in the case of a polyolefin resin, polyethylene, polypropylene, polybutene, polyisoprene, ethylene-propylene copolymer,
Ethylene-vinyl acetate copolymer, ethylene-α olefin copolymer, propylene-α olefin copolymer, ethylene-ethyl acrylate copolymer and their acid-modified products (unsaturated carboxylic acids or Graft polymerized anhydrides), ionomers (metal hydrates of olefin-unsaturated carboxylic acid copolymers) and the like can be appropriately selected, and the same or different resins selected from these can be used as wood resin. Foam molded body 2 and decorative sheet 1
Can be used for

When different kinds of resins are combined, it is preferable that the resins are compatible with each other or adhere to each other well. However, even if they are not so, both are compatible and / or bonded. Can be used if the physical properties after mixing can be maintained by adding a compatibilizer and / or an adhesive. However, in such a case, the compatibilizer and / or the adhesive may be one or both of the woody resin foam molded article 2 and the decorative sheet 1 so that it is not necessary to separately add the compatibilizer and / or the adhesive at the time of recycling. Is desirably added in advance to the resin composition constituting the above.

If necessary, the thermoplastic resin constituting the decorative sheet 1 may include at least one selected from the same various additives as those of the thermoplastic resin 3 constituting the above-mentioned foamed wooden resin article 2. Can be added.

The specific structure of the decorative sheet 1 is not particularly limited. For example, a single-layer decorative sheet having a transparent or colored sheet with a pattern printed thereon, a colored sheet with a pattern printed thereon. Applications include multi-layer decorative sheets with a clear sheet attached to the printed surface by, for example, dry lamination, extrusion lamination, heat lamination, etc., back-printed single-layer decorative sheets with a pattern printed on the back side of a transparent sheet, etc. Can be appropriately selected according to the conditions. In the case of a multi-layer decorative sheet, it is needless to say that the same type or different types of thermoplastic resin should be used as the thermoplastic resin constituting each layer.

The type of design of the printed pattern applied to the decorative sheet 1 is not particularly limited, and can be arbitrarily selected from, for example, a wood pattern, a stone pattern, a cloth pattern, an abstract pattern, and the like. In particular, if a wood-grained decorative sheet is used, cutting and
There is no sense of incongruity with the woody resin foam molded body 1 exposed by cutting, and the printing ink has the same color as the woody material. Since there are no problems, it can be said to be the most desirable for the purpose of the present invention.

At this time, when the decorative sheet 1 has a sufficient concealing property by adopting a colored sheet and / or forming a concealed solid printing layer, there is an advantage that stable reproduction of the design is achieved. On the other hand, when the decorative sheet 1 has transparency, the surface of the wooden resin foam molded article 2 containing the wood-based filler 4 can be seen through the decorative sheet 1, There is an advantage that a design expression utilizing a feeling of wood can be realized.

As a binder of the printing ink used for printing the design pattern on the decorative sheet 1, for example, nitrified cotton,
It may be appropriately selected from cellulose, vinyl chloride-vinyl acetate copolymer, polyvinyl butyral, polyurethane, acryl, polyester and the like alone or modified products. These may be aqueous, solvent-based or emulsion-type, and may be arbitrarily selected from a one-pack type or a two-pack type using a curing agent. Further, the ink can be cured by irradiation with ultraviolet rays, electron beams, or the like. Among them, the most common one is a two-part curable urethane resin-based printing ink which is cured with a curing agent comprising a polyol prepolymer as a main component and an isocyanate compound, and is particularly excellent in adhesion to a polyolefin resin.

Other than these binders, coloring agents such as pigments and dyes, extenders, solvents,
Various additives are added. Particularly commonly used pigments include condensed azo, insoluble azo, quinacridone, isoindolinone, anthraquinone, imidazolone, organic pigments such as phthalocyanine, and inorganic pigments such as carbon black, cobalt blue, titanium oxide, zinc oxide, and iron oxide. Examples include pearl pigments such as titanium oxide-coated mica and bismuth oxychloride.

Examples of the design pattern printing method include a gravure printing method, an offset printing method, a gravure offset printing method, a dry offset printing method, a screen printing method, a flexographic printing method, a letterpress printing method, an ink jet printing method, an electrostatic printing method, and the like. A conventionally known appropriate printing method such as a transfer printing method can be used. When a solid printing layer such as a concealed solid printing layer is used in combination, for example, a gravure coating method,
Use coating methods such as microgravure coating, roll coating, knife coating, air knife coating, kiss coating, rod coating, die coating, lip coating, comma coating, flow coating, and dip coating. You can also.

Before the printing of the design pattern, the printing surface of the sheet to be printed may be subjected to, for example, a corona discharge treatment, a plasma treatment, an ozone treatment, a flame treatment, an acid treatment, an alkali treatment, a primer or anchor treatment, etc., if necessary. A surface treatment can be performed to improve the adhesiveness with the printing ink.

In each decorative sheet 1,
A primer coat for bonding to the wood resin foam molded body 2 is applied to the back surface, a top coat for surface protection and gloss adjustment, a conduit expression by an embossing method, a wiping method, a gloss mat method, and the like. It may be applied to the surface.

In the decorative material of the present invention, the method of laminating the decorative sheet 1 on the surface of the wooden resin foam molded article 2 is not particularly limited, and an appropriate lamination may be performed depending on the size and shape of the wooden resin foam molded article 2. You can choose the method. For example, in the case of a flat shape, an adhesive is applied to the front surface of the flat woody resin foam molded body 2 and / or the back surface of the decorative sheet 1 and is bonded in a roll. For a molded article having the same shape, a lapping method can be used, and for a molded article having a complicated three-dimensional surface, a vacuum press lamination method can be used.

Simultaneous painting by laminating a decorative sheet at the same time as molding is also possible by the simultaneous extrusion molding simultaneous lamination method and the injection molding simultaneous lamination method. When using a wood resin foam molded article 2 or a decorative sheet 1 made of a thermoplastic resin such as a polyolefin resin which is difficult to adhere to, a corona discharge treatment, an ozone treatment, a plasma discharge treatment, a flame treatment, It is desirable to improve the adhesiveness by performing a surface treatment such as an acid treatment or an alkali treatment, or a primer coat or an anchor coat.

When the decorative material of the present invention is recycled, it is not necessary to separate and separate the wood resin foam molded article 2 and the decorative sheet 1 from each other. Then, by re-molding, a recycled wood resin foam molded article 2 can be obtained. Here, the method of pelletization and molding,
The method for the original wood resin foam 2 (virgin product) is exactly the same as the method described above. In addition, at the time of recycling, if necessary, a wood-based filler 4, a thermoplastic resin 3, a foaming agent, and other various additives are appropriately added to the crushed material of the cosmetic material of the present invention or its heated melt. May be.

As another recycling method, there is a method of separating and recovering the thermoplastic resin 3 and the wood-based filler 4. In this case, however, the decorative sheet 1 is made of the wood-based resin foam 2. It does not need to be separated from the resin, and can be recovered together with the thermoplastic resin 3 contained in the foamed wooden resin article 2.

Depending on the mode of use of the cosmetic material of the present invention,
For example, it may not be suitable for recycling due to compounding with other resin-based parts. In addition, as a result of repeating the above-described recycle use many times, there is a case where the recycle use becomes unsuitable due to accumulation of mixed foreign substances and natural deterioration of the resin. In such a case, in the decorative material of the present invention, as the thermoplastic resin mainly composed of the thermoplastic resin 3 and the decorative sheet 1 contained in the wooden resin foam molded article 2, non-halogen-based resins such as polyolefin-based resins are used. If the resin is used, it can be incinerated without fear of generating harmful substances such as hydrogen chloride gas and dioxin during combustion. At the time of the incineration disposal, if waste heat is subjected to thermal recycling for reuse in power generation, hot water supply, cooling and heating, and the like, it goes without saying that a more environmentally friendly utilization form can be obtained.

[0062]

EXAMPLES Hereinafter, the present invention will be described in more detail by showing specific examples and comparative examples of the present invention.

Example 1 70 parts by weight of a high melt tension polypropylene resin having a long chain branch by electron beam crosslinking, 30 parts by weight of a maleic acid-modified homopolypropylene resin, and wood were broken by a cutter mill, and the resultant was broken by a ball mill. 400 parts by weight of the pulverized woody filler having an average particle diameter of 20 μm was mixed and pelletized by a twin-screw extruder to prepare a woody resin composition. This woody resin composition is foamed four times by a physical foaming method using butane gas, extruded from a circular die, cut open, shaped into a rectangular parallelepiped having a cross section of 5 mm x 300 mm, and further subjected to corona discharge treatment on the surface. Thus, a virgin polyolefin-based wood resin foam molded article was prepared.

On the other hand, a film formed by blending a pigment such as iron oxide or titanium oxide with a random polypropylene resin and having a thickness of 100
Wood grain printing with urethane-based ink on a colored polypropylene resin sheet of μm, embossed lamination of homopolypropylene resin with a thickness of 100 μm on the printing surface by extrusion lamination, primer coating on the back surface, top coat on the front surface Thus, a decorative sheet made of a polyolefin resin was prepared.

Thereafter, the decorative sheet made of the polyolefin resin was bonded to the surface of the foamed polyolefin-based resin molded article by a lapping method to prepare a virgin product decorative material of the present invention.

Also, the virgin cosmetic material of the woody resin foam molded article and the decorative sheet are crushed as they are without being separated from each other, and then pelletized again by a single screw extruder, which is again subjected to a physical foaming method using butane gas. Foamed about 4 times larger than the circular die, extruded, cut open, formed into a rectangular parallelepiped shape with a rectangular cross section of 5 mm x 300 mm, and further subjected to corona discharge treatment on the surface to form a recycled polyolefin-based wood resin foam A molded body was produced.

Thereafter, the same polyolefin resin decorative sheet as that used for the virgin product is bonded to the surface of the foamed polyolefin-based resin molded product of the recycled product by a lapping method. A cosmetic material of the present invention was produced.

<Comparative Example 1> In Example 1, the woody resin composition was extruded into a rectangular parallelepiped having a cross section of 5 mm x 300 mm by a profile extrusion method without physical foaming with butane gas. Then, a non-foamed polyolefin-based wood resin molded article was obtained, and the other conditions were exactly the same as in Example 1 above (however, the production conditions of the recycled non-foamed polyolefin-based wood resin molded article were the same as those of the above-mentioned virgin product). Virgin and recycled cosmetics were produced.

<Comparative Example 2> In Example 1, a colored polyvinyl chloride resin sheet having a thickness of 100 μm was formed by blending a pigment such as iron oxide or titanium oxide in place of the polyolefin resin decorative sheet. Wood-grain printing is performed with urethane-based ink.
The same procedure as in Example 1 was used except that a polyvinyl chloride resin clear sheet of μm was embossed and laminated at the same time, a primer coat was applied to the back surface, and a top coat was applied to the front surface. Made virgin and recycled cosmetics.

<Comparative Example 3> In Example 1, virgin products and recycled products were used in exactly the same manner as in Example 1 except that 30 parts by weight of talc were used instead of 400 parts by weight of the wood-based filler. Was prepared.

<Evaluation of Performance> Example 1 and Comparative Examples 1 to
Regarding the cosmetic material of virgin product and recycled product, the moldability, saw cutting property, nailing property, adhesion with vinyl acetate aqueous emulsion type adhesive for wood, design
The wood texture (by visual and tactile sensations) was evaluated. Table 1 shows the evaluation results.

[0072]

[Table 1]

From the evaluation results in Table 1 above, the thermoplastic resin and the wood-based filler are contained, and the surface of the foamed wooden resin foam molded article is filled with the thermoplastic resin contained in the wood resin foam molded article. The decorative material of the present invention in which a decorative sheet mainly composed of a thermoplastic resin of the same type as the resin is laminated, has a feeling of wood, has good cutting properties, nailing properties, and good workability such as adhesiveness with a general-purpose adhesive. Moreover, it was confirmed that the cosmetic material had both excellent design properties and recyclability.

[0074]

As described above in detail, the decorative material of the present invention contains a thermoplastic resin and a wood-based filler, and is provided on the surface of the foamed wood-resin foam. Since the decorative sheet mainly composed of the same thermoplastic resin as the thermoplastic resin contained in the molded body is laminated, it is excellent in workability such as cutting and nailing, high design with the decorative sheet and wood resin foam Because it has a visual and tactile woody feel due to the molded article, it can be easily recycled without the need to separate the woody resin foam and the decorative sheet, and since the woody resin foam is foamed, In addition to being able to easily and firmly bond decorative sheets with general-purpose adhesives for wood such as aqueous emulsion type and solvent type containing volatile components, it is similar to natural wood due to the elasticity and heat insulation properties derived from the foam structure. Warm and soft And a buffer against such touch or impact.

As described above, the decorative material of the present invention makes use of the high designability of the decorative sheet, and is useful for building interior materials, fittings, and household electrical appliances which have been difficult to use in conventional woody resin molded articles having poor designability. It can be used sufficiently for applications such as surface materials. Moreover, it is possible to apply various types of post-processing that has been conventionally performed on wood-based decorative materials, and in particular, the present invention allows the use of general-purpose wood adhesives in the bonding operation, and makes it possible to use conventional plywood and medium-sized plywood. Density fiberboard (MDF)
As easy to use as a general-purpose wood material such as has been realized,
It is a very large material that contributes to industrial development and protection of the global environment as a non-corrosive and easily recyclable material replacing conventional wood materials.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view schematically illustrating an embodiment of a cosmetic material of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Decorative sheet 2 Wood resin foam molding 3 Thermoplastic resin 4 Wood filler 5 Bubbles

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification code FI Theme coat ゛ (Reference) C08L 101/00 C08L 101/00 E04F 13/18 E04F 13/18 A F-term (Reference) 2E110 AA42 AA57 AB04 AB23 BA02 BA12 BB32 GA24X GA32W GA33X GA43X GB43W GB43X GB62X 4F100 AA20H AA23H AK01A AK01B AK03A AK03B AK07 AK51 AL04 AL05A AL07 AP00A BA02 BA44 CA23 DE01A DJ01A EC03 EC032 EH17 EH171 EJ02 EJ021 EJ40 EJ402 EJ55 EJ552 GB08 HB00B HB01B JB16A JB16B JL01 JL16 YY00A 4J002 AB01W AH00X BB00W BC02W BD04W BE02W BG00W CF00W CG00W CL00W GL01

Claims (9)

[Claims] 1. A foamed wood resin foam containing a thermoplastic resin and a wood-based filler, and a thermoplastic resin similar to the thermoplastic resin contained in the wood resin foam formed on the surface of the foamed wood resin foam. A decorative material characterized by being laminated with a decorative sheet mainly composed of: 2. The foamed wood resin article according to claim 1, wherein the foamed resin article has at least a portion containing a wood-based filler or entirely contains a wood-based filler. Cosmetic materials. 3. The wood-based filler has an average particle size of 1 to 200.
The decorative material according to claim 1, wherein the thickness is μm. 4. The blending ratio of the wood-based filler in the portion containing the wood-based filler is as follows:
The cosmetic material according to any one of claims 1 to 3, wherein the cosmetic material is used in an amount of 10 to 500 parts by weight based on 0 part by weight. 5. The decorative material according to claim 1, wherein said foamed wooden resin article has a foamed part in a part thereof or is entirely foamed. . 6. The expansion ratio of the foamed wooden resin article is 1.
The cosmetic material according to any one of claims 1 to 5, wherein the ratio is 1 to 10.0 times. 7. The decorative material according to claim 1, wherein said thermoplastic resin is a polyolefin resin. 8. The decorative material according to claim 1, wherein said decorative sheet has a wood grain design. 9. The decorative material according to claim 1, wherein said decorative sheet has transparency.