JP2016147389A - Decorative plate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorative plate which has weather resistance, contamination resistance and solvent resistance, and can improve non-combustibility, workability and weather resistance.SOLUTION: A decorative plate (20) has a decorative sheet (10) in which a weather-resistant resin layer (4) and a fluororesin layer (5) are laminated on one surface side of a base material layer (1) in this order. The other surface side of the base material layer (1) constituting the decorative sheet (10) is stuck to a composite panel (7) in which a mixed resin layer (7a) containing a polyethylene resin and aluminum hydroxide is sandwiched between metal plates (7b). The weather-resistant resin layer (4) is formed of a mixture of an acrylic resin and an acrylic resin-based rubber, has a mixing ratio of the acrylic resin of 40 mass% or more and 70 mass% or less, has a mixing ratio of the acrylic resin-based rubber of 30 mass% or more and 60 mass% or less, has a ratio of the thickness of the fluororesin layer (5) to the thickness of the weather-resistant resin layer (4) in a range of 10:90 to 40:60, and has non-combustibility.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a decorative board in which a decorative sheet is bonded to a composite panel.

  Conventionally, as a decorative board, there exists a technique of patent document 1 (paragraph 0003), for example. In the technique described in Patent Document 1, an acrylic resin having excellent weather resistance is used for the outermost layer of the decorative sheet.

JP 2000-326451 A

However, although acrylic resin is excellent in weather resistance, there is a problem that dirt is likely to adhere because the stain resistance, oil resistance, and solvent resistance are low, and the attached dirt cannot be wiped off with a solvent. is there. There is also a problem that workability and nonflammability are low.
The present invention pays attention to the above points, and has a weather resistance, a stain resistance, and a solvent resistance, and a decorative board capable of improving both nonflammability, workability, and weather resistance. The purpose is to provide.

  In order to solve the above problems, a decorative sheet according to one embodiment of the present invention has a decorative sheet in which a weather-resistant resin layer and a fluororesin layer are laminated in this order on one surface side of a base material layer, and the decorative sheet The other surface side of the base material layer constituting the substrate is bonded to a composite panel in which a mixed resin layer containing polyethylene resin and aluminum hydroxide is sandwiched between metal plates, and the weather resistant resin layer is made of acrylic resin and acrylic resin rubber. The mixing ratio of the acrylic resin is 40% by mass to 70% by mass, the acrylic resin rubber is 30% by mass to 60% by mass, and the thickness of the fluororesin layer and the weather resistant resin layer The thickness ratio is in the range of 10:90 to 40:60 and is nonflammable.

Here, incombustibility is based on ISO 5660-1 and conforms to the Building Standards Act Article 2 No. 9 and the Building Standards Act Construction Ordinance Article 108-2. (1) The total calorific value for 20 minutes after the start of heating is 8 MJ / m ² or less. (2) The maximum heat generation rate continues for 10 seconds or more and exceeds 200 kW / m ² for 20 minutes after the start of heating. (3) It is preferable to have incombustibility sufficient to satisfy the condition of no cracks and holes harmful to fire prevention for 20 minutes after the start of heating.

  According to one embodiment of the present invention, the weather resistant resin layer and the fluororesin layer are stacked on the base material layer, and thus have weather resistance, contamination resistance, and solvent resistance. Further, the acrylic resin of the weather resistant resin layer is 40% by mass or more and 70% by mass or less, the acrylic resin rubber is 30% by mass or more and 60% by mass or less, and the ratio between the thickness of the fluororesin layer and the thickness of the weather resistant resin layer is Since the range is from 10:90 to 40:60, both nonflammability, workability, and weather resistance can be improved. Thus, according to one embodiment of the present invention, there is provided a decorative board that has weather resistance, stain resistance, and solvent resistance, and that can improve both incombustibility, workability, and weather resistance. be able to.

It is sectional drawing which shows the decorative board which concerns on embodiment based on this invention.

Next, embodiments of the present invention will be described with reference to the drawings.
Here, the drawings are schematic, and the relationship between the thickness and the planar dimensions, the ratio of the thickness of each layer, and the like are different from the actual ones. Further, the embodiment described below exemplifies a configuration for embodying the technical idea of the present invention, and the technical idea of the present invention is that the material, shape, structure, etc. of the component parts are as follows. It is not something specific. The technical idea of the present invention can be variously modified within the technical scope defined by the claims described in the claims.

(Decorative board 20)
As shown in FIG. 1, the decorative board 20 of the present embodiment has a weather resistant resin layer 4 and a fluororesin layer 5 laminated in this order on one surface side of the base material layer 1 to form a decorative sheet 10, A composite panel 7 is bonded to the other surface side of the base material layer 1 via an adhesive layer 6. Thereby, the decorative sheet 10 and the decorative board 20 have weather resistance, stain resistance, and solvent resistance.
In FIG. 1, the decorative sheet 10 has a pattern layer 2 between the base material layer 1 and the weather resistant resin layer 4, and the pattern pattern layer 2 and the weather resistant resin layer 4 are bonded with the transparent adhesive layer 3. The case is illustrated. The pattern pattern layer 2 and the transparent adhesive layer 3 may be omitted.

(Base material layer 1)
The base material layer 1 is a sheet-like layer made of a thermoplastic resin. It does not specifically limit as a thermoplastic resin, A well-known thermoplastic resin can be used. For example, a polyolefin resin such as polyethylene, polypropylene, polybutene, polymethylpentene, an ethylene-vinyl acetate copolymer or a saponified product thereof, a polyolefin copolymer such as an ethylene- (meth) acrylic acid (ester) copolymer, Polyester resins such as polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polyarylate, polycarbonate, copolymerized polyester (typically known as PET-G, which is a 1,4-cyclohexanedimethanol copolymerized polyethylene terephthalate resin), poly Acrylic resins such as methyl methacrylate, polyamide resins such as 6-nylon, 6,6-nylon, 6,10-nylon and 12-nylon, styrene resins such as polystyrene, AS resin and ABS resin, cell Fiber derivatives such as acetoacetate and nitrocellulose, chlorinated resins such as polyvinyl chloride and polyvinylidene chloride, fluorinated resins such as polyvinyl fluoride, polyvinylidene fluoride, polytetrafluoroethylene, ethylene-tetrafluoroethylene copolymer, etc. Alternatively, two or more kinds of copolymers or mixtures selected from these, mixtures, composites, laminates, and the like can be used. In particular, polyolefin resin is more preferable in view of productivity in a melt extrusion apparatus, environmental compatibility, mechanical strength, durability, price, and the like. Further, the thermoplastic resin is colored by mixing pigments, and a base material color that matches the design of the decorative sheet 10 is set.

(Picture pattern layer 2)
The design pattern layer 2 is a layer on which a design for imparting design properties is printed. As the pattern, for example, a pattern suitable for a place where the decorative sheet 10 is used, such as wood grain, cork, stone grain, tile, pottery, and abstract pattern can be selected. Further, the printing ink is not particularly limited as long as the printability and weather resistance are taken into consideration, and a known printing ink can be used. For example, a printing ink having pigments of isoindolinone, disazo, polyazo, diketopyrrolopyrrole, quinacridone, phthalocyanine, titanium oxide, and carbon black can be used. Moreover, the expression of a pattern can be enriched by mix | blending combining a pigment. Moreover, weather resistance can also be made favorable by adding a ultraviolet absorber, a light stabilizer, etc.
In addition, as a pattern printing method, for example, a known printing method such as gravure printing, offset printing, silk screen printing, ink jet printing, etc. can be used. A coating technique or apparatus may be used.

(Transparent adhesive layer 3)
The transparent adhesive layer 3 is a sheet-like layer made of a transparent adhesive. The transparent adhesive is not particularly limited, and a known adhesive can be used. For example, a thermoplastic resin such as a polyamide resin, an acrylic resin, or a vinyl acetate resin, or a curable resin such as a thermosetting urethane resin can be used. Further, for example, a two-component curable urethane resin or polyester resin using isocyanate as a curing agent may be used. In this embodiment, an acrylic resin-polyester resin-vinyl chloride acetate resin that is a heat sealant is used as the transparent adhesive.

(Weather-resistant resin layer 4)
The weather resistant resin layer 4 is a sheet-like layer made of a mixture of an acrylic resin and an acrylic resin rubber. The acrylic resin is not particularly limited, and a known acrylic resin can be used. For example, a methyl methacrylate resin or a polymethyl methacrylate resin (Tg is about −20 ° C.) can be used. Moreover, you may add a well-known ultraviolet absorber and light stabilizer to an acrylic resin. These mixing ratios are set such that the acrylic resin is 40 mass% or more and 70 mass% or less, and the acrylic resin rubber is 30 mass% or more and 60 mass% or less. Thereby, workability can be improved. “The mixing ratio is 40% by mass or more and 70% by mass or less of acrylic resin and 30% by mass or more and 60% by mass or less of acrylic resin rubber” means that the mixing ratio of acrylic resin and acrylic resin rubber is mass. The ratio refers to 4: 6 to 7: 3.

(Fluorine resin layer 5)
The fluororesin layer 5 is a sheet-like layer made of a fluororesin. It does not specifically limit as a fluororesin, A well-known fluororesin can be used. For example, polyvinylidene fluoride (PVDF), tetrafluoroethylene resin (PTFE), tetrafluoroethylene perfluoroalkoxy vinyl ether copolymer (PFA), tetrafluoroethylene / hexafluoropropylene copolymer (FEP), polychloro Trifluoroethylene (PCTFE), tetrafluoroethylene / ethylene copolymer (ETFE), chlorotrifluoroethylene / ethylene copolymer (ECTFE), and polyvinyl fluoride (PVF) can be used. In particular, in consideration of the bending whitening property and the adhesion to the weather resistant resin layer 4, polyvinylidene fluoride (PVDF Tg is −39 ° C.) is more preferable. In terms of whitening resistance, it is more preferable to set the ratio of the thickness of the fluororesin layer 5 to 20% or more and 40% or less with respect to the thickness of the weathering resin layer 4. When the decorative sheet 10 of the present embodiment is bonded to the composite panel 7 and then folded, the outermost layer (the fluororesin layer 5) extends larger than the inner layer (the weather resistant resin layer 4), but the outermost layer ( Since the Tg of the fluororesin layer 5) is low, fine cracks that cause whitening are less likely to occur.

  Moreover, it is preferable to set the ratio of the thickness of the fluororesin layer 5 and the thickness of the fluororesin layer 5 in the range of 10:90 to 40:60. Thereby, nonflammability can be improved. Furthermore, considering the bending whitening property and weather resistance, it is preferable to set the total thickness of the weather resistant resin layer 4 and the fluororesin layer 5 within a range of 20 μm to 80 μm. In particular, 30 μm or more and 60 μm or less are more preferable in terms of bending whitening property and weather resistance.

(Adhesive layer 6)
The adhesive layer 6 is a sheet-like layer made of an adhesive. It does not specifically limit as an adhesive agent, A well-known adhesive agent can be used. For example, a thermoplastic resin such as a polyamide resin, an acrylic resin, or a vinyl acetate resin, or a curable resin such as a thermosetting urethane resin can be used. Further, for example, a two-component curable urethane resin or polyester resin using isocyanate as a curing agent may be used.

(Composite panel 7)
The composite panel 7 includes a mixed resin layer 7a serving as a core and metal plates 7b attached to both surfaces of the mixed resin layer 7a.
The mixed resin layer 7a is a layer made of a mixed resin containing a polyethylene resin and aluminum hydroxide. The metal plate 7b is a plate-like member made of metal. The metal is not particularly limited, and a known metal can be used. For example, aluminum, galvalume, stainless steel, or titanium can be used. In particular, considering weight reduction, aluminum or gallium is more preferable. Thereby, the composite panel 7, that is, the member to be bonded to the decorative sheet 10 can be lightweight and highly rigid.

(Other configurations)
An uneven pattern may be added to the surface of the decorative sheet 10. Examples of the method for forming the uneven pattern include hot embossing. Thereby, the designability of the decorative board 20 can be improved.

(Effect of this embodiment)
The invention according to this embodiment has the following effects.
(1) The decorative board 20 according to the present embodiment has a decorative sheet 10 in which a weather resistant resin layer 4 and a fluororesin layer 5 are laminated in this order on one surface side of the base material layer 1. The other surface side of the base material layer 1 is bonded to a composite panel 7 in which a mixed resin layer 7a containing polyethylene resin and aluminum hydroxide is sandwiched between metal plates 7b, and the weather resistant resin layer 4 is made of acrylic resin and acrylic resin. It consists of a mixture with a resin rubber, and the mixing ratio is 40% by mass or more and 70% by mass or less for acrylic resin, 30% by mass or more and 60% by mass or less for acrylic resin rubber, and the thickness of the fluororesin layer 5 And the thickness of the weather resistant resin layer 4 are in the range of 10:90 to 40:60, and are nonflammable.

According to such a structure, since the weather resistant resin layer 4 and the fluororesin layer 5 are laminated on the base material layer 1, it has weather resistance, contamination resistance, and solvent resistance. Further, the acrylic resin of the weather resistant resin layer 4 is 40 mass% or more and 70 mass% or less, the acrylic resin rubber is 30 mass% or more and 60 mass% or less, and the thickness of the fluororesin layer 5 and the thickness of the weather resistant resin layer 4 are Since the ratio of 10:90 to 40:60 is used, both nonflammability, workability, and weather resistance can be improved. As a result, it is possible to provide a decorative board 20 that has weather resistance, stain resistance, and solvent resistance, and that can improve both nonflammability, workability, and weather resistance.
Further, since the composite panel 7 in which the mixed resin layer 7a containing polyethylene resin and aluminum hydroxide is sandwiched between the metal plates 7b is used, it is lightweight and high in rigidity.

(2) In the decorative board 20 according to the present embodiment, the metal plate 7b is an aluminum plate or a galvalume plate.
According to such a configuration, the decorative board 20 can be further reduced in weight.
(3) The decorative board 20 according to the present embodiment has an uneven pattern on the decorative sheet surface.
According to such a structure, the designability of the decorative board 20 can be improved.

Next, examples according to the present invention will be described.
Example 1
In Example 1, the base material layer 1 was provided using a colored polypropylene resin. The thickness of the base material layer 1 was 70 μm. After performing the corona discharge treatment on each of the front surface and the back surface of the base material layer 1, the pattern pattern layer 2 was provided on the front surface of the base material layer 1 by printing a wood grain pattern by gravure printing with urethane printing ink. Then, the back surface primer layer was provided in the back surface of the base material layer 1 by the gravure printing with the coating liquid for back surface primer layers. The composition of the backside primer layer coating solution is a two-component curable polyester urethane (mixed in a ratio of 100: 5 (mass ratio) of polyester polyol and polyisocyanate): 100 parts by mass, diluent solvent (ethyl acetate and methyl isobutyl ketone) The mixed solvent mixed at a ratio of 1: 1 (mass ratio): 20 parts by mass. The thickness of the back primer layer was 1 μm.

  Subsequently, the polyvinylidene fluoride resin and the weathering resin layer forming mixture were melted and extruded by a T-die to provide a laminate composed of the fluororesin layer 5 and the weathering resin layer 4. The composition of the weather-resistant resin layer forming mixture is acrylic resin (structural unit: methyl methacrylate, PMMA resin): 20 parts by mass, acrylic rubber ("SA-FW001 (trade name)", manufactured by Kuraray Co., Ltd., methacrylic resin , Structural unit: methyl methacrylate, particulate, average particle size: 100 nm, PMMA resin rubber): 80 parts by mass. The weather resistant resin layer 4 had a mass ratio of 40:60 between the acrylic resin (PMMA resin) and the acrylic resin rubber (PMMA resin rubber). In the laminate, the thickness of the fluororesin layer 5 was 5 μm, the thickness of the weather resistant resin layer 4 was 45 μm, the total thickness was 50 μm, the thickness of the fluororesin layer 5: the thickness of the weather resistant resin layer 4 = 10: 90.

Subsequently, a coating solution made of a two-component curable urethane-based adhesive having a polyester resin as a main chain is applied on the pattern layer 2 to form a transparent adhesive layer 3 (thickness in a dry state: 6 μm). The decorative sheet 10 was provided by laminating the thus formed laminate by a dry laminating method. Thereafter, the adhesive layer 6 is formed on the decorative sheet 10 with a two-component curable urethane adhesive (a coating amount in a dry state of 25 g / m ² ), and then the composite panel 7 is pasted through the adhesive layer 6. Thus, a decorative board 20 was obtained. The thickness of the mixed resin layer 7a (core material) of the composite panel 7 was 3 mm. Aluminum was used as the material of the metal plate 7b. The thickness of the metal plate 7b was 0.5 mm.

(Example 2)
The thickness of the fluororesin layer 5 was adjusted to 20 μm, and the thickness of the weather resistant resin layer 4 was adjusted to 30 μm, that is, the thickness of the fluororesin layer 5: the thickness of the weather resistant resin layer 4 = 40: 60. Otherwise, the decorative sheet 10 of Example 2 was produced by the same procedure as in Example 1.
(Example 3)
The mass ratio of the acrylic resin and the acrylic resin rubber of the weather resistant resin layer 4 was adjusted to 70:30. Otherwise, the decorative sheet 10 of Example 3 was produced by the same procedure as in Example 1.

Example 4
The thickness of the fluororesin layer 5 was adjusted to 20 μm, and the thickness of the weather resistant resin layer 4 was adjusted to 30 μm, that is, the thickness of the fluororesin layer 5: the thickness of the weather resistant resin layer 4 = 40: 60. Otherwise, the decorative sheet 10 of Example 4 was produced by the same procedure as in Example 3.
(Comparative Example 1)
The thickness of the fluororesin layer 5 was adjusted to 10 μm, and the thickness of the weather resistant resin layer 4 was adjusted to 40 μm, that is, the thickness of the fluororesin layer 5: the thickness of the weather resistant resin layer 4 was adjusted to 20:80. Moreover, the mass ratio of the acrylic resin and the acrylic resin rubber of the weather resistant resin layer 4 was adjusted to 20:80. Otherwise, the decorative sheet 10 of Comparative Example 1 was produced by the same procedure as in Example 1.

(Comparative Example 2)
The mass ratio of the acrylic resin and acrylic resin rubber of the weather resistant resin layer 4 was adjusted to 80:20. Otherwise, the decorative sheet 10 of Comparative Example 2 was produced by the same procedure as in Comparative Example 1.
(Comparative Example 3)
The thickness of the fluororesin layer 5 was adjusted to 2 μm, and the thickness of the weather resistant resin layer 4 was adjusted to 48 μm, that is, the thickness of the fluororesin layer 5: the thickness of the weather resistant resin layer 4 = 4: 96. Moreover, the mass ratio of the acrylic resin of the weather resistant resin layer 4 and the acrylic resin rubber was adjusted to 50:50. Otherwise, the decorative sheet 10 of Comparative Example 3 was produced by the same procedure as in Example 1.

(Comparative Example 4)
The thickness of the fluororesin layer 5 was adjusted to 25 μm, and the thickness of the weather resistant resin layer 4 was adjusted to 25 μm, that is, the thickness of the fluororesin layer 5: the thickness of the weather resistant resin layer 4 = 50: 50. Otherwise, the decorative sheet 10 of Comparative Example 4 was produced by the same procedure as Comparative Example 3.
(Evaluation judgment)
The following evaluation was implemented about the decorative sheet 10 of each above Example and each comparative example.

(Non Flammable)
Nonflammability was evaluated as follows.
In accordance with ISO 5660-1, fire resistance test using a cone calorimeter tester according to the fire prevention test method and performance evaluation standards based on Article 2-9 of the Building Standards Act and Article 108-2 of the Building Standards Act Construction Order was conducted. . The gross calorific value of the heating starting after 20 min (MJ / ^{m 2)} is at 8 MJ / ^{m 2} or less, the maximum heat release rate of the start of heating after 20 minutes, not exceed 200 kW / ^{m 2} to continue for 10 seconds or more In this case, it was determined to pass “◯”. However, the base material was also evaluated for cracks, and the base material had no cracks or holes.

(Appropriate lapping (workability))
Lapping suitability, that is, workability was evaluated as follows.
Lapping processing (profile processing) was performed. Then, immediately after the lapping process, a sheet that did not peel off due to the stress of the decorative sheet 10 was determined to be acceptable.

(Weatherability)
The weather resistance was evaluated as follows.
The weather resistance was evaluated as follows using a metal weather.
After performing the irradiation mode of the following conditions for 20 hours, performing the condensation state for 4 hours in the condensation mode of the following conditions was performed for 312 hours as one cycle (24 hours).
・ Irradiation mode: Illuminance 65mW / cm2 (measured with Ushio Unimeter UIT-101), BP temperature 53 ° C, humidity 50%, 20 hours ・ Condensation mode: 30 ° C, 98%, 4 hours (before and after condensation mode) 30 seconds shower spray)
After conducting the test for 312 hours under the above conditions, the appearance fading and peeling were confirmed by visual confirmation. And when there was no remarkable discoloration or peeling, it was set as the pass "(circle)".
The evaluation results are shown in Tables 1 and 2.

  From Table 1 and Table 2, as represented by Examples 1 to 4, the acrylic resin is 40% by mass to 70% by mass, and the acrylic resin rubber is 30% by mass to 60% by mass. When the ratio of the thickness of the fluororesin layer 5 to the thickness of the weather resistant resin layer 4 is in the range of 10:90 to 40:60 and satisfies the scope of the present invention, nonflammability, workability, and weather resistance It was found that both properties were good. Here, in Example 1, the acrylic resin is 40% by mass or more and 70% by mass or less, the acrylic resin rubber is 30% by mass or more and 60% by mass or less, the thickness of the fluororesin layer 5 and the thickness of the weather resistant resin layer 4 When the ratio was adjusted within the range of the present invention in the range of 10:90 to 40:60, the same effects as in Examples 1 to 4 were obtained.

  As represented by Comparative Example 1, when the acrylic resin is smaller than 40% by mass (lower limit value) and the acrylic resin rubber is larger than 60% by mass (upper limit value), the weather resistance is rejected. " As represented by Comparative Example 2, when the acrylic resin is larger than 70% by mass (upper limit) and the acrylic resin rubber is smaller than 30% by mass (lower limit), the workability is rejected. " On the other hand, as represented by Examples 1 to 4, when the acrylic resin of the weather resistant resin layer 4 is 40% by mass to 70% by mass and the acrylic resin rubber is 30% by mass to 60% by mass, Both weather resistance and workability could be improved.

  Moreover, as represented by Comparative Example 3, when the ratio of the fluororesin layer 5 and the weather resistant resin layer 4 is out of the range of 10:90 to 40:60 (4:96), nonflammability Was rejected as “x”. Further, as represented by Comparative Example 4, when the ratio of the fluororesin layer 5 and the weather resistant resin layer 4 is out of the range of 10:90 to 40:60 (50:50), the workability is increased. It was rejected “x”. On the other hand, as represented by Examples 1 to 4, when the ratio of the fluororesin layer 5 and the weather resistant resin layer 4 is in the range of 10:90 to 40:60, nonflammability and workability are obtained. Both were good.

DESCRIPTION OF SYMBOLS 1 Base material layer 2 Picture pattern layer 3 Transparent adhesive layer 4 Weather resistant resin layer 5 Fluorine resin layer 6 Adhesive layer 7 Composite panel 7a Mixed resin layer 7b Metal plate 10 Decorative sheet 20 Decorative plate

Claims (3)

A decorative sheet in which a weather resistant resin layer and a fluororesin layer are laminated in this order on one surface side of the base material layer, and the other surface side of the base material layer constituting the decorative sheet is made of polyethylene resin and aluminum hydroxide Are bonded to a composite panel sandwiched between metal plates with a metal plate,
The weather resistant resin layer is made of a mixture of an acrylic resin and an acrylic resin rubber, and the mixing ratio of the acrylic resin is 40% by mass to 70% by mass, and the acrylic resin rubber is 30% by mass to 60% by mass. % Or less,
The ratio of the thickness of the fluororesin layer and the thickness of the weather resistant resin layer is in the range of 10:90 to 40:60,
A decorative board characterized by having nonflammability.   The decorative plate according to claim 1, wherein the metal plate is an aluminum plate or a galvalume plate.   The decorative board according to claim 1 or 2, wherein the decorative sheet surface has an uneven pattern.

Images