JP3133531B2 - Suede-like decorative sheet and method for producing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative sheet used for decorating a surface in a matte state such as a suede.

[0002]

2. Description of the Related Art In general, the surface of such products is formed in a matte shape in a wide field such as furniture, home appliances, building materials, etc. In recent years, in particular, a super matte (suede-like) such as suede has been used. It is preferred to apply a surface to the product. There are various methods for forming the surface of these products into a suede-like matte. Among them, a so-called suede-like decorative sheet in which a suede-like surface layer is formed in advance on the surface of a base material sheet or the like is used. Is preferred because it can provide a suede-like surface to a product by a simple operation of simply applying it to the surface of various products.

Conventionally, as the above-mentioned suede-like decorative sheet, a sheet having a matte layer formed on the surface side by applying a paint containing bead pigment is used.
The above-mentioned bead pigment is obtained by dispersing a pigment fine powder in a synthetic resin to form granules.By adding the bead pigment to a coating material, the matting effect of the object to be coated is increased, and from which direction Even if you look at it, you can get a matte surface,
It is used as a matting agent to express suede-like matting.

[0004]

However, in the conventional suede-like decorative sheet as described above, a coarse-grained bead pigment is dispersed in a vehicle, and this is applied to a substrate sheet or the like and matted on the surface thereof. Because the layer is formed, there is a problem that the bead pigment is separated and settled at the time of coating, furthermore, since the coating applied to the surface of the base sheet is as thin as several μm to several tens of μm, There has been a problem with poor workability that gloss uniformity tends to occur and a uniform and beautiful matte surface cannot be obtained. Further, in order to obtain a sufficient gloss, the paint containing such bead pigments had to be diluted with a relatively low-volatile solvent such as xylol and dried at a high temperature of 80 ° C. or higher. For this reason, for example, when a base sheet made of a general-purpose thermoplastic resin such as polyvinyl chloride is used to apply a coating containing a bead pigment to the base sheet, the heat and the solvent at the time of the coating are used. The material sheet may be deteriorated such as deformation such as whitening, swelling, or sagging or warpage.

On the other hand, in order to solve such a problem,
For example, a paint to which bead pigments are added is coated and formed on a heat-resistant and solvent-resistant film such as biaxially stretched polyethylene terephthalate, and then transferred to a thermoplastic resin base sheet and matted on the base sheet. A method in which a layer is formed to obtain a suede-like decorative sheet has been proposed (Japanese Patent Laid-Open No. Hei 2
-26800, JP-A-2-52796).

However, in such a method, although there is no possibility that the base sheet is deteriorated, the problem that the matte layer formed on the surface of the decorative sheet is apt to cause uneven gloss is not sufficiently solved.

SUMMARY OF THE INVENTION The present invention has been made in order to solve the above-mentioned drawbacks of the prior art, and provides a suede-like decorative sheet provided with a design having a good touch such as suede and an excellent matting effect, and the decorative sheet. An object of the present invention is to provide a manufacturing method which is excellent in workability.

[0008]

The suede-like decorative sheet of the present invention has a particle size distribution of 0.5 μm to 200 μm and a most frequent particle size of 10 μm to 80 parts per 100 parts by weight of the thermoplastic resin.
0.5 to 100 parts by weight of a bead pigment having an average particle size of 0.1 μm to 100 μm defined by JIS-B-0610, and JIS-Z-8741. Surface gloss value (60 ° incidence) measured by a specular gloss measurement method according to
It is characterized by having at least a resin layer having a matte fine unevenness of 30% formed on the surface.

The method for producing a suede-like decorative sheet according to the present invention is characterized in that the particle size distribution is 0.5 μm to 200 μm and the most frequent particle size is 10 μm to 80 parts per 100 parts by weight of the thermoplastic resin.
A composition containing 0.5 to 100 parts by weight of a μm bead pigment was added to form a resin layer to form a resin layer. Thereafter, the resin layer was heated and softened while being pressed with an embossing plate to form a resin layer.
-B-0610 center line average roughness (R
a) is 0.1 μm to 100 μm, and JIS-Z
It is characterized in that fine matte unevenness having a surface gloss value (incident at 60 °) of 0.1% to 30% measured by a specular gloss measurement method according to -8741 is formed on the surface of the resin layer. .

[0010]

Embodiments of the present invention will be described below in detail with reference to the drawings. The drawing is a cross-sectional view showing the suede-like decorative sheet 1 of the present invention.

The decorative sheet 1 of the present invention is formed by forming a thermoplastic resin into which a bead pigment 3 has been added and kneaded into a sheet, and further forming an uneven pattern 4 on the surface thereof by using an embossing plate. It has at least a layer 2. In addition, as shown in FIG. 2, the decorative sheet 1 of the present invention may have a configuration in which the resin layer 2 is laminated on the base sheet 5 as necessary.

The bead pigment 3 used in the present invention is a pigment composed of spherical fine particles of a resin, and contains a coloring agent such as a pigment or a dye therein as required.
In particular, as a material having excellent matting effect and scratch resistance, for example, fine powder surfaces of ordinary pigments such as Fe ₂ O ₃ , TiO ₂ , CaCO ₃ , quinacridone, etc. can be used to coat polyurethane, acrylic, epoxy, polyester, nylon, fluorine, etc. resin,
An elastic resin such as a vinyl chloride-vinyl acetate copolymer, or a dispersion obtained by adding a plasticizer, a stabilizer, a surfactant, and the like to the resin, if necessary, may be formed into a spherical shape. Alternatively, there may be mentioned those obtained by coating the periphery of the above-mentioned pigment with the composition and forming the pigment in a granular form.

The particle size of the bead pigment 3 has a particle size distribution of 0.5 μm to 200 μm and a most frequent particle size of 10 μm.
Those having a size of μm to 80 μm are used. In addition, as a more preferable particle size, a particle size distribution is 1 μm to 60 μm, and a most frequent particle size is 10 μm to 30 μm.

The addition amount of the bead pigment 3 kneaded into the thermoplastic resin depends on the degree of the matte design of the obtained resin layer 2,
Alternatively, in consideration of the surface physical properties of the thermoplastic resin, the amount is 0.5 to 100 parts by weight, more preferably 1 to 30 parts by weight, per 100 parts by weight of the thermoplastic resin. At this time,
If the added amount is less than 0.5 parts by weight, suede-like luster and feel cannot be sufficiently obtained. If the addition amount is 100 parts by weight or more, the resin layer 2 formed by forming a thermoplastic resin into a film may become brittle.

Bead Pigment 3 Added to Thermoplastic Resin
Is not limited to one color, and two or more colors can be used. Also,
When two or more color bead pigments 3 are used, the particle size distribution and the most frequently occurring particle size of the bead pigments 3 can be different for each color. For example, as shown in FIG. 2, the color of the bead pigment 3 of the resin layer 2 is composed of three different colors such as red (3A), yellow (3b), and black (3c), and the red bead pigment (3A) Use the one with the most frequent particle size for yellow (3
For b) and the black (3c) bead pigments 3, those having the most frequent particle size are used. When combined in this manner, the matte layer 4 has a three-dimensional effect between the red bead pigment (3A): the yellow bead pigment (3b) or the red bead pigment (3A): the black bead pigment (3c). can get.

As the thermoplastic resin into which the bead pigment 3 is kneaded, a thermoplastic resin which can be formed into a solid sheet and is suitable for embossing is appropriately selected. Examples of such a thermoplastic resin include polyvinyl chloride, a copolymer of vinyl chloride and ethylene, vinyl acetate, or an acrylate ester, a poly (meth) acrylate ester,
Examples include polyethylene, polypropylene, polystyrene, acrylonitrile-styrene copolymer, acrylonitrile-butadiene-styrene copolymer (ABS resin) and the like.

In the present invention, the uneven pattern 4 formed on the surface of the decorative sheet 1 has a center line average roughness (Ra) defined by JIS-B-0610 of 0.1 μm or less.
100 μm, more preferably 1 μm to 10 μm,
In addition, the surface gloss value (60 ° incidence) measured by the specular gloss measurement method according to JIS-Z-8741 is 0.1%.
To 30%, more preferably 0.1% to 3.0%.

Next, a method for producing the suede-like decorative sheet of the present invention will be described.

In order to carry out the production method of the present invention, the above-mentioned bead pigment 3 is first added to the thermoplastic resin in an amount of 0.5 to 100 parts by weight based on 100 parts by weight of the thermoplastic resin.
More preferably, 1 part by weight to 30 parts by weight are added and kneaded sufficiently, and then the above resin is formed into a film by an appropriate method such as a calendering method, an extrusion method, a casting method (including a sol coating method), and the resin layer 2 is formed. Form. Note that the resin layer 2 is 5
It is preferable to form it with a thickness of 0 μm or more.

At this time, if the thickness of the resin layer 2 is less than 50 μm, uneven gloss due to poor dispersion of the bead pigments 3 in the resin tends to be conspicuous. In addition, since the coarse-particle bead pigment 3 is added, the strength of the sheet-like resin layer 2 becomes insufficient, and the resin layer 2 is cut during processing such as embossing or printing as required as described below. Or the resin layer 2 is significantly elongated. Therefore, in such a case, as described later, the resin layer 2 is laminated on another base material sheet, and then embossing or the like is performed. On the other hand, the upper limit of the thickness of the resin layer 2 is
Although it depends on a method such as film formation or post-processing, when the resin layer 2 formed into a belt-like sheet by forming a resin is wound around a roll or the like, it is preferably about 500 μm.

Next, a concavo-convex pattern 4 is formed on the surface of the obtained resin layer 2. As a method of shaping the concavo-convex pattern 4, various known embossing methods are used. These are methods in which the surface of the target material is formed into a concavo-convex shape of the embossing plate by heat or pressure, and a press embossing machine such as a flat plate press or a roll embossing machine can be used. In addition, the roll embossing method is a method in which a concavo-convex pattern of a cylindrical embossing plate is formed by hot pressing.

The heating and pressurizing conditions of the material are different depending on the thermo-pressure behavior of the thermoplastic resin. In the case of a normal thermoplastic resin, the material is heated to an appropriate temperature between the softening point or heat deformation temperature and the melting point or melting temperature. Then, the embossing plate is pressed and shaped, and cooled to fix the shape. As a heating method, known methods such as infrared irradiation, hot air blowing, heat conduction from a heating roller, and dielectric heating are used.

The above-mentioned embossing roll only needs to have a concavo-convex shape corresponding to the desired concavo-convex pattern 4 to be provided on the surface of the decorative sheet 1 as described above. Instead of the embossing roll, an embossing plate (lithographic plate) is used. ) May be used. Also, as the shape of the embossed aperture, various known irregularities,
Glossy ones can be used. For example, there may be mentioned those obtained by copying natural irregularities such as grain and satin, and various matte surfaces.

In producing the decorative sheet 1,
A base sheet 5 is prepared, and the base sheet 5 and the resin layer 2 formed into a sheet shape are laminated and integrated by doubling embossing, and at the same time, an uneven pattern 4 is formed on the surface of the resin layer 2. If desired, a decorative sheet 1 as shown in FIG. 2 in which a resin layer 2 having a surface 4 formed thereon is laminated on a base sheet 5 can also be manufactured. Alternatively, after forming the resin layer 2 on the base sheet 5 by a known coating method and transfer printing, the concavo-convex pattern 4 can be formed on the surface of the resin layer 2 by embossing. According to such a method, embossing can be applied to the thin resin layer 2 having a thickness of less than 50 μm without fear of cutting or the like.

The doubling embossing means that the resin layer 2 and the base material sheet 5 are sandwiched between the embossing roll and the press roll plate so that the embossing roll comes into contact with the resin layer 2 side, and heat and pressure are applied. In this method, the resin layer 2 and the base sheet 5 are fused and bonded to each other, and at the same time, the concavo-convex pattern 4 is formed on the surface of the resin layer 2 on the embossing roll side.

The material of the base sheet 5 laminated and integrated with the resin layer 2 by doubling embossing may be a resin that can be thermally fused to the resin layer 2, for example, the same as the thermoplastic resin forming the resin layer 2. No. In addition, if necessary, the resin layer 2
When the base sheet 5 and the base sheet 5 are laminated, if a pigment such as a brilliant pigment or a coloring pigment is kneaded into the base sheet 5, the design is further improved.

The processing conditions for doubling embossing can be appropriately determined according to the material of the thermoplastic resin used. For example, when vinyl chloride is used as the thermoplastic resin, the temperature of the embossing plate is about 30 to 70 ° C, and the temperature of the thermoplastic resin is about 120 to 170 ° C.

Further, a decorative layer can be formed on the base sheet 5 as required. The decorative layer is provided to improve the decorativeness of the decorative sheet 1, and is composed of a pattern layer 6, a metal deposition layer, and the like, and the pattern layer 6 is formed using a normal printing ink, for example, a commonly used printing ink. ,
A desired pattern such as a picture, a pattern, a pattern, or the like, or the entire surface is formed by solid printing on the surface of the base sheet 5. Printing methods include gravure, silk screen, and offset. The decorative layer is not limited to a pattern layer 6 on which a pattern, a pattern, a pattern, or the like has been applied with ordinary ink, or may be a solid printing layer, a metal-deposited layer, a partial metal-deposited layer, or the like. It may be formed from layers or more.

Although not particularly shown, a concealing layer may be provided to conceal the surface of the base material sheet 5 under the resin layer 2. The concealing layer can form a matte layer or a decorative layer on the surface without being affected by the material of the base sheet 5. The hiding layer can be formed by printing using an ink or the like to which a hiding pigment such as titanium oxide is added in a vehicle.

Further, on the surface of the decorative sheet 1, a colored or colorless transparent protective layer 7 can be provided as required. As the transparent protective layer 7, a transparent synthetic resin film may be heat-sealed or bonded, or a transparent synthetic resin paint may be applied. The type of the resin is appropriately selected according to the required surface properties, but especially when abrasion resistance and stain resistance are required, for example, an ionizing radiation-curable resin such as urethane acrylate, polyester acrylate, or epoxy acrylate, Epoxy, polyurethane, thermosetting resin such as polysiloxane, fluorine resin such as polytetrafluoroethylene, polyvinylidene fluoride, and if weather resistance is required, for example, fluorine resin such as tetrafluoroethylene, polyvinylidene fluoride, Examples thereof include acrylic resins such as polymethyl methacrylate, and thermosetting resins such as polysiloxane. Various additives may be added to these resins as needed. The transparent protective layer 7 needs to be provided before embossing the surface of the resin layer 2. Also,
The thickness of the transparent protective layer 7 is such that the bead pigment 3 contained in the resin layer 2 does not hinder the tactile sensation such as the suede on the surface of the decorative sheet 1 and is preferably provided in a range of 0.5 μm to 10 μm.

In the decorative sheet 1 of the present invention, a matte design is imparted by adding a bead pigment to the resin layer 2, and furthermore, the concave and convex pattern 4 is formed on the surface of the resin layer 2 so that the resin layer 2 contains the matte design. In combination with the obtained bead pigment 3, a suede-like touch and a matting effect can be sufficiently obtained. In addition, gloss unevenness, color unevenness, and the like are greatly reduced as compared with the conventional coating method and transfer method alone.

In the method for producing a decorative sheet according to the present invention, since the thermoplastic resin into which the bead pigments 3 are kneaded is formed into a sheet, there is no possibility of uneven gloss due to poor dispersion of the bead pigments. Furthermore, when laminating the resin layer 2 which is a mat layer on the base material sheet 5 as needed, the base material sheet 5 is laminated by doubling embossing, so that the base material sheet 5 is not deteriorated by heat or a solvent.

When the suede-like decorative sheet 1 of the present invention is used, other materials such as building materials and household electric appliances are applied by means of applying an adhesive or the like to the back side of the decorative sheet 1 and bonding the same. Used laminated on the surface of the product. Further, the decorative sheet 1 of the present invention can be used as the pressure-sensitive adhesive sheet 1 by laminating it with a release substrate 9 such as a paper separator via the pressure-sensitive adhesive layer 8.

The present invention will be described in more detail with reference to specific examples. Example 1 Urethane-based black bead pigment (a) having an average particle size of 20 μm and a most frequent particle size of 20 μm and an average particle size of 20 μm were most frequently added to colored paste-like polyvinyl chloride [Band Chemistry: BWN blended]. 20 parts by weight of a mixture of a urethane-based white bead pigment (b) having a particle diameter of 20 μm (Labcolol, manufactured by Dainichi Seika Kogyo Co., Ltd.) at a ratio of a: b = 30: 70 was added, and sol casting was performed Then, the above polyvinyl chloride is formed into a sheet-like film to produce a polyvinyl chloride sheet 2 having a thickness of 0.15 mm. After a while, the sheet 2
Is heated to 150 ° C and embossed plate [made of cobblestone vinyl: Nashiji 2
No.], the surface is embossed, and Ra = 1
A decorative sheet 1 having a matte texture pattern 4 having a surface gloss value of 4 μm and a surface gloss value (60 ° incidence) of 15% was formed on the surface.

Example 2 20 parts by weight of a mixture of the same bead pigment (a) as in Example 1 and non-colored paste-like polyvinyl chloride were added by a sol casting method. A polyvinyl chloride sheet 2 having a thickness of 0.09 mm is produced by forming a film of vinyl chloride into a sheet. Thereafter, the sheet 2 and the colored polyvinyl chloride sheet (BWN blending, 0.06 mm) 5 were subjected to doubling embossing with an embossing plate used in Example 1, and the same concavo-convex pattern 4 as in Example 1 was formed on the surface. A decorative sheet 1 was obtained.

Example 3 An abstract pattern was printed on a colored paste-like polyvinyl chloride with a gravure roll to form a base sheet 5, and the base sheet 5 and the polychloride produced in Example 2 were printed. Double embossing was performed on the vinyl sheet 2 with the embossing plate used in Example 1 to obtain a decorative sheet 1 on the surface of which an uneven pattern 4 similar to that of Example 1 was formed.

Example 4 On the polyvinyl chloride sheet 2 produced in Examples 1 to 3, a silicone acrylic resin [OP-3] manufactured by Showa Ink Co., Ltd. was coated at 2 μm / dry by a gravure reverse method. Thereafter, embossing was performed in the same manner as in each example to obtain a decorative sheet 1 having a concave-convex pattern 4 formed on the surface.

Example 5 Paper separator [Oji Chemical:
OKC IIONC] 9 was coated with an adhesive [Soken Chemical: SK Dyne 1307M] 8 at 40 g / m ² · dry and laminated on the back side of the decorative sheet obtained in Examples 1 to 4 to obtain the adhesive decorative sheet 1 Obtained.

In each case, the decorative sheet 1 obtained in each of Examples 1 to 5 did not cause uneven gloss due to poor dispersion of the bead pigment 3 when the resin layer 2 was formed, and exhibited an excellent suede-like touch and matte. The effect was obtained.

In particular, the decorative sheet 1 obtained in Example 4 was excellent in abrasion resistance, stain resistance and the like.

[0041]

As described above, the present invention combines the excellent matte state such as the suede by the bead pigment contained in the thermoplastic resin with the concavo-convex pattern formed on the surface of the decorative sheet. As compared with the decorative cosmetic sheet, a more excellent suede-like touch and matting effect can be obtained. Further, according to the method of the present invention, since the thermoplastic resin to which the bead pigment is added is formed into a sheet-like film, it is possible to prevent uneven gloss due to poor dispersion of the bead pigment.

Further, in the method of the present invention, a resin layer to be a matte layer is formed by forming a thermoplastic resin containing bead pigment into a sheet, so that a paint containing bead pigment is applied to the base sheet. There is no problem that the substrate sheet is deteriorated unlike the conventional method of forming a matte layer by coating.

The suede-like decorative sheet of the present invention can easily impart the above-described excellent suede-like design to various product surfaces by a simple operation of simply attaching the decorative sheet.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing one example of a suede-like decorative sheet of the present invention.

FIG. 2 is a sectional view showing another example of the suede-like decorative sheet of the present invention.

FIG. 3 is a sectional view showing another example of the suede-like decorative sheet of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Decorative sheet 2 Resin layer 3 Bead pigment 4 Uneven pattern

Continuation of the front page (51) Int.Cl. ⁷ Identification code FI B32B 27/20 B32B 27/20 A 33/00 33/00 // B32B 27/00 27/00 E (58) Field surveyed (Int.Cl. . ^7, DB name) D06N 7/00 B05D 5/06 B29C 59/02 B32B 3/30 B32B 7/02 103 B32B 27/20 B32B 33/00 B32B 27/00

Claims (2)

(57) [Claims] 1. A particle size distribution of 0.5 to 200 μm and a most frequent particle size of 10 to 8 parts by weight per 100 parts by weight of a thermoplastic resin.
0.5 to 100 parts by weight of a 0 μm bead pigment, a center line average roughness (Ra) defined by JIS-B-0610 is 0.1 to 100 μm, and JIS-Z-8741. Surface gloss value (60 ° incidence) measured by a specular gloss measurement method according to
A suede-like decorative sheet comprising at least a resin layer having a matte fine irregularity of 30% formed on a surface thereof. 2. A particle size distribution of 0.5 μm to 200 μm and a most frequent particle size of 10 μm to 8 parts per 100 parts by weight of the thermoplastic resin.
A composition containing 0.5 to 100 parts by weight of a 0 μm bead pigment was added to form a resin layer to form a resin layer. Thereafter, the resin layer was heated and softened while being pressed with an embossing plate.
The center line average roughness (R
a) is 0.1 μm to 100 μm, and JIS-Z
It is characterized in that fine matte unevenness having a surface gloss value (incident at 60 °) of 0.1% to 30% measured by a specular gloss measurement method according to -8741 is formed on the surface of the resin layer. A method for producing a suede-like decorative sheet.