CN111479690A - Decorative material and method for producing decorative material - Google Patents

Abstract

The invention provides a decorative material which has excellent water resistance and heat insulation, and has excellent adhesion between a decorative layer and a non-foamed resin layer even if the decorative layer is placed in a high-temperature, damp-heat environment. The present invention relates to a decorative material having a decorative layer, a non-foamed resin layer and a foamed resin layer, wherein the decorative layer and the non-foamed resin layer are bonded by thermal fusion bonding.

Description

Decorative material and method for producing decorative material

Technical Field

The present invention relates to a decorative material and a method for producing the decorative material.

Background

Conventionally, wood materials have been used as decorative materials for window trims (raised window sills), lavatories (floor materials), and the like (see, for example, patent document 1). However, since places such as window edges, toilets, and toilets are environments where condensation or water (humidity, urine, and the like) is large and where the temperature difference is large in hot summer and cold winter, if the decorative sheets used in these places are made of wood materials, they are likely to mold or warp due to poor water resistance, and cannot be used stably.

In order to satisfy such water resistance of the decorative material, it is considered to form the decorative material with a resin material that is a non-wood material, and particularly, a decorative material using a resin foamed layer having excellent water resistance and heat insulation properties has been studied (for example, patent document 2 and the like).

Documents of the prior art

Patent document

Patent document 1: japanese patent laid-open publication No. 2001-123647

Patent document 2: japanese laid-open patent publication No. 2008-238728

Disclosure of Invention

Problems to be solved by the invention

The decorative material having a resin foamed layer generally has a structure in which a decorative layer such as a decorative pattern layer and a non-foamed resin layer are laminated on the resin foamed layer via an adhesive layer, and is a non-wood material, so that it is excellent in water resistance, and can be said to be a decorative material capable of solving the above-mentioned conventional problems. However, when the decorative material is used in a high-temperature, humid and hot environment such as a windowsill and a bathroom wall surface, there is a problem that the adhesive strength of the adhesive layer for bonding the decorative layer and the non-foamed resin layer is lowered.

Under such circumstances, an object of the present invention is to provide a decorative material which is excellent in water resistance and thermal insulation properties and also excellent in adhesion between a decorative layer and a non-foamed resin layer even when exposed to a high-temperature, moist-heat environment.

Means for solving the problems

As a result of intensive studies to solve the above problems, the present inventors have found that when a decorative material having a structure in which a non-foamed resin layer and a decorative layer are laminated on a foamed resin layer via an adhesive layer is used under a high-temperature, moist-heat environment, the adhesive constituting the adhesive layer may be hydrolyzed, and in this case, the adhesive strength of the adhesive layer may be reduced.

As a result of further intensive studies, the present inventors have found that a decorative material laminated without interposing an adhesive layer that may cause hydrolysis between the non-foamed resin layer and the decorative layer does not cause the problem of the reduction in adhesiveness due to hydrolysis even when the decorative material is placed in a high-temperature, moist-heat environment, and can maintain excellent adhesiveness, thereby completing the present invention.

The present invention relates to a decorative material (hereinafter, also referred to as the decorative material of the invention 1) having a decorative layer, a non-foamed resin layer and a foamed resin layer, wherein the decorative layer and the non-foamed resin layer are bonded by thermal fusion bonding.

The present invention also relates to a decorative material (hereinafter, also referred to as the decorative material of the 2 nd invention) having a decorative layer, a non-foamed resin layer, and a foamed resin layer, wherein a heat fusion bonding portion (1) is provided between the decorative layer and the non-foamed resin layer.

In the following description, unless otherwise mentioned, the decorative material of the 1 st invention and the decorative material of the 2 nd invention will be collectively referred to as "the decorative material of the invention".

The decorative material of the present invention preferably has a resin film layer between the non-foamed resin layer and the foamed resin layer.

The resin film layer and the non-foamed resin layer are preferably bonded by thermal fusion bonding.

Further, a heat-fusion bonding part (2) is preferably provided between the non-foamed resin layer and the resin film layer.

The decorative layer and the non-foamed resin layer preferably contain resins of the same type.

The non-foamed resin layer and the resin film layer preferably contain a homologous resin.

The finishing material of the present invention is preferably a finishing material for a window frame.

The present invention also relates to a method for producing a decorative material having a decorative layer, a non-foamed resin layer, and a foamed resin layer, the method comprising: preparing the decorative layer; a step of thermally fusing and adhering the non-foamed resin layer to the decorative layer; and a step of bonding the foamed resin layer to a surface of the non-foamed resin layer opposite to the side to which the decorative layer is thermally bonded.

The present invention also relates to a method for producing a decorative material having a decorative layer, a non-foamed resin layer, a resin film layer, and a foamed resin layer, the method comprising: preparing the decorative layer; a step of thermally fusing and adhering the non-foamed resin layer to the decorative layer; a step of bonding the resin film layer to a surface of the non-foamed resin layer opposite to the side to which the decorative layer is thermally adhered; and a step of bonding the resin film layer to the foamed resin layer.

ADVANTAGEOUS EFFECTS OF INVENTION

The decorative material of the present invention comprises a decorative layer, a non-foamed resin layer and a foamed resin layer, wherein the decorative layer and the non-foamed resin layer are bonded by thermal fusion bonding, or a thermal fusion bonding part (1) is provided between the non-foamed resin layer and the decorative layer, and therefore, the decorative material is excellent in water resistance and heat insulation, and also extremely excellent in adhesion between the non-foamed resin layer and the decorative layer even when exposed to a high-temperature, moist-heat environment.

Drawings

Fig. 1 is a schematic view showing a cross section of a preferred example of the decorative material of the present invention.

Fig. 2 is a schematic view showing a cross section of a preferred example of the decorative material of the present invention.

Fig. 3 is a schematic cross-sectional view showing a preferred example of the decorative material of the present invention.

Fig. 4 is a schematic view showing a cross section of a preferred example of the decorative material of the present invention.

Fig. 5 is an example of an elastic modulus graph showing the relationship between the load (N) and the elongation (%) of the test piece.

Fig. 6 shows a sectional view in the thickness direction of a window frame decorative material as a preferred example of the decorative material of the present invention, (b) shows an example of a perspective view of the window frame decorative material, (c) shows a sectional view in the thickness direction of a raw material laminate used when the window frame decorative material shown in (a) and (b) is assembled, (d) shows a sectional view of another example of the window frame decorative material as a preferred example of the decorative material of the present invention, and (e) shows a sectional view of another example of the decorative material of the present invention.

In fig. 7, (a) is an example of a cross-sectional view of the sash decorative material having the edge tape attached to the side surface of the bent portion, and (b) and (c) are perspective views each showing an example of the sash decorative material having a notch formed in the side surface.

Fig. 8 shows a sectional view in the thickness direction of a raw material laminate used when assembling a window frame decorative material which is a preferred example of the decorative material of the present invention, and (b) shows a sectional view of another example of the window frame decorative material which is a preferred example of the decorative material of the present invention.

Fig. 9 shows a cross-sectional view (a) showing an example of a window in which a window frame decorative material, which is a preferred example of the decorative material of the present invention, is applied to a building, a plan view (b) showing an example of a window in which a window frame decorative material, which is a preferred example of the decorative material of the present invention, is applied to a building, and a perspective view (c) showing an example of a window in which a window frame decorative material, which is a preferred example of the decorative material of the present invention, is applied to a building.

Fig. 10 (a) to (d) are cross-sectional views in the thickness direction of the raw material laminate and the window frame decorative material used when assembling the window frame decorative material, which is a preferable example of the decorative material of the present invention.

Fig. 11 is a plan view showing an example of a window frame finishing material as a preferred example of the finishing material of the present invention and an example of a window in which the window frame finishing material as a preferred example of the finishing material of the present invention is applied to a building.

Detailed Description

The decorative material of the present invention has a decorative layer, a non-foamed resin layer and a foamed resin layer.

The decorative material of claim 1, wherein the decorative layer and the non-foamed resin layer are bonded to each other by thermal fusion bonding.

The decorative layer and the non-foamed resin layer are thermally fused to form a thermally fused joint (1) between the decorative layer and the non-foamed resin layer, thereby obtaining the decorative material of the invention 2.

In the decorative material of the present invention, since the decorative layer and the non-foamed resin layer are not bonded by the adhesive layer, the adhesive in the adhesive layer is not hydrolyzed to decrease the adhesive strength after the decorative layer and the non-foamed resin layer are left in a high-temperature, humid and hot environment, and the adhesion between the decorative layer and the non-foamed resin layer is extremely excellent.

In the decorative material of the present invention, the total thickness of the decorative layer and the non-foamed resin layer is preferably 50% or less with respect to the thickness of the foamed resin layer. If the total thickness of the decorative layer and the non-foamed resin layer exceeds 50% of the thickness of the foamed resin layer, the decorative material of the present invention may be largely warped. The total thickness of the decorative layer and the non-foamed resin layer is preferably 3% at the lower limit, 45% at the upper limit, 5% at the lower limit, and 40% at the upper limit, with respect to the thickness of the foamed resin layer.

In the decorative material of the present invention, it is preferable that both of the non-foamed resin layer and the foamed resin layer have a thermal linear expansion coefficient of 8 × 10^-5A temperature of not more than DEG C, and a difference between a coefficient of thermal linear expansion of the non-foamed resin layer and a coefficient of thermal linear expansion of the foamed resin layer is 3 × 10^-5Within/° c.

When the thermal linear expansion coefficients of the non-foamed resin layer and the foamed resin layer both exceed 8 × 10^-5The decorative material of the present invention may be warped at/° c.

In the decorative material of the present invention, the foamed resin layer preferably has a compressive modulus of elasticity of 15MPa or more. When the compressive modulus of elasticity is less than 15MPa, excellent load resistance cannot be obtained, and impact resistance may be poor. The modulus of elasticity in compression of the foamed resin layer is more preferably 15MPa to 150MPa, and still more preferably 20MPa to 150MPa, from the viewpoint of obtaining excellent load resistance and impact resistance. Here, the compression modulus of elasticity was measured using a foamed resin layer in accordance with JIS a 9511: 1999 "foamed Plastic Heat insulating Material" was measured by preparing a test piece by the method described in "foamed Plastic Heat insulating Material". Specifically, a test piece in the shape of a rectangular parallelepiped having a length of 100mm, a width of 100mm and a thickness of 5mm was cut out from the foamed resin layer, and the compression modulus was measured at a compression rate of 10 mm/min using a tensile-compression tester. 5 test pieces were prepared, and the compression modulus was measured for each test piece in the above manner, and the arithmetic average of these was defined as the compression modulus. The thickness of the rectangular parallelepiped test piece was changed to 3mm instead of the thickness described in JIS.

Next, a typical structure of the decorative material of the present invention will be described with reference to fig. 1 to 3.

Fig. 1 to 3 are schematic views showing a cross section of a preferred example of the finishing material 10 of the present invention.

In the embodiment shown in fig. 1, the decorative material 10 of the present invention includes a foamed resin layer 1, a non-foamed resin layer 2, and a decorative layer 3 in this order, and has a heat fusion bonding portion (1) a between the non-foamed resin layer 2 and the decorative layer 3 as shown in an enlarged view. In the embodiment shown in fig. 2, the decorative layer 3 including the base resin layer 4, the pattern layer 33, the transparent resin layer 5, and the surface protective layer 6 is provided on the non-foamed resin layer 2, and the resin film layer 7 is provided between the foamed resin layer 1 and the non-foamed resin layer 2.

In the embodiment shown in fig. 3, the non-foamed resin layer 2 has a 3-layer structure and has a structure including a 1 st thermoplastic resin layer 21, a glass composition layer 22, and a 2 nd thermoplastic resin layer 23 in this order.

As shown in fig. 1 to 3, in the decorative material 10 of the present invention, a thermal fusion bonding portion (1) a is interposed between the non-foamed resin layer 2 and the decorative layer 3, and the thermal fusion bonding portion (1) a is a portion where the non-foamed resin layer 2 and the decorative layer 3 are bonded by thermal fusion bonding. Therefore, there is substantially no interface between the non-foamed resin layer 2 and the decorative layer 3, and the resin materials constituting the non-foamed resin layer 2 and the decorative layer 3 are integrated and continuously laminated.

However, as for the state in which the non-foamed resin layer 2 and the decorative layer 3 are laminated, the non-foamed resin layer 2 and the decorative layer 3 may be laminated in a state in which an interface is present, as long as the non-foamed resin layer 2 and the decorative layer 3 are not laminated through a layer (for example, an adhesive layer or the like) other than the non-foamed resin layer 2 and the decorative layer 3.

The phrase "the interface does not substantially exist" means that the interface between the non-foamed resin layer 2 and the decorative layer 3 cannot be visually determined when the decorative material 10 of the present invention is viewed in cross section, and further, even if the interface between the non-foamed resin layer 2 and the decorative layer 3 is enlarged by 100 times by a microscope or the like from the cross section direction, the interface cannot be determined from an enlarged image.

In the decorative material of the present invention, as in the case of the non-foamed resin layer 2 shown in fig. 2, the non-foamed resin layer 2 shown in fig. 3, and the cosmetic layer 3, when the non-foamed resin layer and/or the decorative layer have a multilayer structure, the thermal fusion bonded portion (1) a is interposed between the layers (for example, the non-foamed resin layer 2 and the base resin layer 4 in fig. 2, the base resin layer 4 and the 2 nd thermoplastic resin layer 23 in fig. 3, and the like) in which the non-foamed resin layer and the cosmetic layer are opposed to each other.

As described later, various resin materials can be used as the resin materials constituting the decorative layer and the non-foamed resin layer, and in the present invention, the resin materials constituting the decorative layer and the non-foamed resin layer are preferably made of a homologous resin.

The decorative layer and the non-foamed resin layer are firmly bonded to each other by forming the resin materials constituting the decorative layer and the non-foamed resin layer from the same resin and forming a thermal fusion bonding part (1) by thermal fusion bonding.

The "homologous resin" means JIS K6899-1: 2015 "plastic-symbols and acronyms-part 1: the basic polymer and its properties "described in the 5 th item" the same general classes of resins as the plastic materials using the symbols for the constituent elements related to the homopolymer, copolymer and natural polymer.

Further, the "homologous resin" of the polymer blend or the polymer alloy means that, according to JIS K6899-1: 2015, the base polymer of the main component, i.e. the initially recited shorthand notation of the base polymer included in "+" classifies the same polymer, polymer blend or polymer alloy.

Here, when the abbreviated symbol classification having hyphenation after "PE" is such as abbreviated symbol classification "PE-HD" (polyethylene, high density) and "PE-L D" (polyethylene, low density), it can be regarded as a homologous resin in the category of PE (polyethylene) as a base polymer.

(foamed resin layer)

The foamed resin layer is a layer that mainly imparts heat insulation, load resistance, and impact resistance to the decorative material of the present invention, and is formed by foaming a foamed resin composition.

The expansion ratio in the foamed resin layer is preferably 5 to 20 times. If the amount is outside this range, a decorative material having excellent heat insulation properties, load resistance and impact resistance may not be obtained. The expansion ratio of the foamed resin layer is more preferably 5 to 15 times, and still more preferably 5 to 12 times, from the viewpoint of obtaining more excellent heat insulation properties and load resistance.

In the decorative material of the present invention, the value of the compressive modulus of elasticity of the foamed resin layer measured under the above measurement conditions is preferably 15MPa or more.

The method of foaming the above-mentioned foamable resin composition is not particularly limited, and any known method can be used, and foaming by a bead method is preferable in terms of obtaining a homogeneous foamable resin layer. The bead method is a method comprising: the foamed resin layer is obtained by filling an inner cavity of a mold with foamed resin particles (pre-foamed particles) as a raw material, and thermally adhering the pre-foamed particles to each other while secondarily foaming the filled pre-foamed particles with steam to integrate the pre-foamed particles.

The resin used for the foamed resin particles preferably includes a thermoplastic resin.

The thermoplastic resin is preferably a monomer or a copolymer of Polyethylene (PE), polypropylene (PP), Polystyrene (PS), a styrene-modified polyolefin resin, a polyolefin resin such as an ethylene-vinyl acetate copolymer resin (EVA) or an ethylene- (meth) acrylic resin, an acrylonitrile-butadiene-styrene copolymer (ABS resin), an acrylonitrile-styrene copolymer, a polyvinyl chloride resin (PVC), a polyethylene resin such as a polyvinyl acetate resin or a polyvinyl alcohol resin, a polyester resin such as a polyethylene terephthalate resin (PET resin), a thermoplastic resin such as nylon, a polyacetal resin, an acrylic resin, a polycarbonate resin or a polyurethane resin, or a mixed resin thereof.

Among them, polystyrene resin is preferable in view of the strength of the resin itself.

The styrene monomer forming the polystyrene resin is not particularly limited, and any known styrene monomer may be used, and examples thereof include styrene, α -methylstyrene, vinyltoluene, chlorostyrene, ethylstyrene, isopropylstyrene, dimethylstyrene, and bromostyrene.

The above-mentioned foamed resin particles can be generally obtained as follows: the resin particles are produced by polymerizing seed particles made of a resin forming the foamed resin particles by absorbing a monomer such as a styrene monomer and, if necessary, a plasticizer, impregnating the resin particles with a foaming agent simultaneously with or after the polymerization, and then foaming the resin particles. In addition, the foamed resin particles can also be obtained by the following method: a method in which a blowing agent is impregnated into particles obtained by suspension polymerization of a monomer such as a styrene monomer in an aqueous medium; polystyrene resin is put into an extruder, melt-kneaded together with a foaming agent, extruded through a die having small holes into pressurized circulating water, and cut by a rotary cutter in contact with the die to foam the obtained pellets.

Preferred examples of the foaming agent include inorganic foaming agents such as sodium hydrogen carbonate, sodium carbonate, ammonium hydrogen carbonate, ammonium carbonate and ammonium nitrite; nitroso compounds such as N, N ' -dimethyl-N, N ' -dinitrosoterephthalamide and N, N ' -dinitrosopentamethylenetetramine; azo compounds such as azodicarbonamide, azobisisobutyronitrile, azocyclohexylnitrile, and azodiaminobenzene; sulfonyl hydrazide compounds such as benzenesulfonyl hydrazide and toluenesulfonyl hydrazide; azide compounds such as calcium azide, 4' -diphenyldisulfonylazide and p-toluenesulfonylazide.

Further, as the blowing agent, preferable examples include a volatile blowing agent such as an aliphatic hydrocarbon such as propane, n-butane, isopentane, n-pentane, and neopentane, and a fluorinated hydrocarbon such as difluoroethane and tetrafluoroethane, which have a zero ozone destruction coefficient, as a physical blowing agent.

These blowing agents may be used alone or in combination of two or more.

The amount of the blowing agent to be added is appropriately determined depending on the desired expansion ratio and compression modulus, and is preferably 0.5 to 15 parts by mass, more preferably 1 to 10 parts by mass, based on 100 parts by mass of the resin.

Preferred examples of the plasticizer include fatty acid ester compounds such as propylene glycol fatty acid ester, glycerin fatty acid ester, sorbitan fatty acid ester, and sucrose fatty acid ester; phthalate compounds such as dibutyl phthalate (DBP), dioctyl phthalate (DOP) and diisononyl phthalate (DINP); adipate compounds such as diisobutyl adipate and dioctyl adipate; sebacate compounds such as dibutyl sebacate and di (2-ethylhexyl) sebacate; glycerin fatty acid ester compounds such as glycerin tristearate and glycerin tricaprylate; natural oils and fats such as liquid paraffin, coconut oil, palm oil, and rapeseed oil.

The plasticizer may be added when the monomer is polymerized, or may be added when the blowing agent is impregnated.

The amount of the plasticizer to be added is appropriately determined depending on the desired expansion ratio and compression modulus, and is preferably 0.2 parts by mass or more and less than 3 parts by mass, and more preferably 0.4 parts by mass or more and less than 1.6 parts by mass, based on 100 parts by mass of the resin. When the amount of the plasticizer added is 0.2 parts by mass or more, the secondary transition temperature is lowered, and thus pre-foaming and molding at low temperature are excellent; when the amount of the plasticizer added is less than 3 parts by mass, the foam is less likely to shrink, and a good appearance can be obtained.

The above-mentioned expandable resin beads may contain additives such as flame retardants, flame retardant aids, lubricants, anti-caking agents, thermal adhesion promoters, antistatic agents, spreading agents, cell regulators, crosslinking agents, fillers, colorants, and heat insulating property enhancers (e.g., radiation inhibitors) within a range that does not impair the physical properties.

In the bead method, for example, the expandable resin particles are filled in the cavity of a mold, and the filled pre-expanded particles are secondarily expanded with a heating time of 10 seconds to 40 seconds using a heat medium such as steam of preferably 100 ℃ to 150 ℃, more preferably 100 ℃ to 120 ℃, and simultaneously the pre-expanded particles are integrated with each other by thermal fusion bonding, thereby obtaining an expandable resin layer. In this case, the average particle diameter of the expanded resin beads to be used is preferably 0.2mm to 4mm, more preferably 0.5mm to 2 mm. The average particle diameter of the foamed resin particles can be obtained as follows: JIS Z8801-1(2006) "test sieves-part 1: in the metal mesh screen ", a plurality of screens having different meshes defined therein are stacked in this order from a small-mesh screen to a large-mesh screen, 100g of expandable resin particles are put into the uppermost screen, and the expandable particles are classified by a vibrating screen, thereby obtaining the average particle diameter.

Specifically, the average particle diameter of the expanded resin beads remaining on the screen of each mesh is multiplied by the number ratio of the expanded resin beads, and the sum of the values is defined as the average particle diameter of the expanded resin beads.

Average particle size ═ Σ (number ratio on each sieve × average particle size of particles on each sieve)

Here, the number ratio is a value obtained from the weight ratio of the expandable beads remaining on each sieve and the mesh size of each sieve.

In the present invention, the foamed resin layer is not limited to the bead method described above, and can be obtained by: the resin composition for forming a foamed resin layer, which contains a resin for a foamed resin layer, a foaming agent, a plasticizer, an inorganic filler, and other additives as required, is formed into a film on an unfoamed resin layer by a film forming method such as an extrusion film forming method or a calender film forming method using a T die, and then is foamed at a temperature of about 220 ℃ to 250 ℃ using a heated foaming furnace, thereby obtaining the foamed resin layer.

Further, as the foamed resin layer, a commercially available heat insulating board, for example, a bead-method polystyrene foam heat insulating board, an extrusion-method polystyrene foam heat insulating board, or the like may be used as long as the foaming ratio and the compression modulus are within the predetermined ranges.

The thickness of the foamed resin layer is slightly affected by the expansion ratio and the like, but is preferably 3mm to 15mm, more preferably 5mm to 15mm, and still more preferably 5mm to 12 mm. When the thickness of the foamed resin layer is within the above range, excellent heat insulation properties, load resistance and impact resistance can be obtained.

The thickness of the foamed resin layer is preferably larger than the thickness of a non-foamed resin layer described later. By making the thickness of the layer thicker than the non-foamed resin layer, excellent heat insulation properties, load resistance and impact resistance can be obtained, and stress warpage due to a difference in elongation due to temperature and the like between other layers such as the non-foamed resin layer is less likely to occur.

(non-foamed resin layer)

The non-foamed resin layer is a layer that mainly imparts shape stability, water resistance, impact resistance and scratch resistance to the decorative material of the present invention, and preferably has a tensile elastic modulus of 180MPa or more. When the tensile modulus of elasticity is less than 180MPa, scratch resistance cannot be obtained. From the viewpoint of obtaining scratch resistance, the tensile modulus of elasticity is preferably 180MPa to 3000MPa, more preferably 1000MPa to 3000MPa, and still more preferably 2000MPa to 2500 MPa.

When the tensile elastic modulus is within the above range, stress warpage due to a difference in elongation from other layers such as a foamed resin layer due to temperature or the like is less likely to occur. Here, the tensile elastic modulus (E) is calculated as follows: a non-foamed resin layer punched out into a dumbbell-shaped test piece as described in JIS K6732(1996) was prepared, and the tensile modulus of elasticity was calculated from the linear portion at the beginning of the obtained tensile stress-strain curve by the following equation under the temperature condition of 20 ℃ under the conditions of a tensile compression tester at a tensile speed of 50 mm/min and an inter-chuck distance of 80 mm. Fig. 5 shows an example of an elastic modulus graph showing a relationship between a load (N) and an elongation (%) on a test piece.

E＝△p/△E

E: modulus of elasticity in tension

△ p stress difference between two points on a straight line based on original average cross-sectional area

△ E Strain Difference between the same two points

The non-foamed resin layer preferably contains a thermoplastic resin.

The thermoplastic resin is preferably a monomer or a copolymer of a polyethylene resin such as a polyvinyl chloride resin, a polyvinyl acetate resin, or a polyvinyl alcohol resin, a polyolefin resin such as polyethylene, polypropylene, polystyrene, a styrene-modified polyolefin resin, an ethylene-vinyl acetate copolymer resin (EVA), or an ethylene- (meth) acrylic acid resin, a polyester resin such as a polyethylene terephthalate resin (PET resin), a thermoplastic resin such as an acrylic resin, a polycarbonate resin, a polyurethane resin, an acrylonitrile-butadiene-styrene copolymer (ABS resin), or an acrylonitrile-styrene copolymer, or a mixed resin thereof. Among them, polyolefin resins, acrylonitrile-butadiene-styrene copolymers, and polyvinyl chloride resins are preferable.

Further, it preferably contains a resin homologous to the decorative layer and the resin film layer described later. The non-foamed resin layer is made of a resin having the same system as that of the decorative layer and the resin film layer described later, and the non-foamed resin layer, the decorative layer and the resin film layer are thermally bonded to each other to form a thermal fusion bonding part (1) and a thermal fusion bonding part (2), whereby the decorative layer and the non-foamed resin layer are firmly bonded to each other.

The "homologous resin" is defined as in the above.

In the present invention, the non-foamed resin layer preferably contains an inorganic compound. By containing the inorganic compound, the linear expansion coefficient of the non-foamed resin layer can be reduced, and as a result, warpage of the decorative material of the present invention can be suppressed.

Examples of the inorganic compound include talc, calcium carbonate, silica, and mica.

The content of the inorganic compound is preferably 10 parts by mass or more and 70 parts by mass or less with respect to 100 parts by mass of the resin component in the non-foamed resin layer. When the content of the inorganic compound is less than 10 parts by mass, the linear expansion coefficient of the non-foamed resin layer may not be sufficiently reduced, and when it exceeds 70 parts by mass, the tensile elastic modulus of the non-foamed resin layer may be insufficient. The content of the inorganic compound is more preferably in a range of 15 to 65 parts by mass, and still more preferably in a range of 20 to 40 parts by mass.

The non-foamed resin layer may be formed of one layer, or may be a laminate formed of two or more layers.

When the non-foamed resin layer has two or more thermoplastic resin layers, the types of resins forming the two or more thermoplastic resin layers may be the same or different, and the thicknesses of the two or more thermoplastic resin layers may be the same or different.

The thickness of the non-foamed resin layer is preferably 0.3mm to 10mm, and more preferably 1mm to 5 mm. When the thickness of the non-foamed resin layer is within the above range, excellent water resistance, impact resistance and scratch resistance can be obtained. Further, stress warpage due to a difference in elongation due to temperature or the like from other layers such as a foamed resin layer is less likely to occur.

As described above, the thickness of the non-foamed resin layer is preferably smaller than that of the foamed resin layer. Stress warpage due to a difference in elongation from other layers such as a foamed resin layer due to temperature or the like is less likely to occur.

In the decorative material of the present invention, the thickness of the non-foamed resin layer is obtained by subtracting the thickness of the foamed resin layer and the thickness of the decorative layer before thermal fusion from the total thickness of the decorative material. The decorative material of the present invention may be measured by cross-sectional observation using an optical microscope. However, in the case where the interface between the non-foamed resin layer and the decorative layer does not actually exist and cannot be specified by an optical microscope, the interface can be specified by observing the molecular orientation disorder between the non-foamed resin layer and the decorative layer by an electron microscope or the like, and the thickness of the non-foamed resin layer can be measured.

The decorative material of the present invention may be obtained by subjecting the back surface of the non-foamed resin layer to an easy adhesion treatment.

The back surface of the non-foamed resin layer is a surface of the non-foamed resin layer opposite to the surface to which the decorative layer is bonded.

By performing the easy adhesion treatment, the adhesion between the layers constituting the decorative material of the present invention can be suitably obtained.

Examples of the easy adhesion treatment include an adhesion treatment, a primer treatment, a corona treatment, and a plasma treatment.

(resin film layer)

The decorative material of the present invention preferably has a resin film layer on a surface of the non-foamed resin layer opposite to the surface to which the decorative layer is bonded.

By providing the resin film layer, the balance between the tension generated when the decorative layer is bonded and the tension can be easily adjusted, and the occurrence of warpage due to the difference between the linear expansion coefficients of the resin film layer and the non-foamed resin layer when the decorative material of the present invention is heat-removed can be more appropriately prevented.

The resin film layer preferably contains a thermoplastic resin. The thermoplastic resin is preferably a monomer or a copolymer of a polyethylene resin such as a polyvinyl chloride resin, a polyvinyl acetate resin, or a polyvinyl alcohol resin, a polyolefin resin such as polyethylene, polypropylene, polystyrene, a styrene-modified polyolefin resin, an ethylene-vinyl acetate copolymer resin (EVA), or an ethylene- (meth) acrylic acid resin, a polyester resin such as a polyethylene terephthalate resin (PET resin), a thermoplastic resin such as an acrylic resin, a polycarbonate resin, a polyurethane resin, an acrylonitrile-butadiene-styrene copolymer (ABS resin), or an acrylonitrile-styrene copolymer, or a mixed resin thereof.

The resin film layer may be provided with an easy adhesion treatment similar to the treatment applied to the rear surface of the non-foamed resin layer on the side laminated with the foamed resin layer.

The resin film layer preferably contains a resin homologous to the resin material constituting the non-foamed resin layer. The resin film layer is made of a resin material that is homologous to the resin material of the non-foamed resin layer, and the resin film layer and the non-foamed resin layer are firmly bonded together by forming a thermal fusion bonding section (2) between the non-foamed resin layer and the resin film layer by thermal fusion bonding.

The "homologous resin" is defined as in the above.

Preferably, all of the decorative layer, the foamed resin layer, and the resin film layer contain a homologous resin. Thus, when the non-foamed resin layer and the decorative layer are thermally melt-bonded, the resin film layers are also thermally melt-bonded and bonded together, and the steps can be simplified and the layers can be firmly bonded to each other.

In the case of having a resin film layer, the resin film layer may be bonded to the back surface of the non-foamed resin layer with a known adhesive or the like as needed, even if the easy-adhesion treatment is performed.

Further, the exposed side (the bonding surface with the foamed resin) to which the resin film is bonded may be subjected to an easy-bonding treatment as needed. Examples of the easy adhesion treatment include an adhesion treatment, a primer treatment, a corona treatment, and a plasma treatment, as in the case of the non-foamed resin layer.

The thickness of the resin film layer is preferably 10 μm to 700 μm, and more preferably 40 μm to 200 μm.

When the thickness of the resin film layer is within the above range, the occurrence of warpage due to the difference in linear expansion coefficient between the resin film layer and the non-foamed resin layer when the decorative material of the present invention is heat-removed can be more appropriately prevented.

In the decorative material of the present invention, the thickness of the resin film layer is the thickness of the resin film layer alone, and when the thermal fusion bonding part (2) is formed, the thickness of the resin film layer is the thickness of the resin film layer alone before thermal fusion bonding. The measurement can be performed by cross-sectional microscope observation of the decorative material of the present invention, but when there is substantially no interface and the interface between the non-foamed resin layer and the resin film layer cannot be identified by cross-sectional microscope observation, the interface can be identified by observing molecular orientation disorder at the interface between the non-foamed resin layer and the resin film layer by an electron microscope or the like, and the thickness of the resin film layer can be measured.

(decorative layer)

The decorative layer is a layer for imparting decorativeness to the decorative material of the present invention, and is preferably a colored base resin layer or a decorative sheet having a pattern provided on the base resin layer. As shown in fig. 2, the "decorative sheet" is preferably a decorative sheet having a laminated structure composed of a base resin layer 4, a pattern layer 33, optional layers such as a transparent resin layer 5 and a surface protective layer 6 described later, and the pattern layer 33 and the transparent resin layer 5.

Preferably, the decorative layer contains a resin homologous to the resin material constituting the non-foamed resin layer. The resin film layer and the non-foamed resin layer are firmly bonded together by forming a thermal fusion bonding part (1) by thermal fusion bonding of the decorative layer and the non-foamed resin layer by containing a resin homologous to a resin material constituting the non-foamed resin layer.

The "homologous resin" is defined as in the above.

Further, by providing the concealing layer, the base provided with the finishing material of the present invention can be concealed, and when the foamed resin layer or the non-foamed resin layer or the like is colored or has color unevenness, the color of the surface can be adjusted by intentionally imparting a color.

Further, by providing the pattern layer, it is possible to impart a pattern such as a wood grain pattern, a stone pattern on the surface of rock such as a simulated marble pattern (for example, a limewater marble pattern), a textile pattern such as a simulated cloth pattern or a cloth-like pattern, a tile laying pattern, a brick laying pattern, or a block parquet (registered wood) or a patchwork obtained by combining these patterns to the decorative sheet. These patterns can be formed by multicolor printing using normal process color (yellow, red, blue, and black) printing, or by spot color printing or the like in which color plates of the respective colors constituting the patterns are prepared.

As the ink composition used for the concealing layer or the pattern layer, an ink is used in which a colorant such as a pigment or a dye, an extender pigment, a solvent, a stabilizer, a plasticizer, a catalyst, a curing agent, and the like are appropriately mixed with a binder resin. The binder resin is not particularly limited, and examples thereof include a urethane resin, a vinyl chloride/vinyl acetate copolymer resin, a vinyl chloride/vinyl acetate/acrylic copolymer resin, an acrylic resin, a polyester resin, and a cellulose nitrate resin.

As the binder resin, any binder resin selected from the above may be used alone in 1 kind or in a mixture of 2 or more kinds.

Further, preferable examples of the colorant include carbon black (ink), inorganic pigments such as iron black, titanium white, antimony white, chrome yellow, titanium yellow, red iron oxide, cadmium red, ultramarine blue, and cobalt blue, organic pigments or dyes such as quinacridone red, isoindolinone yellow, and phthalocyanine blue, metallic pigments composed of scaly foils such as aluminum and brass, and pearlescent (pearl) pigments composed of scaly foils such as titanium dioxide-coated mica and basic lead carbonate.

The thickness of the decorative layer is preferably about 500 μm or less.

When the thickness of the decorative layer is within the above range, the decorative material of the present invention can be provided with excellent design properties and can be provided with concealing properties.

In the decorative material of the present invention, the thickness of the decorative layer is a single thickness of the decorative layer before thermal fusion. Further, the measurement can be performed by cross-sectional microscopic observation of the decorative material of the present invention, but since there is substantially no interface with the decorative layer as described above, when the interface between the non-foamed resin layer and the decorative layer cannot be identified by cross-sectional microscopic observation, the interface can be identified by observing the molecular orientation disorder of the interface between the non-foamed resin layer and the decorative layer using an electron microscope or the like, and the thickness of the decorative layer can be measured.

(base resin layer)

The base resin layer is a layer provided as desired, and is preferably a layer formed of a thermoplastic resin. The thermoplastic resin is preferably a thermoplastic resin exemplified as a thermoplastic resin provided in the foamed resin layer. Among them, polyolefin resins are preferable, and polyethylene resins and polypropylene resins are more preferable.

The base resin layer may be transparent or colored, and is preferably colored in view of concealing the base on which the finishing material is provided. As the coloring agent used, the coloring agent exemplified as the coloring agent used in the decorative layer is preferably used.

The thickness of the base resin layer is preferably 10 μm to 150 μm, more preferably 30 μm to 100 μm, and still more preferably 40 μm to 80 μm. When the thickness of the base resin layer is within the above range, handling is easy, and the decorative material of the present invention is not thickened more than necessary.

Various additives such as a filler, a flame retardant, a lubricant, an antioxidant, an ultraviolet absorber, and a light stabilizer may be added to the base resin layer as needed.

(transparent resin layer)

The transparent resin layer is an arbitrary layer provided to protect the decorative layer, and is preferably a layer formed of a thermoplastic resin. The thermoplastic resin is preferably a thermoplastic resin exemplified as the thermoplastic resin provided in the foamed resin layer. Among them, polyolefin resins are preferable, and polyethylene resins, polypropylene resins, and ionomer resins are more preferable.

The transparent resin layer is a transparent resin layer that allows the decorative layer to be seen through. Here, the term "transparent" includes a concept of colored transparency and translucency in addition to colorless transparency.

In addition, various additives such as a filler, a flame retardant, a lubricant, an antioxidant, an ultraviolet absorber, and a light stabilizer may be added to the transparent resin layer as needed within a range where transparency thereof is not impaired.

The thickness of the transparent resin layer is preferably 10 μm to 400 μm, more preferably 30 μm to 250 μm, and still more preferably 50 μm to 100 μm. When the thickness of the transparent resin layer is within the above range, the decorative layer can be protected, handling is easy, and the decorative material does not need to be thickened more than necessary.

(surface protective layer)

The surface protective layer is a layer provided as desired to impart surface characteristics such as impact resistance, load resistance, and scratch resistance to the decorative material of the present invention. The surface protective layer is provided on the outermost surface of the decorative material of the invention.

The surface protection layer is preferably formed as follows: the surface protective layer is formed by applying a resin composition containing a curable resin to the decorative layer, or preferably the transparent resin layer or the adhesive layer, and curing the resin composition. The surface properties of the decorative material of the present invention can be improved by containing a curable resin cured by crosslinking.

The curable resin used for forming the surface protective layer is preferably an ionizing radiation curable resin and a thermosetting resin, and may be a so-called hybrid type resin obtained by combining a plurality of types of these resins (for example, combining an ionizing radiation curable resin and a thermosetting resin).

Among them, ionizing-ray-curable resins are preferable from the viewpoint of increasing the crosslinking density of the resin forming the surface protective layer and improving the surface characteristics, and electron-ray-curable resins are more preferable from the viewpoint of enabling coating without a solvent and easy handling.

The ionizing radiation curable resin is a resin that is crosslinked and cured by irradiation with ultraviolet rays or electron rays, which are rays having energy quanta capable of crosslinking and polymerizing molecules, among electromagnetic waves or charged particle beams. Specifically, it can be suitably selected from polymerizable monomers, polymerizable oligomers, and prepolymers conventionally used as ionizing radiation curable resins.

As the polymerizable monomer, a (meth) acrylate monomer having a radical polymerizable unsaturated group in the molecule is suitable, and among them, a polyfunctional (meth) acrylate is preferable. The polyfunctional (meth) acrylate is not particularly limited as long as it is a (meth) acrylate having 2 or more ethylenically unsaturated bonds in the molecule. These polyfunctional (meth) acrylates may be used singly or in combination of two or more.

Next, examples of the polymerizable oligomer include oligomers having a radical polymerizable unsaturated group in the molecule, such as epoxy (meth) acrylate, urethane (meth) acrylate, polyester (meth) acrylate, and polyether (meth) acrylate.

Further, as the polymerizable oligomer, there are a polybutadiene (meth) acrylate oligomer having a (meth) acrylate group in a side chain of the polybutadiene oligomer and having high hydrophobicity, a silicone (meth) acrylate oligomer having a polysiloxane bond in a main chain, an aminoplast resin (meth) acrylate oligomer obtained by modifying an aminoplast resin having a plurality of reactive groups in a small molecule, and an oligomer having a cationically polymerizable functional group in a molecule, such as a novolak-type epoxy resin, a bisphenol-type epoxy resin, an aliphatic vinyl ether, and an aromatic vinyl ether.

In the present invention, a monofunctional (meth) acrylate may be suitably used together with the above polyfunctional (meth) acrylate for the purpose of reducing the viscosity of the polyfunctional (meth) acrylate and the like, within a range not impairing the object of the present invention. These monofunctional (meth) acrylates may be used alone or in combination of two or more.

Examples of the thermosetting resin include epoxy resins, phenol resins, urea resins, unsaturated polyester resins, melamine resins, alkyd resins, polyimide resins, silicone resins, hydroxyl-functional acrylic resins, carboxyl-functional acrylic resins, amide-functional copolymers, and urethane resins.

Further, as the thermosetting resin, a two-liquid curable resin is also preferable, and specifically, a two-liquid curable resin of a polyol and an isocyanate is preferable.

Here, preferable examples of the polyol include acrylic polyol, polyester polyol, epoxy polyol, and the like.

The isocyanate may be, for example, a polyvalent isocyanate having 2 or more isocyanate groups in a molecule, and examples thereof include aromatic isocyanates such as 2, 4-Tolylene Diisocyanate (TDI), Xylylene Diisocyanate (XDI), naphthalene diisocyanate, and 4, 4' -diphenylmethane diisocyanate, and polyisocyanates such as aliphatic (or alicyclic) isocyanates such as 1, 6-hexamethylene diisocyanate (HMDI), isophorone diisocyanate (IPDI), Methylene Diisocyanate (MDI), hydrogenated tolylene diisocyanate, and hydrogenated diphenylmethane diisocyanate. Alternatively, an adduct or multimer of these various isocyanates, for example, an adduct of toluene diisocyanate, a toluene diisocyanate trimer (trimer), or the like can be used.

The resin composition constituting the surface protective layer may contain various additives within a range not to impair the performance thereof.

Examples of the various additives include ultraviolet absorbers (UVA), light stabilizers (HA L S, etc.), polymerization inhibitors, crosslinking agents, antistatic agents, adhesion improving agents, antioxidants, leveling agents, thixotropy imparting agents, coupling agents, plasticizers, defoaming agents, fillers, solvents, and the like.

The thickness of the surface protection layer is preferably 3 μm to 40 μm, and more preferably 5 μm to 20 μm. When the thickness of the surface protective layer is within the above range, excellent surface characteristics can be obtained.

(adhesive layer)

In the case where the base resin layer and the transparent resin layer are provided, an adhesive layer may be provided between the transparent resin layer and the base resin layer (between the transparent resin layer and the pattern layer in the case where a pattern layer is provided) as needed when these resin layers are laminated.

The adhesive used for the adhesive layer is preferably a moisture-curable adhesive. By using a moisture-curable adhesive as the adhesive, even when the decorative material of the present invention is exposed to a high-temperature, moist-heat environment, the decrease in the adhesion between the transparent resin layer and the decorative layer can be prevented.

The moisture-curable adhesive is not particularly limited, and conventionally known moisture-curable adhesives such as cyanoacrylate-based adhesives and silicone rubber-based adhesives can be used.

The thickness of the adhesive layer is preferably 1 μm to 30 μm, and more preferably 3 μm to 15 μm. When the thickness of the adhesive layer is within the above range, good adhesion can be obtained, and the decorative material of the present invention is not thickened more than necessary.

The decorative material of the present invention is excellent in impact resistance, heat insulation, water resistance, load resistance, scratch resistance, and ease of application, and is suitable for floor materials, particularly for use in water applications such as toilets, and kitchens, or window frames of buildings.

The thickness of the decorative material of the present invention is preferably 5mm or more, more preferably 6mm or more and 30mm or less, and further preferably 10mm or more and 20mm or less, from the viewpoint of obtaining excellent impact resistance, heat insulation, water resistance, load resistance and scratch resistance.

In addition, in view of ease of construction, it is preferable that the thickness of the wooden floor material is the same as that of the wooden floor material installed in a place other than a living room, a corridor, or the like.

The thickness of the wooden floor material is usually 8mm, 12mm, 15mm, etc., and 12mm is a standard thickness.

Note that, according to the characteristics of the final product, the decorative material of the present invention may be subjected to mortise and tenon machining (high-performance construction), groove forming in a V-shape, chamfering of four sides, and the like using a tenoner, a wood mill, and the like.

Fig. 4 shows a structure in which a tongue 8a and a groove 8b are provided on the non-foamed resin layer 2 in the embodiment shown in fig. 2 of the finishing material of the present invention.

The decorative material of the present invention is preferably excellent in weather resistance, and particularly when used as a decorative material for a window frame as described later, it is preferable that the change in appearance is slight even after a 4000-hour test in a solar weather resistance test.

The decorative material for a window frame of the present invention is suitably used as a decorative material for a window frame used for at least a part of a window frame of a building, and comprises a foamed resin layer and a coating layer covering at least a part of the surface of the foamed resin layer, wherein the coating layer comprises a decorative layer and a non-foamed resin layer located on the foamed resin layer side of the decorative layer by a heat fusion bonding portion (1), and the coating layer is provided on the upper surface and the near-front surface of the foamed resin layer.

In the window frame finishing material, the coating layer is preferably provided on the upper surface and the near-front surface of the foamed resin layer so as to cover at least a part of the surface of the foamed resin layer.

The upper surface of the foamed resin layer is a surface which is located on the upper side when the sash decorative material is applied, and the front surface of the foamed resin layer is a surface which is located on the opposite side to the building outer wall surface when the sash decorative material is applied. By providing the coating layers on the upper surface and the near-front surface of the foamed resin layer in this manner, when the finishing material for a window frame is applied to a window, the coating layers can be provided only in a portion that enters the visual field of a user.

Fig. 10 (a) to (d) are cross-sectional views in the thickness direction of the raw material laminate and the window frame decorative material used when assembling the window frame decorative material, which is a preferable example of the decorative material of the present invention.

The finishing material for a window frame shown in fig. 10 (a) can be obtained, for example, by the following method.

First, a groove-shaped cut 106 is provided in a triangular cross-sectional view on the non-foamed resin layer 102 laminated with the decorative layer 103, and the foamed resin layer 101 is laminated at a position adjacent to the cut 106. Then, the raw material laminate is bent at the score 106 so that the foamed resin layer 101 is located inside, and the bending portion 600 is provided, and the non-foamed resin layer 102 is pressure-bonded or bonded via an adhesive to the front end face of the foamed resin layer 101, whereby the sash decorative material shown in fig. 10 (a) can be obtained.

The finishing material for a window frame shown in fig. 10 (b) can be obtained, for example, by the following method.

First, a groove-shaped cut is provided in a non-foamed resin layer 102 laminated with a decorative layer 103 in a triangular sectional view, a foamed resin layer 101 is laminated at a position adjacent to the cut, and the vicinity of the side surface of the foamed resin layer 101 on the side of the cut is cut into a trapezoidal shape so as to form a continuous surface with the cut, thereby providing a groove-shaped cut 106' in a triangular sectional view. Next, another foamed resin layer 101 of a trapezoidal shape cut out of the foamed resin layer 101 is laminated to the non-foamed resin layer 102 via a score 106', thereby producing a raw material laminate. The trapezoidal foamed resin layer 101 is preferably laminated so as to form a continuous surface with the cuts 106'. Then, the bending portion 600 is provided by bending the portion of the score 106 'so that the foamed resin layer 101 is inside, and the trapezoidal foamed resin layer 101 is pressure-bonded or adhesively bonded to the end face of the left foamed resin layer 101 on the score 106' side, whereby the finishing material for a window frame shown in fig. 10 (b) can be obtained.

The decorative sheet for a window frame shown in fig. 10 (c) can be obtained, for example, by the following method.

First, a 2-point groove-shaped cut 106 is provided on the non-foamed resin layer 102 laminated with the decorative layer 103 in a triangular sectional view, and the foamed resin layer 101 is laminated on the outer side of the cut 106 provided on the left side. Next, a cut-out portion 107 is provided in the vicinity of the surface of the foamed resin layer 101 opposite to the non-foamed resin layer 102 side of the side surface of the score 106, and the cut-out portion 107 has a shape that can fit into the non-foamed resin layer 102 and the decorative layer 103 on the outer side of the score 106 on the right side, thereby producing a raw material laminate. Next, the foamed resin layer 101 is bent at the notch 106 so as to be inward, and the bent portion 600 is provided, and the foamed resin layer 101 and the non-foamed resin layer 102 are pressure-bonded or bonded via an adhesive, whereby a decorative sheet for a window frame shown in fig. 10 (c) can be obtained.

The decorative sheet for a window frame shown in fig. 10 (d) can be obtained, for example, by the following method.

First, a cut 106 in the form of a groove at 2 is provided in a triangular shape in a cross-sectional view on the non-foamed resin layer 102 laminated with the decorative layer 103, and the foamed resin layers 101 are laminated on the outer sides of the cuts 106 provided on the left and right sides, respectively. Next, a cut portion 107 'is provided in the vicinity of the surface of the foamed resin layer 101 provided on the left side opposite to the non-foamed resin layer 102 side of the side surface of the score 106, and the cut portion 107' has a shape that can be fitted into the foamed resin layer 101, the non-foamed resin layer 102, and the decorative layer 103 provided on the outer side of the score 106 on the right side, thereby producing a raw material laminate. Next, the left foamed resin layer 101 is bent at the notch 106 so as to be inward, and the bent portion 600 is provided, and the left foamed resin layer 101, the non-foamed resin layer 102, and the right foamed resin layer 101 are pressure-bonded or bonded via an adhesive, whereby the decorative sheet for a window frame shown in fig. 10 (d) can be obtained.

In the window frame finishing material shown in fig. 10 (c) and 10 (d), the lower surface of the foamed resin layer 101 and the coating layer (decorative layer 103 and non-foamed resin layer 102) provided on the lower surface may be formed on the same surface, or may be formed in a protruding state.

In the present invention, it is preferable that the foamed resin layer includes a first region provided with a lower protruding portion protruding downward from a tip portion of the lower protruding portion in the vicinity thereof.

Fig. 6 shows an example of a window frame finishing material which is one of applications of the finishing material of the present invention. Fig. 6 (a) is a sectional view in the thickness direction, and fig. 6 (b) shows an example of a perspective view of a sash decorative material (sash) 60, in which a bent portion 600 is provided in the vicinity of one end (the aforementioned end near the front) of the decorative material of the present invention in which a non-foamed resin layer 62 and a decorative layer 63 are sequentially laminated on a foamed resin layer 61, and a lower protruding portion (hereinafter also referred to as a bent portion 65) in a folded state is formed so that the foamed resin layer 61 is on the inside of the lower protruding portion, with respect to the sash decorative material (sash) 60. The first region where the lower protruding portion (bent portion 65) is provided is, for example, a region indicated by a in fig. 6 (b).

As shown in fig. 6 (c), for example, the sash decorative material 60 is obtained by providing 2-point groove-shaped scores 64 in an M-shape in cross section on the non-foamed resin layer 62 laminated with the decorative layer 63, laminating the non-foamed resin layer 62 between the scores 64 to produce a raw material laminate, laminating another foamed resin layer 61 at a position shifted by the thickness of the foamed resin layer 61, folding the portions of the scores 64 so that the foamed resin layer 61 is inside, and pressure-bonding or bonding the foamed resin layers 61 to each other with an adhesive, thereby obtaining the sash decorative material having the structure shown in fig. 6 (a) and 6 (b).

As another configuration of the sash decorative material, for example, a notch 66 in the form of a groove 4 is provided in a triangular shape in a cross-sectional view on the non-foamed resin layer 62 laminated with the decorative layer 63, the foamed resin layer 61 is bonded to the non-foamed resin layer 62 at a portion adjacent to the notch 66, a cut-out portion 67 is provided in the vicinity of the side surface of the 2 foamed resin layers, and the cut-out portion 67 has a shape that allows both ends of the foamed resin layer 61 to be fitted into the middle. Then, the foamed resin layers 61 are folded at the scores 66 so that the foamed resin layers 61 are inside, and the foamed resin layers 61 are pressure-bonded or bonded via an adhesive, whereby a finishing material for a window frame having a structure shown in fig. 6 (d) can be obtained.

As still another configuration of the sash decorative material, for example, a notch 66 in the form of a groove with 4 places is provided in a triangular shape in a cross-sectional view on the non-foamed resin layer 62 laminated with the decorative layer 63, the foamed resin layer 61(a) is laminated between 2 notches 66 provided on the inner side, the foamed resin layers 61(b) and 61(c) are respectively bonded to the non-foamed resin layer 62 at portions adjacent to the other notches 66, and a cut-out portion 67' having an embedded shape is provided at a position where the side surface of the 2 foamed resin layers 61(b) and 61(c) does not contact the foamed resin layer 61(a) directly in the middle. Then, the foamed resin layer 61(a) is folded at the notch 66 portion so as to be inside, and the foamed resin layers 61(b) and 61(c) are pressure-bonded or bonded via an adhesive, whereby a window frame decorative material having a structure shown in fig. 6 (e) that can be folded without trouble even if the foamed resin layers 61(b) and 61(c) are not precisely machined in size can be obtained. The cut-out portions 67 'provided in the foamed resin layers 61(b) and 61(c) before the folding of the score 66 portion form spaces 67' after the foamed resin layers 61(b) and 61(c) are bonded to each other.

As shown in fig. 6 (a) to (e), the covering layer (the non-foamed resin layer 62 and the decorative layer 63) is preferably further provided on the lower side of the lower side projection of the foamed resin layer 61, and the portion of the covering layer covering the upper side surface of the foamed resin layer 61 and the portion of the covering layer covering the front surface of the foamed resin layer 61 are preferably continuous.

In the window sash decorative material, it is preferable that a portion of the coating layer covering the front surface of the foamed resin layer 61 and a portion of the coating layer covering the lower side surface of the lower side projecting portion (curved portion 65) of the foamed resin layer 61 are continuous, and it is preferable that a portion of the coating layer covering the upper side surface of the foamed resin layer 61, a portion of the coating layer covering the front surface of the foamed resin layer, and a portion of the coating layer covering the lower side surface of the lower side projecting portion of the foamed resin layer are continuous.

Preferably, both side surfaces of the first region in the foamed resin layer and both side surfaces of a region (region B in fig. 6B) other than the first region in the foamed resin layer are flush with each other, and the finishing material for a sash has a rectangular shape in plan view.

The foamed resin layer provided in fig. 6 (c) to (e) and fig. 10 (a) to (d) may be provided by laminating the foamed resin layer with the coating layer in a flat state and then cutting the laminated foamed resin layer into a desired shape.

As shown in fig. 7 (a), the edge tape 71 as an end face wood (wood material) is preferably attached to at least one side surface of the bent portion of the finishing material for a window frame (window frame) 701. Examples of the edge Band include Panefri Band and Marblet S manufactured by Panefri Industrial company. Alternatively, the decorative layer 3 may be bonded to a side surface, or the non-foamed resin layer 2 may be bonded to a side surface, and the decorative layer 3 (the coating layer) may be provided on at least one side surface of the first region. In this case, it is preferable that the covering layer covering at least a part of the surface of the foamed resin layer and at least one selected from the group consisting of an edge tape, a decorative layer, and a covering layer attached to at least one side surface of the first region of the foamed resin layer have the same pattern.

The sash finishing material may be provided with the notch 73 on one side surface to which the edge tape 71 is attached, as in a sash finishing material (sash) 701 shown in fig. 7 (b), or may be provided with the notches 73 on both side surfaces to which the edge tape 71 is attached, as in a sash finishing material (sash) 702 shown in fig. 7 (c).

The above-mentioned lateral edge strips 71 are preferably arranged at locations where no cut 73 is made.

In addition, in the case where the notch 73 is provided on one side surface to which the edge tape 71 is attached, it is preferable that one of the two side surfaces in the first region a of the foamed resin layer 61 protrudes from one of the two side surfaces in the region B of the foamed resin layer 61 other than the first region a and is shaped like L in a plan view, and in the case where the notch 73 is provided on the two side surfaces to which the edge tape 71 is attached, it is preferable that the two side surfaces in the first region a of the foamed resin layer 61 protrude from the two side surfaces in the region B of the foamed resin layer 61 other than the first region a and is shaped like T in a plan view.

In the present invention, the foamed resin layer may have a trapezoidal shape in a plan view as shown in fig. 11. The foamed resin layer 110 shown in fig. 11 can be applied to a window provided at a corner portion by combining short sides with each other, for example.

The decorative material for a window frame has a decorative layer, a non-foamed resin layer, and a foamed resin layer, and the ratio of the total thickness of the decorative layer and the non-foamed resin layer to the thickness of the foamed resin layer and the compressive modulus of elasticity of the foamed resin layer are each defined to a predetermined value, so that the decorative material is excellent in water resistance and heat insulation properties, and also excellent in load resistance, and further has a bent portion in the vicinity of one end of the decorative material, so that the occurrence of warpage can be appropriately prevented.

In such a sash decorative material, the foamed resin layer is preferably formed of 2 or more foamed resin members. Specifically, for example, in the case of the configurations shown in fig. 6 (a) to (e), the foamed resin layer is composed of 3 members; in the case of the configuration shown in fig. 8 (a) and 8 (b), the foamed resin layer is composed of 3 members. Fig. 8 shows an example of a sash decorative material as a preferred example of the decorative material of the present invention, and fig. 8 (a) is a cross-sectional view in the thickness direction of a raw material laminate used when assembling the sash decorative material as a preferred example of the decorative material of the present invention, and in the case of the sash decorative material (sash), a lower protruding portion (hereinafter also referred to as a bent portion) in a folded state is formed so that a non-foamed resin layer 82 and a decorative layer 83 are laminated in this order on a foamed resin layer 81 in the vicinity of one end portion (the aforementioned end portion near the front) of the decorative material of the present invention, and the foamed resin layer 81 is located inside.

As shown in fig. 8 (a), for example, a material laminate can be produced by providing a score 86 in the form of a groove with 4 places in a triangular cross-sectional view on the non-foamed resin layer 82 laminated with the decorative layer 83, laminating a foamed resin layer 81 on the outside of the score 86, laminating another foamed resin layer 81 at a position shifted by the thickness of the foamed resin layer 81, folding the portion of the score 86 so that the foamed resin layer 81 is inside, and pressure-bonding or bonding the foamed resin layers 81 to each other with an adhesive, thereby obtaining a finishing material for a window frame having the structure shown in fig. 8 (a).

As shown in fig. 8 (b), a groove-like notch 86 in 2 is provided in a triangular sectional view, and the foamed resin layers 81(b) and 81(c) having tapered side surfaces are laminated so that the edge portions thereof are disposed at the notch 86 portion, and then the foamed resin layers 81(b) and 81(c) are bent at the notch 86 portion so that the foamed resin layers 81(b) and 81(c) are located inside, and the foamed resin layers 81(b) and 81(c) are pressed against each other or bonded via an adhesive, whereby a window frame finishing material having the structure shown in fig. 8 (b) can be obtained.

The decorative material of the present invention having the decorative layer 3 is excellent in weather resistance, and particularly when the decorative material of the present invention is used for a window frame, it is preferable that the decorative material has a slight change in appearance even when a sunshine weather resistance test is performed for 4000 hours (test conditions described later) with the side of the decorative layer as the surface.

[ method for producing decorative Material ]

The decorative material of the present invention can be produced, for example, by a method including the steps of: and thermally fusing the non-foamed resin layer to the decorative layer. The manufacturing method of the decorative material is also one of the invention.

That is, the method for producing a decorative material of the present invention is a method for producing a decorative material having a decorative layer, a non-foamed resin layer, and a foamed resin layer, and is characterized by comprising the steps of: preparing the decorative layer; a step of thermally fusing and adhering the non-foamed resin layer to the decorative layer; and a step of bonding the foamed resin layer to a surface of the non-foamed resin layer opposite to the side to which the decorative layer is thermally adhered (hereinafter, also referred to as a method for producing the decorative material of the present invention) to each other.

The method for producing a decorative material of the present invention is a method for producing a decorative material having a decorative layer, a non-foamed resin layer, a resin film layer, and a foamed resin layer, the method comprising: preparing the decorative layer; a step of thermally fusing and adhering the non-foamed resin layer to the decorative layer; a step of bonding the resin film layer to a surface of the non-foamed resin layer opposite to the side to which the decorative layer is thermally adhered; and a step of bonding the resin film layer and the foamed resin layer (hereinafter, also referred to as a method for producing a decorative material according to claim 2).

Here, the method for manufacturing a decorative material according to the 2 nd aspect of the present invention includes the same steps except for the step for bonding the resin film layer between the non-foamed resin layer and the foamed resin layer. Thus, the method for manufacturing the decorative material of the present invention will be described as "the method for manufacturing the decorative material of the present invention" without particularly distinguishing between the method for manufacturing the decorative material of the present invention of the 1 st and the method for manufacturing the decorative material of the present invention of the 2 nd.

(preparation of foamed resin layer)

First, the foamed resin layer is prepared.

Preferably, the foamed resin layer is foamed by a bead method or a film-forming method such as an extrusion film-forming method using a T die or a calendering film-forming method using a resin composition for forming a foamed resin layer, preferably at an expansion ratio of 5 to 20 times as high as the above, to have a compressive elastic modulus of 15MPa or more.

The expansion ratio and the compressive modulus of elasticity of the foamed resin layer can be appropriately adjusted by the foaming temperature at the time of foaming, the type of the resin, the amount of the foaming agent and the plasticizer, and the like.

(preparation of non-foamed resin layer)

Subsequently, the non-foamed resin layer is prepared.

Preferably, the non-foamed resin layer is formed by a film forming method such as an extrusion film forming method or a calendering film forming method using a T die, and the tensile elastic modulus is 180MPa or more.

The tensile elastic modulus of the non-foamed resin layer can be appropriately adjusted depending on the type of resin, the type or amount of the inorganic compound, and the like.

(Process for Forming decorative layer)

A decorative layer is formed on the non-foamed resin layer or the base resin layer provided as needed by using the ink composition. The ink composition may be applied by a method such as gravure printing, offset printing, screen printing, flexo printing, ink jet printing, and the like. When the concealing layer (solid print layer) is formed, it may be formed by various coating methods such as gravure printing, bar coating, roll coating, reverse roll coating, comma coating, and the like.

(Process for laminating transparent resin layer)

The transparent resin layer is preferably formed after the decorative layer is formed, if necessary, through a moisture-curable adhesive layer. The adhesive layer may be formed by various coating methods such as gravure printing, bar coating, roll coating, reverse roll coating, comma coating, or an extrusion film-forming method using a T die. The transparent resin layer may be formed by the following method: a method of forming a film by an extrusion film-forming method using a T die and simultaneously laminating; a method of laminating a film prepared in advance by a film forming method such as an extrusion film forming method or a rolling film forming method using a T die by a dry lamination method or a thermal lamination method; and so on.

(Process for Forming surface protective layer)

The surface protection layer may be formed as follows: after the decorative layer forming step or the resin layer laminating step in the case of laminating a transparent resin layer, the surface protective layer can be formed by applying a curable resin composition on the decorative layer or on the transparent resin layer, applying the curable resin composition to a thickness of 3 μm or more and 40 μm or less after curing by a known method such as gravure printing, bar coating, roll coating, reverse roll coating, comma coating, or the like, to form an uncured resin layer, and then heating or irradiating the uncured resin layer with an ionizing radiation such as an electron beam or ultraviolet ray to cure the uncured resin layer.

The heating temperature in the case of thermal curing is appropriately determined depending on the resin used.

When an electron beam is used as the ionizing radiation, the acceleration voltage is appropriately selected according to the thickness of the resin or layer to be used, and it is generally preferable to cure the uncured resin layer at an acceleration voltage of 70kV or more and 300kV or less. The radiation dose is preferably the amount at which the crosslinking density of the resin layer is saturated, and is generally selected in the range of 5kGy to 300kGy (0.5Mrad to 30 Mrad), preferably 10kGy to 50kGy (1Mrad to 5 Mrad).

The electron beam source is not particularly limited, and various electron beam accelerators such as a kockcroft walton (cockcroft wharton) type, a van der graff type, a resonance transformer type, an insulating core transformer type, a linear type, a ground nanometer (Dynamitron) type, and a high frequency type can be used.

When ultraviolet rays are used as the ionizing radiation, radiation including ultraviolet rays having a wavelength of 190nm to 380nm is emitted.

The ultraviolet source is not particularly limited, and for example, a high-pressure mercury lamp, a low-pressure mercury lamp, a metal halide lamp, a carbon arc lamp, or the like is used.

(Process for bonding non-foamed resin layer and decorative layer)

The adhesion of the non-foamed resin layer and the decorative layer can be laminated by a hot-melt adhesive part (1) formed by hot-melt adhesion as long as the resin materials of the non-foamed resin layer and the decorative layer contain the same resin.

The method for thermally fusing and adhering the non-foamed resin layer and the decorative layer is not particularly limited, and examples thereof include: a method in which the non-foamed resin layer is remelted in advance after molding, and then integrated with the decorative layer by pressing or flat pressing with a temperature-adjusting roller; a method of inserting a molding roll of a non-foamed resin layer in a film forming process of a film forming method such as an extrusion film forming method or a calendering film forming method using a T die so as to contact and cover the back surface of the decorative layer with the non-foamed resin layer, and thermally welding the decorative layer by heat retained by the non-foamed resin layer; the non-foamed resin layer and the decorative layer are heated by a far infrared heater or the like, and are inserted between rollers in a state where the surfaces are melted, and are thermally welded.

In this case, the non-foamed resin layer is preferably produced so that the tensile elastic modulus is 180MPa or more. The tensile modulus of the non-foamed resin layer can be appropriately adjusted depending on the type of resin, the type or amount of the inorganic compound, and the like.

(Process for bonding resin film layer and non-foamed resin layer)

The method for producing a decorative material according to the present invention includes a step of bonding the resin film layer to a surface of the non-foamed resin layer opposite to the side to which the decorative layer is thermally bonded.

The resin film layer and the non-foamed resin layer can be laminated by a hot-melt adhesive part (2) formed by the hot-melt adhesion, as long as the resin materials of the resin film layer and the non-foamed resin layer contain the same resin.

The method of forming the heat fusion bonded part (2) by heat fusion bonding the resin film layer and the non-foamed resin layer is not particularly limited, and the same method as that of the heat fusion bonded part (1) can be exemplified.

If the resin materials of the resin film layer and the non-foamed resin layer do not contain the same type of resin, they may be laminated with the adhesive constituting the adhesive layer as described above.

(Process for bonding foamed resin layer and non-foamed resin layer)

The bonding of the foamed resin layer obtained in the step of preparing the foamed resin layer and the non-foamed resin layer forming the decorative layer can be performed using, for example, a heat-sensitive adhesive, a pressure-sensitive adhesive, a hot-melt adhesive, or the like. As the hot melt adhesive, for example, a reactive hot melt adhesive such as a urethane-based reactive hot melt adhesive (hereinafter referred to as "PUR-based adhesive") is preferable. The PUR adhesive contains a functional group (isocyanate group) that reacts with moisture in the component, and after cooling and curing, reacts with moisture adhering to a substrate or a decorative sheet or moisture supplied through the substrate or the decorative sheet.

Has a feature of not melting even when heated after the reaction and having high adhesive strength.

Since the interface between the foamed resin layer and the non-foamed resin layer is distant from the surface of the decorative material of the present invention, even when the decorative material of the present invention in which the foamed resin layer and the non-foamed resin layer are bonded with an adhesive is placed in a high-temperature, moist-heat environment, hydrolysis of the adhesive hardly occurs, and the adhesive strength hardly decreases.

The method for producing a decorative material according to claim 2 includes a step of bonding the resin film layer and the foamed resin layer, and the adhesive may be used in the step of bonding the resin film layer and the foamed resin layer.

The decorative material for a window frame, which is a preferable example of the decorative material of the present invention, has the decorative layer, the non-foamed resin layer, and the ratio of the total thickness of the decorative layer and the non-foamed resin layer to the thickness of the foamed resin layer and the compressive modulus of elasticity of the foamed resin layer are each defined to a predetermined value, and therefore, the decorative material is excellent in water resistance and heat insulation properties, and also excellent in load resistance.

Fig. 9 (a) is a cross-sectional view showing an example in which a window frame decorative material, which is a preferred example of the decorative material of the present invention, is applied to a building window, fig. 9 (b) is a plan view showing an example in which a window frame decorative material, which is a preferred example of the decorative material of the present invention, is applied to a building window, and fig. 9 (c) is a perspective view showing an example in which a window frame decorative material, which is a preferred example of the decorative material of the present invention, is applied to a building window.

That is, the window frame finishing material 90 as a preferred example of the present invention is usually applied to the indoor side of the lower portion of the window 93 provided on the building outer wall surface 91 through the adhesive portion 92 such as mortar.

The window of a building to which the window frame finishing material as a preferable example of the present invention is applied is not particularly limited, and for example, a window frame including a convex windowsill can be appropriately used.

The window frame finishing material according to a preferred example of the present invention is applied to at least a part of the window frame, and in the case of a square window frame, for example, the window frame finishing material according to a preferred example of the present invention is applied to any one or all of four sides of the window frame. Wherein the construction can be properly performed to the lower edge of the window frame.

The present invention relates to a decorative material having a decorative layer, a non-foamed resin layer and a foamed resin layer, wherein a heat-fusion bonding part (1) is provided between the decorative layer and the non-foamed resin layer.

The decorative material of the present invention is excellent in water resistance and heat insulation, and also excellent in adhesion between the decorative layer and the non-foamed resin layer even when exposed to a high-temperature, humid environment.

Examples

The present invention will be described in further detail with reference to examples, but the present invention is not limited to these examples.

(evaluation and measurement method)

The decorative materials obtained in examples and comparative examples were evaluated and measured by the following methods.

(evaluation of hydrolysis resistance: peeling Strength)

The decorative materials obtained in examples and comparative examples were left to stand at 80 ℃ and 90% humidity for 1 year, and the degree of decrease in the adhesion between the non-foamed resin layer and the decorative layer from the adhesion immediately after the production was evaluated. That is, the adhesion force in the state before and after the test was compared.

The samples obtained by cutting the decorative materials obtained in examples and comparative examples into pieces having a width of 1 inch (2.5cm) were each stretched in a direction of 180 ° at a part of a peeled end portion between the non-foamed resin layer and the decorative layer using a Tensilon universal tester ("RTC-1210A type", manufactured by ORIENTEC corporation) to measure the peel strength between the non-foamed resin layer and the decorative layer. The conditions were the stretching speed: 200 mm/min, atmosphere temperature: at 20 ℃. The peel strength was evaluated according to the following criteria. The evaluation results are shown in Table 1.

(evaluation of warpage)

In the decorative materials obtained in examples and comparative examples, the decorative layer and the non-foamed resin layer were laminated and cut to a side of 30 cm. After that, the cut material was left to stand for 1 hour, and the warpage of the cut material when it was placed on a horizontal surface was visually confirmed, and evaluated according to the following criteria.

++: no reaction

+: slight warping is generated

-: to generate warpage

(example 1)

A pattern layer having a stone pattern with a thickness of 2 μm was formed on a colored polypropylene resin film (thickness: 60 μm, color: white) by gravure printing using an ink composition (acrylic urethane).

Then, a transparent polypropylene resin film (thickness: 80 μm) was dry-laminated on the pattern layer.

An undercoat layer having a thickness of 1 μm was formed on the transparent polypropylene resin film using a two-component curable urethane resin. Then, on the undercoat layer, a coating amount of 15g/m was applied by gravure printing²An electron beam-curable resin composition (acrylate) was applied to form a coating film, and the coating film was crosslinked and cured by irradiation with an electron beam to form a surface protective layer (thickness: 15 μm), thereby producing a decorative sheet (thickness: 160 μm) as a decorative layer.

Next, polypropylene containing 30 mass% talc was extruded in a thickness of 2mm by an extruder, and when the polypropylene was in a state of about 200 ℃, the decorative layer was bonded to the front surface side by hot melt bonding, and an undercoat layer having a thickness of 1 μm was formed on the back surface side (the side opposite to the hot melt bonding surface) of the polypropylene by a two-liquid curable urethane resin, thereby forming a non-foamed resin layer having a thickness of about 2mm (2.001 mm).

Next, an EPS resin (15 times foamed, compression modulus of elasticity: 23MPa, thickness: 9.8mm) as a foamed resin layer was laminated to the non-foamed resin layer to which the decorative sheet was laminated with a modified silicone adhesive to produce a decorative material.

The results of evaluation of the obtained decorative material are shown in table 1.

(example 2)

A pattern layer having a stone pattern with a thickness of 2 μm was formed on a colored polypropylene resin film (thickness: 60 μm, color: white) by gravure printing using an ink composition (acrylic urethane).

Then, a transparent polypropylene resin film (thickness: 80 μm) was dry-laminated on the pattern layer.

An undercoat layer having a thickness of 1 μm was formed on the transparent polypropylene resin film using a two-component curable urethane resin. Then, on the undercoat layer, a coating amount of 15g/m was applied by gravure printing²An electron beam-curable resin composition (acrylate) was applied to form a coating film, and the coating film was crosslinked and cured by irradiation with an electron beam to form a surface protective layer (thickness: 15 μm), thereby producing a decorative sheet (thickness: 160 μm) as a decorative layer.

Then, polypropylene containing 30 mass% of talc was extruded in a thickness of 2mm by an extruder, and in a state where the polypropylene was at about 200 ℃, the decorative layer was bonded to the front surface side by hot melt bonding, and similarly, the colored polypropylene resin film (thickness: 60 μm, color: white system) was bonded to the back surface side by hot melt bonding, and further, a primer layer having a thickness of 1 μm was formed on the exposed side (the side opposite to the hot melt bonded surface) of the colored polypropylene resin film by a two-liquid curable urethane resin, to thereby prepare a non-foamed resin layer having a thickness of about 2mm (2.061 mm).

Next, an EPS resin (15 times foamed, compression modulus of elasticity: 23MPa, thickness: 9.8mm) as a foamed resin layer was laminated to the non-foamed resin layer to which the decorative sheet was laminated with a modified silicone adhesive to produce a decorative material.

The results of evaluation of the obtained decorative material are shown in table 1.

(example 3)

A pattern layer having a stone pattern with a thickness of 2 μm was formed on a colored polyethylene terephthalate resin film (thickness: 50 μm) by gravure printing using an ink composition (acrylic urethane).

Next, by gravure printing, at a coating weight of 15g/m²An electron beam-curable resin composition (acrylate) was applied to form a coating film, and the coating film was crosslinked and cured by irradiation with an electron beam to form a surface protective layer, thereby producing a decorative sheet (about 70 μm) as a decorative layer.

Next, a polyethylene terephthalate resin (hereinafter, PET resin) containing 30 mass% of talc was extruded at a thickness of 2mm by an extruder, and was laminated to the decorative layer by thermal fusion bonding in a state where the PET resin was at about 200 ℃.

Next, an EPS resin (15 times foamed, compression modulus of elasticity: 23MPa, thickness: 9.8mm) as a foamed resin layer was laminated to the non-foamed resin layer to which the decorative sheet was laminated with a modified silicone adhesive to produce a decorative material.

Comparative example 1

A pattern layer having a stone pattern with a thickness of 2 μm was formed on a colored polypropylene resin film (thickness: 60 μm, color: white) by gravure printing using an ink composition (acrylic urethane), and a back surface primer layer with a thickness of 1 μm was formed on the opposite side of the pattern layer by gravure printing using an ink composition (urethane).

Next, an adhesive layer having a thickness of 2 μm was formed using a urethane-based adhesive for dry lamination, and a transparent polypropylene resin film (thickness: 80 μm) was provided by dry lamination on the pattern layer.

An undercoat layer having a thickness of 1 μm was formed on the transparent polypropylene resin film using a two-component curable urethane resin. Then, on the undercoat layer, a coating amount of 15g/m was applied by gravure printing²An electron beam-curable resin composition (acrylate) was applied to form a coating film, and the coating film was crosslinked and cured by irradiation with an electron beam to form a surface protective layer (thickness: 15 μm), thereby producing a decorative sheet (thickness: 160 μm) as a decorative layer.

Next, a PP resin sheet (2mm thick) containing 30% talc was prepared, and after the surface of the PP resin sheet was subjected to plasma treatment, the decorative layer was laminated with a urethane adhesive to prepare a non-foamed resin layer.

Next, after plasma treatment was performed on the back surface of the non-foamed layer, an EPS resin (15 times foamed, compression modulus of elasticity: 23MPa, thickness: 9.8mm) as a foamed resin layer was laminated with a urethane adhesive to produce a decorative material.

Comparative example 2

A decorative layer was produced in the same manner as in comparative example 1.

An ABS resin sheet (2mm) containing 20% talc was prepared, and the decorative material was bonded to the ABS resin sheet with a urethane adhesive to prepare a non-foamed resin layer.

Next, an EPS resin (15 times foamed, compression modulus of elasticity: 23MPa, thickness: 9.8mm) as a foamed resin layer was laminated to the non-foamed resin layer to which the decorative sheet was laminated with a urethane adhesive to produce a decorative material.

As shown in table 1, the decorative materials of examples exhibited excellent adhesion that could not be measured (adhesion to an extent that could not be measured, and a part of the edge could not be peeled off as a preparation before the peel strength was measured) both before the test immediately after the sample was made and after the test when the decorative materials were left to stand in a high-temperature, humid and hot environment, and no decrease in adhesion was observed. On the other hand, the decorative material of the comparative example was able to peel off a part of the end portion even in the sample in a state before the test, and was able to peel off a part of the end portion after the test, and was observed to be decreased in peel strength compared to that before the test.

Industrial applicability

According to the present invention, since the decorative material has the structure including the decorative layer, the non-foamed resin layer and the foamed resin layer, and the thermal fusion bonding part (1) is provided between the non-foamed resin layer and the decorative layer, the decorative material is excellent in water resistance and heat insulation, and the adhesion between the non-foamed resin layer and the decorative layer is extremely excellent even when the decorative material is exposed to a high-temperature, moist-heat environment. The decorative material of the present invention is suitable for use as a floor material for housing, particularly a floor material for use in a toilet, a kitchen or the like for water drainage, and a window frame.

Description of the symbols

1. 61, 81, 101, 110 foamed resin layer

2. 62, 82, 102 non-foamed resin layer

3. 63, 83, 103 decorative layer

4 base resin layer

5 transparent resin layer

6 surface protective layer

7 resin film layer

8a tongue

8b female tenon

10. 50 a-d, 51 decorative material

21 st thermoplastic resin layer

22 glass composition layer

23 nd 2 thermoplastic resin layer

33 patterned layer

52 Metal clamp

55-urethane adhesive

60. Decorative material for 701, 702, 90 window frame

60' metal clamp

600 bending processing part

64. 66, 86, 106' scoring

65 bending part

67. 67 ', 107' cut-out

71 edge zone

73 cuts

91 outer wall surface

92 bonding part

93 window

A Hot melt adhesive bonding part (1)

Claims (10)

1. A decorative material having a decorative layer, a non-foamed resin layer and a foamed resin layer, characterized in that,

the decorative layer and the non-foamed resin layer are bonded by thermal fusion bonding.

2. A decorative material having a decorative layer, a non-foamed resin layer and a foamed resin layer, characterized in that,

a heat-fusion bonding part (1) is provided between the decorative layer and the non-foamed resin layer.

3. The decorating material as claimed in claim 1 or 2, wherein a resin film layer is provided between the non-foamed resin layer and the foamed resin layer.

4. The decoration material of claim 3, wherein the resin film layer and the non-foamed resin layer are bonded by thermal fusion bonding.

5. The ornament material according to claim 3, wherein a heat fusion bonding part (2) is provided between the non-foamed resin layer and the resin film layer.

6. The decoration material of claim 1, 2, 3, 4 or 5, wherein the decoration layer and the non-foamed resin layer comprise homologous resins.

7. The decoration material of claim 3, 4 or 5, wherein the non-foamed resin layer and the resin film layer comprise homologous resins.

8. The finishing material of claim 1, 2, 3, 4, 5, 6 or 7, which is a finishing material for window frames.

9. A method for manufacturing a decorative material having a decorative layer, a non-foamed resin layer, and a foamed resin layer, comprising the steps of:

preparing the decorative layer;

a step of thermally fusing and adhering the non-foamed resin layer to the decorative layer; and

and a step of bonding the foamed resin layer to a surface of the non-foamed resin layer opposite to the side where the decorative layer is thermally adhered.

10. A method for manufacturing a decorative material having a decorative layer, a non-foamed resin layer, a resin film layer, and a foamed resin layer, comprising the steps of:

preparing the decorative layer;

a step of thermally fusing and adhering the non-foamed resin layer to the decorative layer;

a step of bonding the resin film layer to a surface of the non-foamed resin layer opposite to the side where the decorative layer is thermally adhered; and

and a step of bonding the resin film layer to the foamed resin layer.

Images