JP2000326456A - Decorative sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve physical properties such as resistance to solvents, resistance to chemicals, resistance to weather and others by forming a base sheet constituted of a polyester resin film containing a coloring agent. SOLUTION: A decorative sheet 1 is a film oriented in the biaxial direction, the vertical direction and the horizontal direction, and a colored substrate layer 3 and a pattern layer 4 forming a grain pattern demonstrating a wood skin pattern of grains such as straight grains or cross grains are laminated on a colored polyester film 2 as a polymer composed of a dicarboxylic acid and a glycol polycondensated together. Also an anchor coat layer 5 is formed on the decorative sheet, and an ethyelene-vinyl alcohol copolymer resin film layer 7 is laminated on the anchor coat layer 5 through an olefin resin layer 6. Physical properties such as resistance to solvents, resistance to chemicals, resistance to weather and others can be improved by the arrangement.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative sheet used for various kinds of furniture and building interior materials.

[0002]

2. Description of the Related Art As a conventional decorative sheet, (1) thin paper is printed by an ordinary method, and a coating layer of an amino alkyd resin or a urethane resin is provided for surface protection,
(2) A transparent polyvinyl chloride film laminated on a polyvinyl chloride film after normal printing, and (3) A polyvinyl chloride film laminated on a thin paper. It has been known. Further, in order to bring out a three-dimensional appearance and improve the design, the above (2),
In the decorative sheet of (3), there is also known a decorative sheet in which, after laminating a polyvinyl chloride film, embossing is performed, and further, ink is filled in recesses of the emboss to express, for example, a wood grain conduit pattern.

However, in the decorative sheet of the above (1), since the strength of the sheet is insufficient, V cut,
It is not suitable for curved surface processing such as lapping, and is inferior in physical properties such as abrasion resistance and chemical properties such as water resistance, solvent resistance, chemical resistance and the like, and in the decorative sheets (2) and (3). All of them use polyvinyl chloride film, which generates chlorine compounds when subjected to incineration as a means of treating waste materials.Therefore, there is a problem that incineration cannot be used. Is required.

[0004] In order to solve the above-mentioned drawbacks, there is a decorative sheet in which thin paper is used as a base sheet and an olefin resin film or an ethylene-vinyl alcohol copolymer resin film is laminated on the surface protective layer instead of the polyvinyl chloride film. However, since the thin paper as the base sheet is inferior in workability, there has been a problem that the thin paper layer is easily broken in the secondary processing such as V-cut or wrapping and peeled off from the processed portion.

[0005]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems, and has as its object to reduce harmful gases such as chlorine compounds when using incineration as a means for treating waste materials. Generation is extremely low, solvent resistance,
An object of the present invention is to provide a decorative sheet which is excellent in physical properties such as chemical resistance and weather resistance and is suitable for secondary workability such as V-cut and wrapping and has excellent design properties.

[0006]

In order to achieve the above object, a solution of the present invention is to form a pattern layer on the upper surface of a base sheet, and form an extruded olefin resin layer on the upper surface of the pattern layer. A laminated sheet comprising a transparent resin film layer interposed therebetween, wherein the base sheet is made of a polyester resin film containing a coloring agent. With this configuration, the generation of harmful substances such as chlorine compounds during incineration and the like can be suppressed as much as possible, and can be easily disposed of. In addition, the secondary workability such as V cut and lapping is excellent. Furthermore, since the base sheet is excellent in strength, heat resistance, and especially heat resistance dimensional stability, the dimensions of the sheet are stable even during printing or extrusion sticking with an olefin-based resin, so that the decorative sheet has a very high designability. It is possible.

An anchor coat layer is laminated between the pattern layer and the extruded layer of the olefin resin. By providing the anchor coat layer, the adhesive force between the pattern layer and the extruded layer of the olefin resin can be increased.

An embossing process is performed on the upper surface of the transparent resin film layer to form an embossed concave portion, and the embossed concave portion is filled with a coloring ink by wiping, and then a decorative sheet is provided with a gloss adjusting resin layer. ,
The design of the decorative sheet can be enhanced.

By providing a decorative sheet having a gloss adjusting resin layer and a matte pattern layer on the upper surface of the transparent resin film layer,
A gloss sheet is formed between the gloss adjusting resin layer and the matte pattern layer, and it is actually a convex surface, but it can be visually felt on the concave surface to create an embossed pattern, and it is a decorative sheet with excellent design properties Can be obtained at low cost.

By forming the transparent resin film layer from an ethylene-vinyl alcohol copolymer resin film, it is possible to obtain a decorative sheet having not only the above-mentioned features but also improved surface properties such as solvent resistance, chemical resistance, and weather resistance. You can do it.

[0011]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, specific embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a sectional view showing a laminated structure of an embodiment of the decorative sheet of the present invention, FIG. 2 is a sectional view showing a laminated structure of another embodiment of the decorative sheet of the present invention, FIG.
1 is a sectional view showing a laminated structure of another embodiment of a decorative sheet of the present invention, wherein 1, 1 ′ and 1 ″ are decorative sheets, 2 is a colored polyester resin film, 3 is a colored base layer, and 4 is a pattern 5, an anchor coat layer, 6 an olefin-based resin layer, 7 an ethylene-vinyl alcohol copolymer resin film layer, 8 a colored ink layer, 9 a gloss adjusting resin layer, 1
0 represents each of the matte picture layers.

As shown in FIG. 1, the basic structure of the decorative sheet 1 of the present invention is such that a colored undercoat layer 3, a picture pattern layer 4, and an anchor coat layer 5 are formed on a colored polyester resin film 2.
And an ethylene-vinyl alcohol copolymer resin film layer 7 is laminated on the anchor coat layer 5 with an olefin resin layer 6 interposed therebetween.

The colored polyester resin film 2 used in the present invention is a film that is melt-extruded from a so-called extrusion die, and is usually a film oriented biaxially in a vertical direction and a horizontal direction. And a polymer obtained by condensation polymerization from glycol, and the dicarboxylic acids include terephthalic acid, isophthalic acid, phthalic acid, 2,6-naphthalenedicarboxylic acid, adipic acid,
Sebacic acid and the like, and as the glycol,
Examples include ethylene glycol, trimethylene glycol, tetramethylene glycol, cyclohexane dimethanol, and the like. Specifically, for example, polyethylene terephthalate, polytetramethylene terephthalate, polyethylene-p-oxybenzoate, poly-1,4-cyclohexylene dimethylene terephthalate, polyethylene-
2,6-naphthalenedicarboxylate and the like. In the case of the present invention, polyethylene terephthalate is particularly preferred.

In the present invention, pigments and / or pigments are added to the colored polyester resin film 2 in order to impart hiding properties.
Alternatively, it is necessary to incorporate a dye. Pigments can be classified into inorganic pigments and organic pigments,
Examples of the inorganic pigment include titanium oxide white, zinc white, carbon black, red iron oxide, vermilion, graphite, ultramarine, cobalt blue, cobalt purple, zinc chromate, and the like. Typical organic pigments include phthalocyanine, dioxazine, and anthraquinone pigments, such as quinacridone, watch angred, and dioxazine violet. Dyes can be classified into natural dyes and synthetic dyes. Examples of the natural dyes include indigo (indigo). As synthetic dyes, azo dyes,
Indigo dyes, sulfur dyes, nitro dyes, nitroso dyes and the like can be mentioned. These pigments and dyes can be used alone or in combination of two or more, and are excellent in light resistance and in order to have a base sheet having a hiding property,
Inorganic pigments are optimal.

If necessary, the colored polyester resin film 2 is subjected to a surface treatment. A so-called coating may be used to provide a primer treatment for improving the adhesion of the printing ink, or a primer for bonding to the back substrate, that is, an easily adhesive resin layer. The thickness of the colored polyester resin film 2 is 2
The thickness is preferably from 0 to 100 μm, and from 40 to 50 μm in view of cost and good handling in use.

On the upper surface of the colored polyester resin film 2, if necessary, a colored underlayer 3 and, for example, a wood grain pattern such as oak, teak, walnut, or the like, which shows a wood grain pattern of a straight-grained or wood-grained grain are formed. The picture pattern layer 4 is formed by gravure printing with normal ink,
As the ink for forming the colored base layer 3 and the picture pattern layer 4 using the normal ink, a conventional cellulose-based, cellulose-alkyd-based, salt-vinyl acetate-based, acrylic-based, acrylic polyol-based binder resin is used. It is preferable to add brilliant pigments such as pearl pigments and metal powders so that the "glow" of the grain can be expressed well.

It is preferable to provide an anchor coat layer 5 on the pattern print layer 4 for the purpose of improving the adhesion between the pattern print layer 4 and the olefin-based resin layer 6. An ink using a vehicle of one or a mixture of two or more resins such as acrylic resin and polyester resin is suitable, and a two-component curing type is preferable for improving the adhesive strength.

As the two-component curable urethane resin constituting the anchor coat layer 5 in the present invention, a polyol component having an OH group as a main component (acryl polyol, polyester polyol, polyether polyol, epoxy polyol, etc.) is used. It is preferable that an isocyanate compound such as tolylene diisocyanate, isophorone diisocyanate, and hexamethylene diisocyanate is added as a curing agent.

The olefin-based resin layer 6 is interposed between the pattern layer 4 and the ethylene-vinyl alcohol copolymer resin film 7 to increase the thickness of the total sheet layer, and to provide a curved surface such as wrapping or V-cut. And, in order to further increase the sense of design fleshy,
This is provided to improve the adhesive strength between them, and good adhesive strength cannot be obtained even if the ethylene-vinyl alcohol copolymer resin film 7 is directly laminated on the pattern layer 4. The olefin resin layer 6 may be formed by extrusion coating an olefin resin such as polyethylene or other resin by an extrusion lamination method, or by drying a rubber, acrylic, epoxy or urethane resin. A method of coating by a lamination method, a method of coating a resin such as a rubber emulsion system, a vinyl acetate-acryl emulsion system, and an epoxy emulsion system by a wet lamination method, etc. are used. In order to impart a feeling of meat holding, a method of extrusion-coating an olefin resin is desirable. The thickness of the olefin resin layer 6 is 20 to 50 μm.
m is preferred.

As the ethylene-vinyl alcohol copolymer resin film 7, a film on which a random copolymer of ethylene and vinyl alcohol is generally formed is used. By changing the ratio of the copolymer components, the rigidity, oil resistance, solvent resistance, and antistatic property of ethylene can be arbitrarily adjusted.
In order to make the film excellent in processability, an ethylene-vinyl alcohol copolymer resin film having an ethylene component of 30 to 45 mol% is used. If it is less than 30 mol%, thermoplasticity, suitability for heat processing and water resistance are poor.
If it exceeds mol%, the rigidity, oil resistance, solvent resistance, and non-charging properties are inferior, which is not preferable. The thickness is 10 to 100
μm is preferred.

Further, as shown in FIG. 2, a decorative sheet 1 'having another structure of the present invention is filled with a coloring ink 8 in an embossed concave portion provided on the surface of the ethylene-vinyl alcohol copolymer resin film layer 7. Then, there is a configuration in which the gloss adjusting resin layer 9 is provided later, and the design effect of the decorative sheet is further enhanced by filling the coloring ink 8 by wiping into the concave portions of the uneven pattern provided on the surface.

The embossing can be performed by any known embossing method. For example, the embossing can be performed by using a normal hot embossing machine, and the surface of the decorative sheet can be provided with irregularities. The concave portion is filled with the coloring ink 8 by wiping. Although the depth of the embossed concave portion is slightly different depending on the pattern or the like expressed by the embossed concave portion, it is particularly preferably about 20 to 100 μm in order to provide a good unevenness feeling on the surface of the decorative sheet. As the emboss, an abstract pattern, a stone pattern, and a cloth pattern can be used in addition to a representation of a wood grain conduit, a reproduction of a glossy state of a painted plate, and a combination thereof.

As the coloring ink 8 filled in the embossed concave portions of the ethylene-vinyl alcohol copolymer resin film 7, a paint or ink is used. For example, a synthetic resin such as a natural resin or a denatured resin thereof, a cellulose derivative, an acrylic resin, a polyester resin, or a polyurethane resin is used as a constituent material of the vehicle, and a coloring pigment, an extender pigment, a plasticizer, and the like are added to the vehicle. A paint or ink is used. As the vehicle to be used, a two-liquid curable urethane resin is preferably used. As the wiping method, any of conventionally used wiping methods such as a doctor blade method and a roll coating method may be used.

Even if the gloss adjusting resin layer 9 is colorless and transparent,
Alternatively, it may be colored and transparent, or may be matte and transparent, and is provided to adjust the glossiness of the surface of the decorative sheet, but also has a role of surface protection. The gloss adjusting resin layer 9 is formed by applying a paint using an appropriate vehicle, and the vehicle may be formed of a thermosetting resin such as a phenol resin, an unsaturated polyester resin, an epoxy resin, a polyurethane resin, and an acrylic resin. One or more mixed resins can be used. Usually, an appropriate amount of a matting agent is dispersed in the paint for forming the gloss adjusting resin layer 9 to give a desired gloss. Examples of the matting agent include mica, silica, alumina, calcium carbonate, silica sand, shirasu balloon and the like. Is used. As a method of applying the paint, a method such as gravure coating, roll coating, and air knife coating is used.

As shown in FIG. 3, a decorative sheet 1 '' having another structure according to the present invention has a gloss adjusting resin layer 9 and a matte pattern layer on the surface of the ethylene-vinyl alcohol copolymer resin film 7. 10 is formed. The matte picture layer 10 is provided on the ethylene-vinyl alcohol copolymer resin film 7 so as to make the emboss-like pattern by actually feeling the convex surface but the concave surface to enhance the design effect of the decorative sheet. This eliminates the need for embossing and wiping steps, and makes it possible to obtain a decorative sheet that is low in cost and excellent in design.

In order to manufacture a decorative board using the decorative sheet of the present invention, a vinyl acetate resin, a urea resin, an epoxy resin, a urethane resin Plywood, using adhesives such as
It is bonded and laminated on a substrate such as an MDF or a particle board. Further, in the production of the decorative sheet, a primer layer such as a polyester resin may be provided in advance on the back surface of the decorative sheet in order to strengthen the adhesion between the decorative sheet and the substrate.

Example 1 A colored solid ink layer and a picture pattern layer composed of a wood grain pattern were gravure-printed on the surface of a colored polyester resin film having a thickness of 50 μm using an ink composed of a nitrocellulose / alkyd resin. An anchor coat layer using a liquid-curable urethane resin as a vehicle is formed, and a polyethylene resin film having a thickness of 30 μm is formed between the anchor coat layer surface and the corona discharge treated surface of a 25 μm-thick ethylene-vinyl alcohol copolymer resin film. A decorative sheet provided with a surface protective layer was prepared by extruding and laminating to about 40 μm.

Example 2 Immediately after passing the decorative sheet obtained in Example 1 through a heated heat drum, the decorative sheet was subjected to hot-press embossing with a metal roll having a wood grain conduit shape. After applying a two-component curable urethane-based coloring ink on the surface of the ethylene-vinyl alcohol copolymer resin film formed by the roll coating method, remove the coloring ink adhering to portions other than the concave portions with a doctor blade. Then, the coloring ink was filled into the embossed concave portions formed on the surface of the laminated sheet and solidified. Further, a two-part curable urethane matting paint was coated on the sheet with a gravure roll having a plate depth of 60 μm to produce a decorative sheet having high design and high workability.

Example 3 A two-part curable urethane resin paint was coated as a gloss adjusting resin layer on the surface of the ethylene-vinyl alcohol copolymer resin film of the decorative sheet obtained in Example 1 by gravure coating. Further, a wood grain conduit printing was carried out with a two-part curable urethane matting ink thereon to prepare an inexpensive decorative sheet having an embossed design.

[0030]

As described above, according to the present invention, the transparent polyester-vinyl alcohol copolymer resin film is laminated as a surface protective layer on the surface of the colored polyester resin film as the base material, so that the solvent resistance is improved. , A decorative sheet with excellent surface properties such as chemical resistance and weather resistance, and secondary processing properties such as V-cut and wrapping. In addition, a polyester resin film containing a coloring agent has strength, heat resistance,
In particular, since the sheet has excellent heat-resistant dimensional stability, the dimensions of the sheet are stable even during printing and when affixed with an olefin-based resin, so that a decorative sheet having a very high design property can be obtained.
In addition, both have a configuration that does not contain chlorine atoms in the resin,
Since the generation of hydrogen chloride and the like in the gas generated during the incineration treatment is extremely small, the decorative sheet can be easily discarded by burning or the like.

Further, since the anchor coat layer made of the two-component curable urethane resin is provided between the pattern layer and the extruded layer of the olefin resin, a decorative sheet having high interlayer adhesive strength can be obtained.

Further, the transparent resin film layer is made of ethylene-
By using a vinyl alcohol copolymer resin film, a decorative sheet having the above characteristics and improved surface properties such as solvent resistance, chemical resistance, and weather resistance can be obtained.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing a laminated structure of an embodiment of a decorative sheet according to the present invention.

FIG. 2 is a cross-sectional view showing a laminated structure of another embodiment of the decorative sheet of the present invention.

FIG. 3 is a sectional view showing a laminated structure of another embodiment of the decorative sheet of the present invention.

[Explanation of symbols]

1, 1 ', 1''decorative sheet 2 colored polyester resin film 3 colored underlayer 4 picture pattern layer 5 anchor coat layer 6 olefin resin layer 7 ethylene-vinyl alcohol copolymer resin film 8 colored ink layer 9 gloss adjusting resin Layer 10 Matte pattern layer

Continued on the front page F-term (reference) 4F100 AK03C AK04 AK41A AK51 AK69D AR00D AR00E AT00A BA04 BA05 BA07 BA10A BA10D BA10E CC00 CC00B DD20E EJ39D EJ55D EJ65A GB08 GB81 HB00B HB00E HB01 JB01 J02L

Claims (5)

[Claims] 1. A laminate comprising a pattern layer formed on an upper surface of a base sheet, and a transparent resin film layer laminated on an upper surface of the pattern layer via an extruded layer of an olefin resin. A decorative sheet, wherein the material sheet comprises a polyester resin film containing a colorant. 2. The decorative sheet according to claim 1, wherein an anchor coat layer is laminated between the pattern layer and the extruded layer of the olefin resin. 3. An embossing process is performed on an upper surface of the transparent resin film layer to form an embossed concave portion, and the embossed concave portion is filled with a coloring ink by wiping, and thereafter, a gloss adjusting resin layer is provided. The decorative sheet according to claim 1 or 2, wherein 4. The decorative sheet according to claim 1, wherein a gloss adjusting resin layer and a matte picture layer are provided on an upper surface of the transparent resin film layer. 5. The decorative sheet according to claim 1, wherein said transparent resin film layer is made of an ethylene-vinyl alcohol copolymer resin film.