JP2001232724A - Decorative thermoplastic resin sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorative thermoplastic resin sheet excellent in the adhesion with an adhesive and printability, reduced in warpage or strain and suitable as a base material of a decorative panel or sheet. SOLUTION: This decorative thermoplastic resin sheet comprises a laminate wherein film-like thermoplastic resin synthetic papers are provided on both surfaces of a base material sheet.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative thermoplastic resin sheet, and more particularly, to a decorative sheet having excellent adhesiveness to an adhesive and printability, and having little warpage or distortion. The present invention relates to a decorative thermoplastic resin sheet which is suitable as a base material of a board or a base material of a decorative sheet to be attached to various kinds of furniture or building interior materials for the purpose of decoration or surface protection.

[0002]

2. Description of the Related Art Conventionally, as a base sheet of a decorative panel such as a floor tile or a wall panel, a sheet made of a vinyl chloride resin has been used because of its moderate flexibility and good workability. Has been awarded. In addition, as a decorative panel for a cabinet of furniture or kitchen products, in general, a decorative sheet on which a woodgrain pattern or the like is printed on a wood-based material, an inorganic-based material, or a metal-based material such as a steel plate is bonded with an adhesive. A structure having a different structure is used. As a decorative sheet used for such a surface decorative board, it has a moderate flexibility, and has good workability such as V-cut workability and lapping workability. Those made of vinyl resin have been awarded. However, such decorative boards and sheets made of vinyl chloride resin have poor durability (resistance to wear, scratches, dents, etc.) and cleaning properties, and generate harmful chlorine and dioxin when incinerated. In addition to being problematic in terms of contamination, the plasticizer contained therein tends to bleed, causing problems such as poor appearance. Therefore, there has been a demand for a decorative board or a decorative sheet which does not use a vinyl chloride resin, has good processability, and is excellent in durability and cleaning properties. For this reason, in recent years, various decorative boards and decorative sheets using a polyolefin-based resin as a base sheet have been developed. However, polyolefin-based resins generally have poor adhesion, so for example, floor tiles and wall panels using polyolefin-based resins as backers,
When affixing to a floor or a wall using an adhesive, there is a problem that the adhesive is easily peeled off. On the other hand, in recent years, due to the trend toward high-end products of consumers, a sense of high quality has been demanded for floor tiles and wall panels, or cabinets for furniture and kitchen products, and therefore, decorative boards and decorative sheets used for them have been required. Also, those having an appearance giving a sense of quality are desired. Therefore, on the surface of the base sheet made of polyolefin-based resin, various printings are performed, and a film having a picture layer is provided.However, polyolefin-based resins generally have poor printability, When laminating a film using an adhesive, there are problems such as poor adhesion to the adhesive. Therefore, in order to solve such a problem, usually, the surface of the base sheet made of polyolefin resin, corona discharge treatment, sand blast treatment, physical or chemical treatment such as chromic acid treatment,
Alternatively, a method of improving adhesion and printability with an adhesive by applying a primer layer or the like has been performed. However, in these methods, although the effect of improving the adhesion to the adhesive and the printability is recognized to some extent, they have not always been sufficiently satisfactory.

[0003]

SUMMARY OF THE INVENTION Under such circumstances, the present invention has excellent adhesiveness with an adhesive and printability, has less warpage and distortion, and has a decorative board such as a floor tile or a wall panel. The purpose of the present invention is to provide a decorative thermoplastic resin sheet suitable as a base material of a decorative sheet or as a base material of a decorative sheet to be adhered to various kinds of furniture and building interior materials for the purpose of decoration or surface protection. It was done as.

[0004]

The present inventor has conducted intensive studies to develop a decorative thermoplastic resin sheet having the above-mentioned excellent functions. Focusing on extremely excellent adhesion and printability, a laminated sheet consisting of a film-like synthetic paper on both sides of a base sheet made of a thermoplastic resin such as polyolefin resin suits its purpose. Find out what can be done,
Based on this finding, the present invention has been completed. That is, the present invention provides (1) a decorative thermoplastic resin sheet comprising a laminate in which film-like thermoplastic resin synthetic paper is provided on both sides of a base sheet, and (2) a base sheet made of a polyolefin resin. Item 2. The decorative thermoplastic resin sheet according to item 1, which is a base sheet, and item (1) or item 2, wherein the film-shaped thermoplastic synthetic resin paper is a polyolefin resin synthetic paper.
(4) The decorative thermoplastic resin sheet according to (1), (2) or (3), wherein the base sheet has a thickness of 0.08 to 10 mm; 5) First
Item 2, Item 3, Item 3 or Item 4, Double-sided decorative partition plate using the decorative thermoplastic resin sheet, (6) Item 1, Item 2
Item 1, 3 or 4, a single-sided or double-sided decorative display board using the decorative thermoplastic resin sheet according to Item 3, (7) Items 1 and 2,
Item, single-sided decorative wallboard using the decorative thermoplastic resin sheet according to item 3, or 4, and (8) the decorative property according to item 1, item 2, item 3, or item 4. Single-sided decorative ceiling panel using a thermoplastic resin sheet, (9) Item 1, Item 2, Item 3 or Item 4
The single-sided decorative flooring using the decorative thermoplastic resin sheet according to the above paragraph, and the decorative thermoplastic resin sheet according to the paragraph (1), the paragraph (2), the paragraph (3) or the paragraph (4). One-sided decorative wainscot,
Is provided.

[0005]

DESCRIPTION OF THE PREFERRED EMBODIMENTS A thermoplastic resin is used as a resin component in a base sheet of the thermoplastic resin sheet of the present invention. Examples of the thermoplastic resin include a polyolefin resin, a polyester resin, and an acrylic resin. Among them, polyolefin resins are particularly preferable. The polyolefin resin is not particularly limited, and may be, for example, a homopolymer of α-olefin such as ethylene, propylene, butene-1, 3-methylbutene-1, 3-methylpentene-1, and 4-methylpentene-1; These copolymers, or copolymers of these with other copolymerizable unsaturated monomers, and the like can be mentioned. Representative examples include high-density, medium-density, low-density polyethylene, linear low-density polyethylene, ultra-high-molecular-weight polyethylene, ethylene-vinyl acetate copolymer, polyethylene such as ethylene-ethyl acrylate copolymer, and propylene alone. Polypropylenes such as polymers, propylene-ethylene block copolymers and random copolymers, propylene-ethylene-diene compound copolymers, and polybutene-
1, poly 4-methylpentene-1 and the like. Among the above polypropylenes, crystalline polypropylene resins are often used. Examples of the crystalline polypropylene resins include isotactic propylene homopolymer having crystallinity and ethylene-propylene having a low ethylene unit content. A random copolymer, a propylene block copolymer composed of a homo part composed of a propylene homopolymer and a copolymer part composed of an ethylene-propylene random copolymer having a relatively high content of ethylene units, and the propylene block copolymer. A crystalline propylene-ethylene-α-olefin copolymer or the like in which each homo part or copolymer part in the block copolymer is further obtained by copolymerizing an α-olefin such as butene-1 is exemplified. This polyolefin-based resin may be used alone, or two or more kinds may be used in combination. Recycled products can also be used, but they are appropriately selected and used depending on the use of the thermoplastic resin sheet. Is preferred. This base material sheet can contain an inorganic filler if desired. The content of the inorganic filler is not particularly limited and is appropriately selected depending on the use of the thermoplastic resin sheet, but is usually in the range of 20 to 85% by weight, preferably 30 to 75% by weight. If the content is less than 20% by weight, cutting workability and rigidity are insufficient, and if it exceeds 85% by weight, sheet formability and impact resistance are reduced, and the weight is increased, which is not preferable. Here, examples of the inorganic filler include calcium carbonate, magnesium carbonate, aluminum hydroxide, magnesium hydroxide, kaolin, silica, perlite, calcium sulfate, barium sulfate, calcined alumina, calcium silicate, talc, mica, and the like. These may be used alone or in combination of two or more.

[0006] Among these inorganic fillers, calcium carbonate, talc, aluminum hydroxide and magnesium hydroxide are preferred from the viewpoint of machinability and economy, and calcium carbonate is particularly preferred. The calcium carbonate is not particularly limited, and any of precipitated calcium carbonate, heavy calcium carbonate, light calcium carbonate and the like can be used. The average particle size of the calcium carbonate is usually in the range of 0.05 to 200 μm, preferably 0.5 to 20 μm. In the base sheet, if desired, various additional components such as antioxidants, heat stabilizers, ultraviolet absorbers, light stabilizers, chlorine scavengers, flame retardants, flame retardant assistants, lubricants, release agents,
A coloring agent, a plasticizer, a softening agent such as process oil or liquid paraffin, and other thermoplastic resins and thermoplastic elastomers can be appropriately contained. In order to prepare this base sheet, first, a thermoplastic resin such as the above-mentioned polyolefin resin, and preferably an inorganic filler such as calcium carbonate of 20 to 85% by weight based on the total amount of the molding material, and further used as required. The compounding material for the base sheet is prepared by blending with various additive components and mixing with a tumbler blender, a Henschel mixer, or the like, or after mixing, melt-kneading and granulating using a single-screw extruder or a multi-screw extruder. Is prepared. This molding material is then
Known methods, such as cast molding, extrusion sheet molding,
It is molded by a method such as calender molding to produce a base sheet. This molding material may be foamed in an extruder to produce a foamed base sheet having an appropriate foaming ratio. The thickness of the base sheet is generally selected in the range of 0.08 to 10 mm, preferably 0.1 to 6 mm, depending on the use of the thermoplastic resin sheet. In the present invention,
For the purpose of improving the adhesion to the synthetic paper provided on both sides of the base sheet thus obtained, if necessary, the base sheet may be subjected to a physical or chemical surface treatment such as an oxidation method or a roughening method. Can be applied. Examples of the oxidation method include corona discharge treatment, chromic acid treatment, flame treatment, hot air treatment, ozone / ultraviolet irradiation treatment and the like, and examples of the unevenness method include a sand blast method and a solvent treatment method. . These surface treatment methods are appropriately selected depending on the type of the base sheet, but generally, a corona discharge treatment method is preferably used from the viewpoint of effects and operability. The thermoplastic resin sheet of the present invention has a film-like thermoplastic resin synthetic paper provided on both sides of the base sheet, and the thermoplastic resin synthetic paper is a combination of a thermoplastic resin and an inorganic filler. And the surface layer is made into paper, and is extremely excellent in adhesion to an adhesive and printability.
As the thermoplastic resin synthetic paper, polyolefin resin, polystyrene resin, polyvinyl chloride resin, polyester resin synthetic paper, and the like are known. In the present invention, polyolefin resin synthetic paper is particularly preferably used. Can be The polyolefin-based resin synthetic paper is formed by mixing calcium carbonate and titanium oxide in an amount of about 5 to 30% by weight based on the total weight of polypropylene or polyethylene, and has a thickness of 50 to 15 in the present invention.
A film having a thickness of about 0 μm is used.

When such a film-shaped thermoplastic synthetic paper is laminated on both sides of the base sheet, the heat lamination method may cause insufficient adhesion to the base sheet. It is preferable to insert an adhesive layer between the material sheet and the synthetic paper, and to laminate the synthetic paper. At this time, as the adhesive layer, a film of the same quality as the base sheet, or
Those exhibiting tackiness when heated, for example, chlorinated polyolefin resin, polyurethane resin, epoxy resin, acrylic resin, vinyl resin, vinyl acetate resin, polyester resin, ethylene-vinyl acetate copolymer resin, acrylic resin Preferred examples include those having a thickness of about 1 to 20 [mu] m made of a known adhesive mainly composed of a vinyl acetate copolymer resin, a polyamide resin, an ionomer resin or the like. When a film of the same quality as the base sheet is used as the adhesive layer, it is advantageous to previously bond the film to the back surface of the synthetic paper with an adhesive such as urethane or acrylic, Thereby, the synthetic paper can be thermally fused to the base sheet. The synthetic paper laminated on both sides of the base sheet may be of the same type or thickness, or may be different, but the resulting thermoplastic resin sheet may have warpage or distortion. In terms of prevention, productivity, etc., those having the same type and thickness are advantageous. The thermoplastic resin sheet of the present invention thus obtained is extremely excellent in adhesiveness with an adhesive and printability,
Has features such as warpage and distortion is suppressed, for example, used as a base material for decorative panels such as floor tiles and wall panels, or for various decorative furniture, kitchen product cabinets, surface decorative panels for building interior materials, etc. It is suitable as a base material of a decorative sheet to be obtained.

FIG. 1 is a cross-sectional view of an example of a decorative thermoplastic resin sheet of the present invention. The film-shaped thermoplastic resin sheet is provided on both surfaces of a base sheet 1 with adhesive layers 2 and 2 ′ interposed therebetween. The structure in which the resin synthetic papers 3, 3 'are laminated is shown. The thermoplastic resin sheet of the present invention is, for example, on a synthetic paper on one side thereof, a grain pattern, a grain pattern, a surface pattern of natural leather, a texture pattern, a gravure print, a screen pattern, an offset print, a pattern layer expressing an abstract pattern, By applying general printing such as flexographic printing and further providing a clear layer on it and laminating various laminate materials, decorative boards such as floor tiles and wall panels, cabinets for furniture and kitchen products, construction A decorative sheet or the like used for a decorative surface of a surface of an interior material or the like can be manufactured. Examples of the various laminate materials include a metal sheet, a transparent or colored plastic sheet, a transparent plastic film having a pattern layer, a transfer film, a scratch-resistant clear film, and further kraft paper, printing paper, nonwoven fabric, woven fabric, and the like. . In addition, the above-mentioned pattern layer is printed on the surface of a film-like thermoplastic resin synthetic paper in advance, and the printed synthetic paper and the non-printed synthetic paper are
Each of them can be laminated on both sides of the base sheet.
When the decorative panel obtained in this manner is to be applied to a construction target such as a floor surface or a wall surface, the decorative panel may be attached via an adhesive such that the back surface thereof faces the construction target. Thus, the decorative board can be firmly fixed. On the other hand, decorative sheets are used, for example, as wood, plywood, laminated wood, or wood-based base materials such as particle boards and hardboards, metal-based base materials such as steel plates, stainless steel plates, and aluminum plates, and inorganic base materials such as gypsum boards. By bonding them with an adhesive so that the back surfaces face each other, it is possible to produce a decorative surface plate for furniture, kitchen product cabinets, building interior materials and the like. The decorative thermoplastic resin sheet of the present invention is a decorative decorative sheet, for example, a board material for furniture, a partition plate, for example, a partition panel, a blind plate, a display plate, for example, a poster board, a cabinet, a box,
It can be suitably used for wall boards, ceiling boards, name tags, floor materials, and wainscots.

[0009]

Next, the present invention will be described in more detail with reference to examples, but the present invention is not limited to these examples. Example 1 (1) Production of base sheet Homopolypropylene [weight average molecular weight of about 320,000, MI
3.1 g / 10 min] 45 parts by weight, 55 parts by weight of calcium carbonate powder having an average particle diameter of 1.0 μm, and 0.2 parts by weight of a hindered phenolic antioxidant are dry-blended and then melted by a twin-screw kneader. A base sheet having a thickness of 3.0 mm was produced by kneading and extrusion sheet molding. Next, corona discharge treatment was performed on both surfaces of the base sheet according to a conventional method. (2) Preparation of thermoplastic resin sheet One side of a synthetic paper having a thickness of 100 μm formed by blending calcium carbonate and titanium oxide with high-density polyethylene,
An adhesive layer having a thickness of 3 μm made of a chlorinated polypropylene resin was provided. On both sides of the base sheet obtained in the above (1), an adhesive layer made of a chlorinated polypropylene resin is placed on the synthetic paper so as to be in contact with the base sheet at a temperature of 15 ° C.
By laminating by heat fusion by a press method at 0 ° C., a base material for a wall panel having a structure shown in FIG. 1 was produced. <Evaluation of Warpage> A sample having a length of 100 cm and a width of 100 cm was cut out, placed on a flat glass plate, and the height of a square corner and a total of eight intermediate points were measured. . As a result, the maximum warpage was 2 mm. <Evaluation of Adhesiveness with Adhesive> A sample having a size of 20 mm × 20 mm was cut out, the sample was adhered to a steel plate using a urethane-based adhesive, allowed to stand for 7 days, and then subjected to a plane tensile test. As a result, cohesive failure of the adhesive occurred at 0.62 N / mm ² . <Evaluation of Printability> One hundred squares of 1 mm ² were prepared within 1 cm ² , and a peel test was carried out using a cellophane tape. The number of peelings was 0 and the printability was good.

Comparative Example 1 A base material for a wall panel was prepared in the same manner as in Example 1, except that synthetic paper was laminated only on one side of the base sheet. With respect to the wall panel base material, warpage was evaluated in the same manner as in Example 1, and adhesion and printability with the adhesive on the side where the synthetic paper was not laminated were evaluated in the same manner as in Example 1. . As a result, the maximum warpage was 5 mm, and cohesive failure of the adhesive occurred at 0.36 N / mm ² . Further, the printability was poor (12 peelings). Example 2 (1) Preparation of base sheet 65 parts by weight of ethylene-vinyl acetate copolymer resin (90% by weight of ethylene unit, weight average molecular weight of about 110,000, melt index (MI) 3.0 g / 10 minutes), average particle size 2.4 diameter
225 parts by weight of μm calcium carbonate powder, 5 parts by weight of diisononyl phthalate as a plasticizer, 2.5 parts by weight of zinc stearate as a lubricant, 2.5 parts of a phosphate ester-based metal roll release agent
After the dry blending of 0.5 parts by weight of the hindered phenol-based antioxidant and 0.5 parts by weight of the hindered phenolic antioxidant, a base sheet having a thickness of 3.0 mm was prepared by sheet molding. Next, corona discharge treatment was performed on both sides of the base sheet according to a conventional method. (2) Production of thermoplastic resin sheet In the same manner as in Example 1 (2), a synthetic paper was laminated on both sides of the substrate sheet obtained in (1) above to produce a floor tile substrate. . About this base material for floor tiles, while evaluating warpage and printability in the same manner as in Example 1,
The adhesion to the adhesive was evaluated as follows. As a result, the maximum warpage was 2 mm, and the printability was good (no peeling).
Met. The adhesive strength was 11.1 kg / 50 mm. <Evaluation of Adhesion with Adhesive> A flexible board having a thickness of 3.0 mm is coated with a urethane-based adhesive, a predetermined comb is inserted, and a floor tile base material cut into a width of 50 mm is pressed on the flexible board with a roller. Four days later, the 90 ° peel strength was measured. Comparative Example 2 A floor tile base material was produced in the same manner as in Example 2 except that synthetic paper was laminated only on one side of the base sheet. With respect to this floor tile base material, warpage was evaluated in the same manner as in Example 2, and adhesion and printability with the adhesive on the side where the synthetic paper was not laminated were evaluated in the same manner as in Example 2. . As a result, the maximum warpage was 5 mm, the adhesive strength was 0.5 kg / 50 mm, and the printability was poor (the number of peelings was 1).
5).

[0011]

The decorative thermoplastic resin sheet of the present invention is
Excellent adhesion and printability with adhesives, less warpage and distortion, as a base material for decorative panels such as floor tiles and wall panels.
Alternatively, it is suitable as a base material of a decorative sheet to be attached to various kinds of furniture, kitchen product cabinets, building interior materials, and the like for the purpose of decoration or surface protection.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of one example of a decorative thermoplastic resin sheet of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Base sheet 2, 2 'Adhesive layer 3, 3' Film-shaped thermoplastic resin synthetic paper

Continued on the front page F term (reference) 4F100 AA08H AA21H AK01A AK01B AK01C AK03A AK03B AK03C AK07 AT00A BA03 BA06 BA10B BA10C BA25A CA23 CB03 DG10B DG10C EJ202 EJ422 EJ551 GB08 JB16JB16B06

Claims (10)

[Claims] 1. A decorative thermoplastic resin sheet comprising a laminate in which film-shaped thermoplastic resin synthetic paper is provided on both sides of a base sheet. 2. The decorative thermoplastic resin sheet according to claim 1, wherein the substrate sheet is a polyolefin resin substrate sheet. 3. The decorative thermoplastic resin sheet according to claim 1, wherein the film-like thermoplastic resin synthetic paper is a polyolefin resin synthetic paper. 4. The decorative thermoplastic resin sheet according to claim 1, wherein the base sheet has a thickness of 0.08 to 10 mm. 5. A double-sided decorative partition plate using the decorative thermoplastic resin sheet according to claim 1, 2, 3 or 4. 6. A single-sided or double-sided decorative display panel using the decorative thermoplastic resin sheet according to claim 1, 2, 3 or 4. 7. A single-sided decorative wallboard using the decorative thermoplastic resin sheet according to claim 1, 2, 3 or 4. 8. A single-sided decorative ceiling plate using the decorative thermoplastic resin sheet according to claim 1, 2, 3 or 4. 9. A single-sided decorative flooring using the decorative thermoplastic resin sheet according to claim 1, 2, 3 or 4. 10. A single-sided decorative waistboard comprising the decorative thermoplastic resin sheet according to claim 1, 2, 3 or 4.