JP2001270055A - Polyester sheet for building material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a non-PVC sheet which is excellent in embossment processability and adhesion and has improved chemical resistance. SOLUTION: In a polyester sheet for building materials having a transparent surface layer which is a double layer sheet comprising the surface layer containing a substantially crystalline aromatic polyester resin composition and a base material layer containing a substantially non-crystalline aromatic polyester resin composition, the thickness of the sheet is 50-250 μm, and the thickness of the surface layer is 20-80 μm.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a polyester sheet for building materials used on the surface of a facing material such as a door or a desk.

[0002]

2. Description of the Related Art Surface materials such as doors and desks using a plastic sheet are manufactured by various methods. Generally, a transparent sheet (hereinafter referred to as "over sheet") is laminated on a colored sheet (hereinafter referred to as "base sheet") on which a grain of wood or the like is printed, and the surface of the over sheet is formed with woodgrain-like irregularities. It is produced by embossing or, in some cases, embossing a recessed portion and printing an oversheet, which is called wiping, on an oversheet to be bonded to a wood substrate such as plywood or particle board.

As the oversheet, a sheet made of a polyvinyl chloride resin composition (hereinafter referred to as "PVC sheet") having excellent workability, material cost, durability and the like has been used. In response to the ecology boom, there is a growing need for oversheets for building materials made of materials other than PVC, and for example, switching to sheets made of a polypropylene-based resin composition (hereinafter referred to as “PP sheets”) has begun. However, PP sheets are too stiff to be used for building materials and workability is poor, surface hardness is low and dents are easily formed,
There are problems such as poor printability and necessity of surface treatment such as corona treatment and anchor coat. Further, a sheet made of a substantially non-crystalline polyester resin (hereinafter referred to as “PETG”) in which about 30 mol% of an ethylene glycol component constituting polyethylene terephthalate is substituted with 1,4-cyclohexanedimethanol is also proposed. This sheet has workability close to that of a PVC sheet, and is particularly excellent in embossability and capable of deep embossing.
When used on the surface of building materials and the like, it has a problem of poor chemical resistance, and has not been used in earnest.

[0004]

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems, and an object of the present invention is to provide excellent embossability and adhesiveness and improve chemical resistance. To provide a polyester sheet for building materials.

[0005]

The polyester sheet for building material of the present invention comprises a layer containing a substantially crystalline aromatic polyester resin composition as a surface layer and a substantially non-crystalline aromatic polyester resin sheet. A two-layer sheet having a layer containing a resin composition as a base material layer, wherein the total sheet thickness is 50 μm to 25 μm.
0 μm, and the surface layer thickness is 20 μm to 80 μm
Wherein the surface layer is in a transparent state. Here, it is preferable that at least one side of the polyester sheet for building material has been subjected to a matting process with a 10-point average roughness of 3 μm to 30 μm.

[0006]

BEST MODE FOR CARRYING OUT THE INVENTION The polyester sheet for building material of the present invention is an oversheet used for the outer surface of a building material used as a facing material for doors, desks, etc., and is a substantially crystalline aromatic polyester. It has a surface layer composed of a base resin composition and a base layer composed of a substantially non-crystalline aromatic polyester resin composition. As used herein, the polyester refers to a dehydration condensate of an aromatic dicarboxylic acid and a diol, and the substantially crystalline aromatic polyester (hereinafter referred to as “crystalline polyester”) used in the present invention is, for example, polyethylene terephthalate. Polyethylene terephthalate (PET), or one obtained by substituting part of terephthalic acid as a constituent component thereof with an aromatic dicarboxylic acid having a different structure and / or substituting part of ethylene glycol with a diol having a different structure, is close to polyethylene terephthalate. It refers to those with remaining crystallinity. However, when a part of the constituent components is substituted with an aromatic dicarboxylic acid or diol having a different structure, the substitution ratio of the aromatic dicarboxylic acid and / or diol having a different structure is about 7 mol% or less. Similarly, polyethylene naphthalate (PEN) or a polymer blend of PEN and PET can be used. The substantially crystalline aromatic polyester-based resin composition means a composition whose main component is a crystalline polyester-based resin.

[0007] The substantially non-crystalline aromatic polyester (hereinafter referred to as "non-crystalline polyester") used in the present invention is a particularly low-crystalline aromatic polyester among so-called aromatic polyesters. A material that does not cause cloudiness or poor fusion due to crystallization even when subjected to thermal processing frequently performed in practical use. Specifically, a non-crystalline polyester resin (trade name: PETG, manufactured by Eastman Chemical Company) in which about 30 mol% of the ethylene glycol component in polyethylene terephthalate has been substituted with 1,4-cyclohexanedimethanol is commercially available. Possible. The substantially non-crystalline aromatic polyester resin composition means a composition whose main component is a non-crystalline polyester resin.

The polyester sheet for building materials of the present invention is a two-layer sheet having a layer containing a crystalline polyester resin composition as a surface layer and a layer containing an amorphous polyester resin composition as a base layer. Here, “comprising” means that the resin composition is contained as a main component, but may contain a UV absorber, a pigment or the like as appropriate within a range that does not impair the effects of the present invention. Further, the polyester sheet for building materials of the present invention has a total thickness of 50 μm to 250 μm.
Within the range. When the total sheet thickness is less than 50 μm, when the oversheet surface of the formed building material product is embossed, it is likely that the depth of the emboss exceeds the oversheet and reaches the lower print layer. It is not preferable. On the other hand, if the total sheet thickness exceeds 250 μm, the processing speed in the laminating step becomes slow, which is not preferable in terms of working efficiency.

The surface layer made of the crystalline polyester resin must have a thickness in the range of 20 μm to 80 μm. By setting the thickness of the surface layer to 20 μm to 80 μm, the chemical resistance can be improved while maintaining the adhesiveness to the non-crystalline polyester and the embossability. When the thickness of the surface layer is less than 20 μm, especially the chemical resistance to an organic solvent or the like cannot be sufficiently improved, and when it exceeds 80 μm, the embossability may decrease.

When the entire sheet is made of a crystalline polyester resin without a base material layer, not only the embossability is poor, but also the adhesion to the underlying printed sheet is poor. is there. Further, the surface layer containing the crystalline polyester-based resin needs to be in a transparent state even by quenching, stretching, or the like. It is not preferable because it is insufficient.

Further, it is desirable that at least one side of the sheet is subjected to a matting process with a 10-point average roughness in a range of 3 μm to 30 μm. The mat on the base material layer has an effect of facilitating the release of air at the interface when the mat is bonded to the printing surface, and the mat on the surface layer has an effect of making the surface of the building material product less liable to be scratched. If the 10-point average roughness of the mat is less than 3 μm, the effect of air bleeding and damage prevention may not be sufficient. If it exceeds 30 μm, it may cause air to remain, or if the surface mat exceeds 30 μm. Is not preferable because the mat may be too strong and the visibility of the printed layer may be insufficient.

In the present invention, a lubricant, an antistatic agent, an anti-blocking agent, etc. may be added to each layer of the sheet, if necessary, or a polymer blend for improving physical properties such as heat resistance may be formed. .

As a method of laminating the base material layer and the surface layer of the polyester sheet for building material of the present invention, for example, a co-extrusion method of co-extruding and laminating the resin composition of each layer, forming each layer into a film, Can be laminated by a laminating method or the like. Specifically, the resin composition of each layer is blended respectively, or in the form of pellets as necessary,
The T dies are put into the respective hoppers of two extruders connected in common, melted at a temperature in the range of 250 to 290 ° C., co-extruded from the two-layer T dies, and cooled and solidified by a cooling roll, water or air cooling. Thus, a two-layer laminate can be formed. The polyester sheet for a building material of the present invention can be formed by a known method without being limited to the above method. For example, according to the description in JP-A No. 10-71763, pages (6) to (7). Obtainable.

[0014] For building materials in the present invention, wall materials, floor materials,
In addition to building materials such as door facings, furniture and furnishings, stored articles and accessories, and those used as facings for electrical appliances are included. Further, the present invention can be applied to other uses as long as the effects of the present invention are required. The polyester sheet for a building material of the present invention can be laminated on a surface of a base sheet, a plywood, a particle board or the like to form a building material or the like. For the method of lamination with the base sheet etc.
Although not particularly limited, for example, lamination can be performed by a normal lamination method or the like.

[0015]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be specifically described below with reference to embodiments. Example 1 A crystalline polyester ("PET9921W", manufactured by Eastman Chemical Co., Ltd.) in which about 2 mol% of ethylene glycol which is a constituent component of polyethylene terephthalate was substituted with cyclohexanedimethanol, and Eastman Chemical which is a non-crystalline polyester PETG676
Using 3 as a substrate layer, an oversheet having a surface layer thickness of 20 μm, a substrate layer thickness of 80 μm, and a total sheet thickness of 100 μm was produced by a T-die coextrusion method. Next, the obtained oversheet was passed between a pair of mat rolls, and both surfaces were subjected to mat processing with a 10-point average roughness of 10 μm to form a polyester sheet for building materials.

Examples 2 to 4 In the same manner as in Example 1 except that the thickness of the surface layer and the thickness of the base material layer were changed as shown in Table 1,
A polyester sheet for building materials was formed.

Comparative Example 1 A crystalline polyester ("PET9921W", manufactured by Eastman Chemical Co., Ltd.) in which about 2 mol% of ethylene glycol which is a constituent component of polyethylene terephthalate was replaced with cyclohexane dimethanol was charged into a hopper of a T-die. An oversheet having a thickness of 100 μm was prepared by a T-die extrusion method. Subsequently, mat processing was performed in the same manner as in Example 1 to form a single-layer polyester sheet for building materials.

Comparative Example 2 A non-crystalline polyester, PETG6763 manufactured by Eastman Chemical Company, was charged into a T-die hopper, and an oversheet having a thickness of 100 μm was prepared by a T-die extrusion method. Next, mat processing is performed in the same manner as in Example 1,
A single-layer polyester sheet for building materials was formed.

Comparative Examples 3 and 4 In the same manner as in Example 1, except that the thickness of the surface layer and the thickness of the base material layer were changed as shown in Table 1,
An oversheet having a thickness of 100 μm was prepared. Next, mat processing was performed in the same manner as in Example 1 to form a two-layered polyester sheet for building materials.

The obtained Examples 1 to 4 and Comparative Examples 1 to
The building material-based polyester sheet No. 4 was bonded to a separately prepared base sheet. That is, a brown-colored base sheet is prepared by a T-die extrusion method using PETG6763 manufactured by Eastman Chemical Co., Ltd., and one side of the base sheet is subjected to woodgrain printing. Lamination by a hot roll is performed while the base sheet surface of the oversheet is superposed on the printing surface of the base sheet, and then the woodgrain-like embossing of the embossing depth shown in Table 1 is performed on the oversheet surface by the needle hole embossing method. With respect to the laminated sheet obtained as a building material product, the adhesive strength, embossability, and chemical resistance were evaluated by the following methods. Table 1 summarizes the obtained results.

Evaluation method: (1) Adhesive strength In order to determine the adhesive strength between the base sheet and the polyester-based sheet for building material, a 180-degree peel test was performed according to JIS K 6854, and the adhesive strength per 10 mm width was measured. Those having a measured adhesive strength value of 10 N or more were indicated by a symbol “○”, and those having a measured adhesion strength of less than 10 N were indicated by a “×”. (2) Embossability The embossed portion was observed with the naked eye, and a symbol without cracks was indicated by “○”, and a symbol with cracks was indicated by “X”. (3) Chemical resistance Ethanol, toluene, curry, and red crayon were each brought into contact with the surface of the polyester sheet for building material, left at room temperature for 24 hours, wiped off, and visually observed for the state of the surface. The symbol “○” indicates that no whitening or coloring was observed on the surface of the oversheet, and the symbol “○” indicates that whitening or coloring was observed.

[0022]

[Table 1]

As is clear from Table 1, the polyester sheets for building materials of Examples 1 to 4 of the present invention are excellent in adhesiveness to the base sheet, embossability and chemical resistance, and are excellent in building material oversheets. It was found that this was a suitable material. On the other hand, the oversheet of Comparative Example 1 lacking the layer made of the non-crystalline polyester resin has poor chemical resistance,
Comparative Example 2 lacking a layer made of a crystalline polyester resin
Was found to be inferior in adhesiveness and embossability. Comparative Examples 3 and 4, in which the thicknesses of the base layer and the surface layer were other than the predetermined thickness, were found to be inferior in chemical resistance or embossability. That is, in order to satisfy all the characteristics simultaneously, it is necessary to provide the configuration of the present invention. Since the polyester sheet for building materials of the present invention is transparent,
The printing of the base was clearly recognized and excellent.

[0024]

As described above in detail, the polyester sheet for building materials of the present invention is a non-PVC sheet, and has excellent embossability and adhesiveness, excellent chemical resistance, and substantially It is a sheet that can improve the chemical resistance while maintaining the workability and the like of a non-crystalline polyester sheet, and is a material suitable as an oversheet for building materials.

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Claims (2)

[Claims] 1. A layer containing a substantially crystalline aromatic polyester-based resin composition as a surface layer, and a layer containing a substantially non-crystalline aromatic polyester-based resin composition as a base layer.
A layer sheet having a total sheet thickness of 50 μm to 250 μm
m, the surface layer thickness is 20 μm to 80 μm, and the surface layer is in a transparent state. 2. The polyester sheet for building materials according to claim 1, wherein at least one surface of the sheet is subjected to a matting process with a 10-point average roughness of 3 μm to 30 μm.