JP2002234128A - Decorative material and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorative material not generating the collapse or rupture of the foamed resin layer of a bent part, following even a fine shape, having a volume feeling and a good feeling and excellent in heat insulating properties and dew condensation preventing properties, and a method for manufacturing the same. SOLUTION: The decorative material is constituted by successively laminating a foamed resin layer 4, a decorative layer 5, a non-foamed resin layer 6 and a gloss adjusting layer 7 on a base material 2 through an adhesive layer and the resin component forming the foamed resin layer 4 is crosslinked.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative material having excellent heat insulating properties, dew condensation preventing properties and shock absorbing properties, used for walls and ceilings of houses and the like.

[0002]

2. Description of the Related Art Conventionally, as building interior materials for ceilings and walls,
2. Description of the Related Art A decorative board in which a decorative sheet made of a synthetic resin film or a paper-based sheet is adhered to a base material such as wood or metal is used. However, in the case of these decorative plates, as the temperature of the base material decreases, the temperature of the decorative sheet surface on the surface also decreases, and dew condensation easily occurs on the surface. In addition, the surface of a decorative member using these decorative plates,
The corners are hard and have the drawback of being easily injured when struck.

[0003] For this reason, a decorative material in which a foamed decorative sheet made of a foamed resin layer is adhered to a base material is used. As a result, the foamed layer is stretched and crushed, or the foamed layer is broken, so that the effect of the foamed layer cannot be obtained. Further, when the foamed decorative sheet is adhered to a curved surface by wrapping or the like, there is a problem that it is difficult to follow a fine shape at the time of wrapping and the design is poor.

[0004]

SUMMARY OF THE INVENTION Accordingly, the present invention has been made in view of the above problems, and an object of the present invention is to prevent a foamed resin layer in a bent portion from being crushed or broken.
In addition, it provides a cosmetic material that has a volume feeling that follows fine shapes, has a good texture, and is excellent in heat insulation and dew condensation prevention properties. To provide a manufacturing method that can

[0005]

Means for Solving the Problems To achieve the above object, the present invention provides a method of forming a foamed resin layer, a decorative layer, a non-foamed resin layer, and a gloss adjusting layer on a substrate via an adhesive layer. In a decorative material obtained by laminating decorative sheets sequentially laminated, a resin component forming the foamed resin layer is crosslinked. With such a configuration, since the resin component forming the foamed resin layer is cross-linked, the foamed layer becomes tough, and the foamed layer at the bent portion does not collapse or break, so that heat insulation and dew condensation prevention properties are obtained. It is an excellent cosmetic material.

Further, the resin component forming the foamed resin layer and the non-foamed resin layer is made of an olefin-based thermoplastic resin. By doing this,
It can suppress the generation of harmful gases such as hydrogen chloride gas during incineration, and can be used as a cosmetic material that is human-friendly. Can be.

A step of melt-extruding a foamed resin layer forming composition comprising an olefinic thermoplastic resin containing a foaming agent, a crosslinking agent and other additives in a non-foamed state to form a foamable resin layer; Forming a decorative layer on one surface of the layer, and forming a non-foamed resin layer by melt coating an olefinic thermoplastic resin on the upper surface of the decorative layer,
A step of forming a decorative sheet by providing a gloss adjusting layer on the entire upper surface of the non-foamed resin layer, a step of forming a laminated material by attaching the decorative sheet to a base material via an adhesive layer, By heating the foamable resin layer to crosslink and foam the foamable resin layer, a cosmetic material having the above effects can be easily and reliably produced.

[0008]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, specific embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a cross-sectional view illustrating an example of a decorative material according to the present invention. FIG. 2 is a cross-sectional view illustrating an example of a method of manufacturing the decorative material according to the present invention.
Is a base material layer, 3 is an adhesive layer, 4 is a foamed resin layer, 5 is a decorative layer, 6 is a non-foamed resin layer, 7 is a gloss adjusting layer, 8 is a foamable resin layer, 10 is a decorative sheet, and 20 is a laminate. Each represents a material.

As shown in FIG. 1, the layer structure of the decorative material 1 of the present invention is such that a foamed resin made of an olefinic thermoplastic resin containing a pyrolytic foaming agent, a crosslinking agent, and other additives is provided on the upper surface of a substrate 2. The decorative material 1 of the present invention has a configuration in which the layer 4, the decorative layer 5, the non-foamed resin layer 6, and the gloss adjusting layer 7 are laminated. It is formed by crosslinking and foaming.

Next, a method for manufacturing the decorative material 1 of the present invention having the above-described structure will be described with reference to the drawings. First, FIG.
As shown in the figure, a foamable resin formed by extruding a foamed resin layer forming composition comprising an olefin-based thermoplastic resin containing a pyrolytic foaming agent, a crosslinking agent, and other additives in a non-foamed state by a melt extrusion method, and forming a film. The layer 8 is formed. Next, as shown in FIG. 2B, a decorative layer 5 is provided on the upper surface of the foamable resin layer 8,
Next, as shown in FIG. 2C, a non-foamed resin layer 6 made of an olefin-based thermoplastic resin is provided on the upper surface of the decorative layer 5, and as shown in FIG. The decorative sheet 10 is produced by providing the gloss adjusting layer 7 on the entire upper surface. Next, as shown in FIG. 2E, the decorative sheet 10 is attached to the upper surface of the base material 2 with the adhesive layer 3 interposed therebetween, and
And Further, as shown in FIG.
Is heated to crosslink and foam the foamable resin layer 8, whereby the decorative material 1 having the foamed resin layer 4 formed of a foam in which the resin film is crosslinked is obtained.

Although not shown, even if the laminated product 20 is bent by a V-cut process or the like and then the processed product is heated and foamed, the foamed resin layer 4 in the bent portion does not collapse or break. With excellent heat insulation and dew condensation prevention properties 1
It is what becomes.

Next, the base material 2 used for the decorative material 1 of the present invention is not particularly limited, and may be a material suitable for the intended use. Examples of the base material include cedar, cypress, and pine. ,
Veneer, plywood, particle board, high-density fiber board, medium-density fiber board, wood board such as lauan etc., cold-rolled steel sheet, galvanized steel sheet, stainless steel sheet, metal sheet such as aluminum sheet, calcium silicate board , Asbestos slate board, inorganic board such as plaster board, acrylic resin such as polymethyl methacrylate, polyolefin resin such as polypropylene, ABS
Resin materials such as resin, polyester resin and melamine resin,
Papers such as thin paper, bleached kraft paper, titanium paper, paperboard, gypsum board paper and the like can be mentioned. The substrate may be in the form of a sheet or a square shaped body in addition to the plate material.

The decorative sheet 10 used in the present invention comprises a single layer or a plurality of layers of synthetic resin and has been subjected to a decoration treatment. The synthetic resin layer constituting the sheet comprises an olefin-based thermoplastic resin, a filler, a pigment, , A foaming agent, a foam cell adjusting agent, a cross-linking agent, and the like, which are kneaded under conditions where the foaming agent does not foam, and formed into a non-foamed state by a known film forming method.

Next, the foamed resin layer 4 and the non-foamed resin layer 6
The resin used for will be described. Cosmetic material 1 of the present invention
As the olefinic thermoplastic resin that is melt-extruded,
For example, polyethylene, polypropylene, polybutene,
A copolymer of one or more polyolefins such as polybutadiene and polyisoprene to two or more olefins such as ethylene, propylene, butene, butadiene and isoprene;
Alternatively, a copolymer of α-olefins having 4 or more carbon atoms (linear low-density polyethylene), or an ethylene-acrylic acid copolymer, an ethylene-methyl acrylate copolymer, an ethylene-ethyl acrylate copolymer, Ethylene-
Methacrylic acid copolymer, ethylene-vinyl acetate copolymer, saponified ethylene-vinyl acetate copolymer, or ionomer, or a mixed resin composed of one or more of these can be mentioned. However, as a preferable resin for forming the foamed resin layer 4, a resin having a low melting point is particularly preferable in order to prevent foaming (foaming during kneading) of the foaming agent before film formation. , Polyethylene, or ethylene-vinyl acetate copolymer resin is preferred. Among them, those having a melt flow rate of 20 to 80 g / 10 minutes are preferable from the viewpoint of extrusion flow characteristics.

The foaming agent used for the foamed resin layer 4 is low-cost, has a small heat of decomposition, is excellent in flame retardancy and self-extinguishing properties, is stable in water, is non-toxic, A thermal decomposition type foaming agent of an azo compound such as azodicarbonamide and azobisformamide is preferable from the viewpoint of imparting flame retardancy to the layer 4, and among them, azodicarbonamide has a high decomposition temperature and foaming is preferred. The decomposition temperature can be lowered by using an accelerator in combination, which is preferable.
As the foaming accelerator, inorganic salt-based, metal soap-based, and acids are used. The amount of addition may be appropriately determined according to the required design properties, but is suitably 0.5 to 15 parts by weight based on 100 parts by weight of the olefin-based thermoplastic resin.

In addition, the resin is crosslinked to prevent the foam from being tough and to prevent the foam from sagging. As the cross-linking agent, an organic peroxide is generally used, and a peroxyketal-based or dialkyl peroxide-based is used, and one that decomposes at a temperature lower than the foaming temperature of the foaming agent is preferable. The addition amount is preferably about 0.5 to 5 parts by weight based on 100 parts by weight of the resin.

Next, as the filler, inorganic substances such as aluminum hydroxide, magnesium hydroxide, and calcium carbonate can be used as a flame retardant and filler.
Inorganic pigments such as iron oxide and the like are used as a coloring agent,
In the present invention, a titanium dioxide pigment is effective for producing a vivid color such as yellow, gray, or white. The amount of the titanium dioxide pigment to be added is preferably 10 to 20 parts by weight based on 100 parts by weight of the ethylene-vinyl acetate copolymer resin.

Next, the decorative layer 5 of the present invention can be generally formed of ink by a known printing method such as gravure printing, offset printing, silk screen printing and the like.
Printed patterns include wood pattern, stone pattern, cloth pattern, leather pattern,
There are printed patterns such as geometric figures, characters, symbols, and solid images. As the ink, as a vehicle, a polyester resin, a polyurethane resin composed of isocyanate and polyol, an acrylic resin, a vinyl acetate resin,
Cellulosic resin, polyamide resin, etc.
It is also possible to use a mixture obtained by mixing a plurality of kinds or more, and adding a pigment, a solvent, various auxiliaries and the like to form an ink.

In order to adjust the surface of the decorative material 1 to a desired gloss, a gloss adjusting layer 7 may be provided. As a method of adjusting the gloss, a method of applying an ink obtained by kneading a matting agent such as silica to the surface is mainly used. As a binder for the ink used, an acrylic resin, a polyurethane resin, a polyester resin, an epoxy resin, or a transparent or translucent resin of these copolymer resins is used.

Although not shown, an improvement in interlayer adhesion between the adhesive layer 3, the decorative layer 5 and the gloss adjusting layer 7 on both surfaces of the foamable resin layer 8 or on the upper surface of the non-foamed resin layer 6 is provided. For the purpose of achieving the above, a means for improving the adhesive strength such as a corona discharge treatment may be appropriately used.

[0021]

Example 1 A foamed resin layer forming composition having the following composition was formed into a film by a T-die extrusion method so that the resin thickness became 80 μm.

[Blending of foamed resin layer forming composition unit weight part] Resin Linear low density polyethylene resin 100 Inorganic filler Calcium carbonate 10 Inorganic pigment Iron oxide 20 Foaming agent ADCA 6 Crosslinking agent Dicklemi peroxide 1 Foam cell conditioner 3

Next, a corona treatment is applied to both the front and back surfaces of the laminated sheet so that the wetting index becomes 40 dyne / m or more, and then the two-part curable urethane ink is applied to one surface using a gravure printing method. (FECT, manufactured by Showa Ink Industry Co., Ltd.), and the grain pattern was printed. Continue on the other side 2
Solid printing was performed using a liquid-curable urethane primer (PUC, manufactured by The Inktech Co., Ltd.). Next, a polyester-based adhesive (Seikabond E2
95 L, manufactured by Dainichi Seika Kogyo Co., Ltd.) at a rate of 10 g / m ² (dry), and a transparent polyolefin resin (E2905, manufactured by Idemitsu Petrochemical Co., Ltd.) having a thickness of 80 g on the adhesive.
It was extruded with a T-die to a thickness of μm and laminated. Next, the surface of the transparent polyolefin-based resin layer is subjected to corona treatment so that the wetting index becomes 40 dyne / m or more, and gravure is performed using a two-component curable urethane-based gloss adjusting ink (ATC, manufactured by The Inktec Co., Ltd.). A decorative sheet was prepared by providing a gloss adjusting layer by a printing method. Subsequently, after laminating the decorative sheet on a plywood having a thickness of 4 mm via an adhesive,
Cut processing was performed to obtain a quadrangular prism-shaped decorative member. Further, this decorative member was heated at 200 ° C. for 80 seconds to foam a layer containing a foaming agent so as to have a thickness approximately four times as large as a non-foamed state, thereby obtaining a desired decorative material.

Example 2 The decorative sheet prepared in Example 1 was laminated on a 0.6 mm thick galvanized steel sheet via an adhesive,
Bending (of which R = 0), forming and then 200 ° C, 80 ° C
After a few seconds, the layer containing the foaming agent was foamed so as to have a thickness about four times that of the non-foamed state, to obtain a desired decorative material.

Comparative Example 1 A decorative sheet was prepared in the same manner as in Example 1, except that the composition for forming a foamed resin layer of Example 1 was mixed as follows.
After laminating the decorative sheet on a galvanized steel sheet having a thickness of 0.6 mm via an adhesive, bending the sheet 90 degrees (R = 0)
Then, heating was performed at 200 ° C. for 80 seconds to foam the layer containing the foaming agent so as to have a thickness approximately four times as large as the non-foamed state, to obtain a desired decorative material. [Blend of foamed resin layer forming composition unit weight part] Resin Linear low-density polyethylene resin 100 Inorganic filler Calcium carbonate 10 Inorganic pigment Iron oxide 20 Foaming agent ADCA 6 Foam cell conditioner 3

Examples 1 and 2 and Comparative Example 1 produced above
Various tests were conducted on the decorative material of Example 1 and the results are shown in Table 1.

Test Method Impact Resistance: According to JIS K5400 (General Paint Test Method) 8.3.2, a load of 500 g was applied to 300 mm.
Drop from the height and observe the cracks on the surface. Dew condensation occurrence: The cosmetic material is left in an environment of 25 ° C. and 70% RH on the front side and 5 ° C. and 10% RH on the back side, and after standing for 30 minutes, dew condensation on the surface is visually checked. Accumulated pressure recovery: 1 square c on the surface of the decorative material in an environment of 60 ° C
After a load of 200 g per m was applied for 24 hours, the sample was allowed to stand at room temperature for 24 hours, and the difference from the original thickness was measured and shown as a rate of change. Appearance: Judge by visually observing the bent part.

[0028]

As is clear from the results shown in Table 1, in the decorative materials of Examples 1 and 2 of the present invention, since the foamed resin layer is cross-linked with the resin, the foamed layer is continuously cut even in the bent portion. There were no cracks in the corners, the low temperature from the base material was hardly transmitted by the foam layer, and the dew was hardly formed. On the other hand, in Comparative Example 1, since the foamed resin layer was not crosslinked, the bent portion was cracked, dew condensation occurred in that portion, and the pressure recovery property was poor.

[0030]

As described above, the cosmetic material of the present invention is
After applying the decorative sheet prepared in a non-foamed state to the substrate and performing bending processing, or even after heating and foaming after wrapping on the substrate, the foamed resin layer is cross-linked at the same time as foaming,
The resin film of the foamed resin layer becomes tough, the foamed portion in the bent portion does not collapse or break, and the decorative member follows the fine shape. Therefore, since the foam layer is not broken,
A cosmetic material having excellent dew condensation prevention properties can be obtained.

[Brief description of the drawings]

FIG. 1 is a laminated sectional view showing an embodiment of a decorative material of the present invention.

FIG. 2 is a cross-sectional view illustrating an example of a method for manufacturing a decorative material according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Cosmetic material 2 Base material layer 3 Adhesive layer 4 Foaming resin layer 5 Decorative layer 6 Non-foaming resin layer 7 Gloss adjustment layer 8 Foamable resin layer 10 Decorative sheet 20 Laminating material

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) B29L 9:00 B29L 9:00 31:58 31:58 (72) Inventor Yoshiaki Kakinuma Ichigaya Kaga, Shinjuku-ku, Tokyo 1-1-1 Machi Dai Nippon Printing Co., Ltd. F-term (reference) 2E110 AA14 AB03 AB04 AB23 BA02 GA32W GA33X GB42W 4F100 AK01B AK01C AK03B AK03C AK63 AP02 AR00D AT00A BA04 BA07 BA10D CA01H CA02H CA13 CA23 DJ01B EA02 EA1 EJ053 EJ422 EJ55 GB08 HB00 HB31 JB16B JB16C JJ02 JK11 JL07 4F213 AA03 AB02 AD05 AG03 AG20 WA06 WA15 WA18 WA43 WA53 WA58 WA83 WB01

Claims (3)

[Claims] 1. A decorative material in which a decorative sheet in which a foamed resin layer, a decorative layer, a non-foamed resin layer, and a gloss adjusting layer are sequentially laminated on a base material via an adhesive layer, the foamed resin layer is formed. A cosmetic material characterized in that the resin component is crosslinked. 2. The decorative material according to claim 1, wherein the resin component forming the foamed resin layer and the non-foamed resin layer comprises an olefin-based thermoplastic resin. 3. A step of melt-extruding a foamed resin layer-forming composition comprising an olefin-based thermoplastic resin containing a foaming agent, a crosslinking agent, and other additives in a non-foamed state to form a foamable resin layer; Forming a decorative layer on one side of the non-foamable resin layer, melt coating an olefinic thermoplastic resin on the upper surface of the decorative layer to form a non-foamed resin layer, Providing a gloss adjusting layer to form a decorative sheet; attaching the decorative sheet to a substrate via an adhesive layer to form a laminate; and heating the laminate to crosslink the foamable resin layer A method for producing a decorative material, comprising a step of foaming.