JP2003145673A - Metallic-tone decorative laminate sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a metallic-tone decorative laminate sheet which exhibits reliable corrosion resistance and high productivity and besides, shows the same degree of gloss and color-tone as a stainless foil and is manufactured by forming a stainless layer using a sputtering process with such advantages that the factors such as light reflection, gloss and corrosion resistance can be imparted to the same degree as the stainless foil and also an adhesive layer need not be formed, hence the reduction of manhour and consequently, the productivity can be upgraded. SOLUTION: This metallic-tone decorative laminate sheet comprises a transparent resin sheet 1 with a hairline 2 formed on the back, a stainless metallic layer 3 formed on the back of the transparent resin sheet 1 by a sputtering process and a colored resin sheet 5 laminated on the back of the stainless metallic layer 3 using an adhesive.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a metal-finished decorative sheet, and more particularly to a metal-finished sheet used for interiors and exteriors of buildings, furniture, home appliances, etc., which has excellent corrosion resistance and productivity. Regarding cosmetic sheets.

[0002]

2. Description of the Related Art Conventionally, various metallic tone decorative sheets have been proposed in order to impart metallic luster to buildings, furniture and home electric appliances.

For example, Japanese Unexamined Patent Publication No. 2001-1444 discloses a decorative plate which can be obtained in a color and design intended for a metallic appearance and is suitable for mass production. This decorative board is provided with a large number of fine grooves by hairline or spin processing on the back surface of a transparent synthetic resin film, further a primer layer, a metal thin film layer or a bright pigment-containing colored layer,
And a decorative layer are laminated in this order. The primer layer is used to enhance the adhesion between the transparent resin film and the metal thin film layer.

According to the decorative plate having such a structure, it is said that a decorative plate having a metallic appearance can be obtained. However, since a large number of layers are required to be laminated as described above, the number of steps is increased. As a result, productivity decreases. Moreover, since the metal thin film layer is formed using aluminum,
When this decorative plate is used for kitchen utensils such as system kitchens, it has inferior gloss, color tone, and metallic feeling compared to stainless steel metal plate, and corrosion progresses from the metal thin film layer exposed on the end surface of the decorative plate to deteriorate the appearance. There is a drawback that.

Further, in Japanese Unexamined Patent Publication No. 8-216334, a first resin sheet having a hairline-shaped emboss on the front surface and a metal layer on the back surface via an adhesive,
A decorative sheet having a metallic luster, in which a second resin sheet is bonded via an adhesive, is disclosed. The metal layer is formed by vapor deposition of a metal such as aluminum, nickel, or titanium, or by using a metal foil, and aluminum metal is used to achieve the same expression as the metallic feeling of a stainless plate.

However, in order to manufacture a decorative board having such a structure, a plurality of steps are required as described above, so that the productivity is poor, and in order to obtain a metallic tone, aluminum,
Since vapor deposition of a metal such as nickel or titanium or a metal foil is used, there is a drawback that corrosion of the metal proceeds from the exposed end of the decorative sheet.

Further, in JP-A-1-188334, a fluororesin film, a transparent metal-depositable resin film provided on the back surface of the fluororesin film, and a metal provided on the transparent resin film are disclosed. A metallic decorative sheet having a vapor deposition layer is disclosed.

However, since the decorative sheet having such a structure uses the fluororesin film, it has a drawback that it cannot be easily discarded from the viewpoint of pollution. Also, a transparent resin film capable of metal deposition is required,
It also has the drawback of poor workability and workability.

[0009]

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned drawbacks and has excellent corrosion resistance,
Moreover, it is an object of the present invention to provide a metallic decorative sheet having excellent gloss and color tone similar to those of stainless steel foil, which is excellent in productivity.

[0010]

The metallic decorative sheet according to claim 1 is a transparent resin sheet having a hairline on the back surface, and a stainless metal layer provided on the back surface side of the transparent resin sheet by a sputtering method. And a colored resin sheet adhered to the back surface side of the stainless metal layer with an adhesive, whereby the above object is achieved.

The metallic decorative sheet according to claim 2 is a transparent resin sheet, a colored layer provided on the back side of the transparent resin sheet, and a stainless metal provided on the back side of the colored layer by a sputtering method. Layer, and a colored resin sheet adhered to the back surface side of the stainless metal layer with an adhesive,
The above object is achieved thereby.

[0012] In one embodiment, a hairline is provided on the back surface side of the transparent resin sheet or the back surface side of the colored layer.

The operation of the present invention is as follows.

When a metal layer (by vapor deposition of metal or sticking of metal foil) is formed directly on the transparent resin sheet, the adhesion strength is weak if directly performed. Therefore, conventionally, an adhesive layer is provided on the resin sheet to form a metal layer. Was attached. In the present invention, since the metal layer can be formed on the transparent resin sheet with good adhesion by forming the metal layer using the sputtering method, it is not necessary to provide the adhesive layer.

Further, the metal layer used in the decorative sheet expressing the stainless steel plate is conventionally made of stainless steel foil, aluminum vapor deposition, or using glitter ink. Is
Light and gloss are inferior to the real one, and the corrosion resistance is poor. In the present invention, by forming the stainless steel layer by the sputtering method, it is possible to impart the same light, gloss and corrosion resistance as the stainless steel foil while improving the adhesion to the resin sheet. Further, since the metal thin film is formed in a vapor phase such as sputtering, it is suitable for mass production, and since it does not require an adhesive layer, the number of steps can be reduced and the productivity of the decorative sheet can be improved.

Although the metallic appearance has a limited range because the color and gloss are determined by the material used, a transparent resin sheet provided with a hairline pattern is used, and a metal thin film is vapor-deposited on the surface. The solution is to form or use a colored layer.

[0017]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described in detail below. (Embodiment 1) As shown in FIG. 1, the metallic decorative sheet of this embodiment is provided with a transparent resin sheet 1 having a hairline 2 on the back surface, and a sputtering method on the back surface side of the transparent resin sheet 1. The stainless metal layer 3 and the colored resin sheet 5 attached to the back surface side of the stainless metal layer 3 with the adhesive 4.

Polyethylene terephthalate sheet is suitable as the transparent resin sheet 1, but other resin sheets such as vinyl chloride resin sheet, olefin resin sheet, polyester resin sheet, acrylic resin sheet, polyamide resin sheet, A polyvinyl alcohol resin sheet, a vinyl chloride-vinyl acetate copolymer resin sheet, an ethylene-vinyl acetate copolymer resin sheet, etc. can also be used. The thickness of the transparent resin sheet 1 is 10 to 1
00 μm is preferable.

Examples of the olefin resin sheet include polyethylene, polypropylene or polymethylpentene sheet, and examples of the polyester resin sheet include polyethylene terephthalate, polybutylene terephthalate,
Alternatively, a polyethylene naphthalate-isophthalate copolymer sheet may be used.

Examples of the acrylic resin sheet include polymethylmethacrylate, polyethylmethacrylate, and polybutylacrylate sheets. Examples of the polyamide-based resin sheet include nylon 6 or nylon 6,6 sheets.

Among them, the polyester resin sheet is
It is suitable because it has mechanical strength, its performance does not deteriorate even after the vapor deposition process, and its transparency is high.

In order to improve the mechanical strength, these transparent resin sheets 1 are preferably biaxially stretched, or at least uniaxially stretched only in the winding direction (longitudinal direction of the sheet). Is preferred.

The hairline 2 formed on the back surface of the synthetic resin sheet 1 refers to a pattern in which very fine lines are lined up. In order to form the hairline 2 on the resin sheet 1, a brush roll, a roll having a rough surface, sand paper, or the like is used. Normally, the sheet is continuously run while rotating the roll or the like. It can be carried out by bringing it into contact with and polishing, and fine grooves are formed. The line thickness can be adjusted by adjusting the thickness of the bristles or metal wire of the brush roll, the surface roughness of the rough surface roll, and the degree of unevenness of the surface of the sandpaper.

The hairline 2 may be a straight hairline in which lines are linearly long, a meandering hairline, or a scratch hairline in which the lines are discontinuous on the way. Such a hairline can be formed by wobbling the roll in a direction parallel to the rotation axis to meander each line, or by intermittently contacting a plurality of brushes with the sheet.

The stainless metal layer 3 provided on the back surface side of the transparent resin sheet 1 is formed by sputtering stainless steel, and the thickness thereof is preferably 200 to 700Å in order to exhibit a good metallic luster.
As disclosed in the prior art, when the metal layer is formed by vapor deposition, the adhesive strength to the sheet is low, an adhesive layer is required, and an adhesive coating step is required.

A colored resin sheet 5 is attached by an adhesive 4 to the back surface side of the stainless metal layer 3 thus formed.

As the adhesive, a conventionally known solvent type adhesive, emulsion type adhesive or the like can be used.
For example, polyethylene resin type, polyamide resin type, polyester resin type, polybutyral resin type, polyvinyl acetate resin type, cellulose resin type, polymethylmethacrylate type, polyvinyl ether resin type, polycarbonate resin type, ethylene-vinyl acetate copolymer , Chlorinated polypropylene resin type, vinyl chloride-vinyl acetate copolymer, acrylic resin type, acrylic-vinyl chloride-vinyl acetate copolymer, natural rubber, artificial rubber, etc., alone or in mixture solvent-type adhesive or emulsion-type adhesive Agents, etc.

As the colored resin sheet 5 used in the present invention, the resin used in the above-mentioned transparent resin sheet 1 can be used, and one colored with a coloring pigment, a bright pigment, a dye, a metal powder or the like can be used. it can.

The metallic decorative sheet having the above-described structure is attached to the surface of the substrate with a conventionally known adhesive, and is used as a building material such as a wall material, a flooring material, a top plate, a door having a stainless metallic appearance. It can be used as a material for furniture, home electric appliances and the like.

As the substrate, a wood board, a plywood, a particle board, a wood board such as a medium density fiber board called MDF, a gypsum board, a calcium silicate board, a wood chip cement board, or a fiber reinforced plastic board or a paper honeycomb board. It is possible to use a composite of various materials, such as one with iron plates on both sides.

A hard coat layer made of a transparent resin may be formed on the surface of the synthetic resin sheet 1. The resin constituting the hard coat layer is preferably a thermosetting resin cured or an ionizing radiation curable resin crosslinked and cured.

For example, acrylic resin, styrene resin, acrylic-styrene copolymer, vinyl chloride resin, vinyl acetate resin, vinyl chloride-vinyl acetate copolymer, polyamide resin, polyvinyl-butyral copolymer, polycarbonate resin, urethane resin. , Urea resin, melamine resin, epoxy resin, alkyd resin, aminoalkyd resin,
Examples thereof include thermosetting resins such as rosin-modified maleic acid resins, and combinations of acrylic polyols or polyester polyols with epoxy resins, melamine resins, polyisocyanates and the like are preferable.

Acrylic acid esters of polyhydric alcohols, epoxy acrylates, urethane acrylates, polyester acrylates, polyether acrylates,
Prepolymers such as acrylate alkyd, melamine acrylate, and silicon acrylate, and ultraviolet and electron beam curable resins containing a polymerizable monomer as a main component are also preferable.

To form the protective film, a resin coating material for forming the protective film is applied by a known coating method such as a roll coating method, a gravure coating method, a reverse coating method, a spray coating method and a dipping method, and then dried ( Or curing).

The decorative sheet thus obtained has a high stain resistance, a unique metallic luster, and a strong corrosion resistance against water and the like. It can be used as a plate, a bottom plate, or the like, or as a door surface of an interior member, a wall surface of a store, or the like. (Embodiment 2) As shown in FIG. 2, instead of providing a hairline on the back surface of the transparent resin sheet 1, the transparent resin sheet 1
The colored layer 7 is provided on the back side of the metal layer, the stainless metal layer 3 is formed on the back side of the colored layer 7 by the sputtering method, and the colored resin sheet 5 is attached to the back side of the stainless metal layer 3 with an adhesive to form a metal. You may comprise a makeup | decoration sheet.

As the colored layer, a pattern layer formed by printing an arbitrary pattern, a woven pattern of cloth or the like, a marbled film formed by extruding different kinds of coloring compositions into a film, a colored layer containing a bright pigment, and a usual layer. There is a colored layer. In particular, it is preferable to use a colored layer containing a bright pigment.

The thickness of the colored layer is preferably 2 to 20 μm so that the stainless steel layer can be seen through from the surface of the decorative sheet.

When the colored layer is formed by printing or coating, the colored layer may be formed on paper or a plastic film and attached to the transparent resin sheet 1. (Embodiment 3) In Embodiment 2, the hairline 2 may be provided on the back surface of the transparent resin sheet 1, or as shown in FIG. 3, the hairline 2 may be provided on the back surface side of the colored layer.

[0039]

EXAMPLES Example 1 Polyethylene terephthalate (PET) having a hard coat layer on the surface and a thickness of 50 μm
A hairline was provided on the back of the sheet. On the back surface of this sheet, 500 stainless steel layer is formed by sputtering method.
It was formed with a thickness of Å. A vinyl chloride resin sheet was attached to this sheet via an adhesive to obtain a decorative sheet.

The resulting decorative sheet had a stainless steel appearance and was excellent in corrosion resistance. (Example 2) 50 μm thick having a hard coat layer on the surface
A hairline was provided on the back surface of the m polyethylene terephthalate (PET) sheet. A stainless metal layer having a thickness of 500 Å was formed on the back surface of this sheet by a sputtering method. A polyolefin sheet was attached to this sheet via an adhesive to obtain a decorative sheet.

The resulting decorative sheet had a stainless steel appearance and was excellent in corrosion resistance.

[0042]

According to the present invention, since the metal layer is formed by the sputtering method, the metal layer can be adhered to the transparent resin sheet with good adhesion, and there is no need to provide an adhesive layer as in the prior art. . Therefore, the number of steps can be reduced and the productivity of the decorative sheet can be improved.

Further, since stainless steel is formed as the metal layer, the same gloss, color and corrosion resistance as the stainless steel foil can be obtained.

Further, since the colored resin sheet or the colored layer is used, a decorative sheet having a different color tone or gloss can be manufactured by selecting various bright pigments contained in the colored layer or the like.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of an embodiment of a metallic decorative sheet of the present invention.

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

FIG. 3 is a cross-sectional view of still another embodiment of the metallic decorative sheet of the present invention.

[Explanation of symbols]

1 Transparent resin sheet 2 hairline 3 Stainless metal layer 4 adhesive 5 Colored resin sheet 7 Colored layer

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Yasuhisa Masuda             845-11 Shinike, Fukuroi City, Shizuoka Prefecture Japan Gravure             Industry Co., Ltd. (72) Inventor             2-17 Uchihonmachi, Chuo-ku, Osaka-shi, Osaka             Katani Sangyo Co., Ltd. Osaka Branch (72) Inventor Riki Takano             2-17 Uchihonmachi, Chuo-ku, Osaka-shi, Osaka             Katani Sangyo Co., Ltd. Osaka Branch F-term (reference) 4F100 AB04B AK01A AK01C AK15                       AK42 AT00A AT00C BA03                       BA07 BA10A EH66B GB07                       GB48 GB81 HB09A JB02                       JL02 JL10C JN24

Claims (3)

[Claims] 1. A transparent resin sheet having a hairline on the back surface, a stainless metal layer provided on the back surface side of the transparent resin sheet by a sputtering method, and an adhesive agent on the back surface side of the stainless metal layer. And a colored resin sheet, and a metal-like decorative sheet. 2. A transparent resin sheet, a colored layer provided on the back side of the transparent resin sheet, a stainless metal layer provided on the back side of the colored layer by a sputtering method, and a back side of the stainless metal layer. A metal-like decorative sheet, comprising: a colored resin sheet adhered to the sheet with an adhesive. 3. A hairline is provided on the back side of the transparent resin sheet or the back side of the colored layer.
The metal-like decorative sheet according to.