JP2005290734A - Decorative sheet for floor material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a decorative sheet which has surface design or the like equal to the design of a conventional woody floor material, and contributes to formation of a floor material excellent in scratch resistance and caster resistance of a floor surface. <P>SOLUTION: The decorative sheet for a floor material is formed of an olefin thermoplastic resin film on which a print layer is printed, an olefin thermoplastic resin layer as thick as 300 to 500 μm, and a surface protective layer having a thickness of 3 to 30 μm laminated on each other in this order from below. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a decorative sheet that is suitably used for flooring in buildings such as detached houses, apartments, condominiums, recreational facilities, and stores.

  Conventionally, flooring materials are widely painted with laminated veneer veneer on plywood, or laminated with veneer and medium density fiberboard (MDF), and then veneered with veneer veneer. Are known.

  However, the wood veneer veneer is a thin slice of natural wood. Due to the problem of depletion of wood resources and the global movement to protect resources, the wood veneer is printed instead of wood veneer veneer veneer. A flooring using a decorative sheet artificially expressed by, for example, has been proposed. Such flooring has advantages such as excellent weather resistance and water resistance because the decorative sheet is a synthetic material, as well as excellent flexibility and stability of the surface design. Compared to the veneer of natural wood, it is a much smoother and homogeneous material, so there is a problem that it is relatively noticeable when a part of the surface is damaged.

  In recent years, the use of indoor furniture such as wheelchair furniture and wheelchairs has been increasing with the westernization of rooms and barrier-free. However, the conventional flooring material using a wooden base material such as laminated plywood is deficient in so-called caster resistance, in which a dent remains along the trajectory when a wheel rolls while applying a large load to a small area. There is a problem.

  For example, Patent Document 1 proposes an invention that solves the above-described problems of surface scratch resistance and caster resistance. Patent Document 1 proposes a configuration in which a hard sheet layer made of a high-hardness material is provided between the wooden base material and the decorative sheet in a decorative material having a decorative sheet on the surface of the wooden base material. ing. The present invention has the same purpose as that of the cited document 1, but its solution is completely different.

JP 2003-11277 A

  The present invention has been made in view of the above circumstances, and has a floor material that has excellent surface scratch resistance and caster resistance while having a surface design equivalent to that of a conventional wooden floor material. An object of the present invention is to provide a decorative sheet.

  That is, the present invention provides a flooring material having at least an olefinic thermoplastic resin layer having a thickness of 300 to 500 μm and a surface protective layer having a thickness of 3 to 30 μm on the olefinic thermoplastic resin film on which the printing layer is printed. The present invention relates to a decorative sheet.

  The flooring material having the decorative sheet of the present invention on its surface is excellent in scratch resistance and caster resistance.

  As shown in FIG. 1, the decorative sheet 1 of the present invention is used by being attached to the surface of the wooden substrate 2 via an adhesive layer or the like.

  FIG. 2 shows a schematic cross-sectional view of one embodiment of the decorative sheet of the present invention. The decorative sheet 100 is provided with a primer layer 15 on one surface of the olefin-based thermoplastic resin film 10, and a printing layer 12 including a solid printing layer 17 and a pattern layer 16 is sequentially printed on the primer layer 15. The olefinic thermoplastic resin layer 11 is laminated on the adhesive layer 18 on the surface 12, and the surface protective layer 14 is formed on the surface of the olefinic thermoplastic resin layer 11.

(Olefin-based thermoplastic resin film 10)
The olefin-based thermoplastic resin film 10 has a function of imparting a design as a flooring. For example, a polyolefin resin such as polypropylene resin, polyethylene resin, ethylene-propylene copolymer, polyolefin-based thermoplastic elastomer resin, polyethylene Terephthalate resin, polyethylene naphthalate resin, copolyester resin (eg, 1,4-cyclohexanedimethanol copolyethylene terephthalate resin, commonly known as PET-G resin), polyester resin such as amorphous polyester resin, polyacrylonitrile resin Acrylic resin such as polymethyl methacrylate resin, polyvinyl chloride resin, etc. can be used, but adhesion with olefinic thermoplastic resin layer 11 and prevention of curling of the laminated sheet (when different materials are laminated) Over because there tends to Le), giving results (durability such as weather resistance in building materials, from the viewpoint of processing suitability) such as embossing to use olefin resin film preferably.

  The film 10 may be colored by addition of a known colorant or may not be colored. The thickness of the film 10 is 50 μm or more, preferably about 50 to 150 μm, more preferably 50 to 80 μm. When the thickness of the film is too thin, the masking is insufficient when the masking property is required. The upper limit of the thickness is not particularly limited, but if it is 50 μm or more, it is preferable that the thickness is thin. On the other hand, the thicker the one, the higher the cost, and the more easily available is about 150 μm. Is up to.

(Primer layer)
The primer layer 15 is provided for the purpose of improving the adhesiveness between the olefinic thermoplastic resin layer 11 and the printing layer such as the pattern layer 16 and the solid printing layer 17. In the present invention, the primer layer must be formed. It is not necessary, and it may be provided if necessary. Examples of the resin forming the primer layer include ester resins, urethane resins, acrylic resins, polycarbonate resins, vinyl chloride-vinyl acetate copolymers, polyvinyl butyral resins, and nitrocellulose resins. These resins may be used alone or mixed to form a coating composition or an ink composition, and a conventional coating means such as a roll coating method or a gravure printing method may be used to form a thickness of about 1 to 6 μm. Good.

(Print layer 12)
FIG. 2 shows a configuration having a pattern layer 16 and a solid print layer 17 as the print layer 12. The pattern layer 16 and the solid print layer 17 can be generally formed on the film 10 using ink by a known printing method such as gravure printing, offset printing, and silk screen printing. Although FIG. 2 shows a configuration in which both the pattern layer 16 and the solid print layer 17 are provided, any one of the configurations may be used. Although it does not specifically limit as the pattern layer 16, For example, a wood grain pattern, a stone pattern, a cloth pattern, a crest pattern, a geometric pattern, a character, a symbol, a line drawing, and various abstract pattern patterns are mentioned, for example. The thickness of the pattern portion is usually about 1 to 15 μm. The solid printing layer 17 is solid printed with a coloring ink having a concealing property, and its thickness is usually about 1 to 10 μm.

  Examples of the ink composition used for the pattern layer 16 and the solid print layer 17 include vehicles such as chlorinated polyolefins such as chlorinated polyethylene and chlorinated polypropylene, polyesters, polyurethanes composed of isocyanates and polyols, polyacryls, polyvinyl acetates, polychlorinateds. One, two or more kinds of vinyl, vinyl chloride-vinyl acetate copolymer, cellulose resin, polyamide resin, etc. may be used in combination, and pigments, solvents, various auxiliary agents and the like may be used. However, in consideration of environmental problems, adhesion to the printing surface, and the like, it is preferable to use one or a mixture of two or more of polyester, polyurethane composed of isocyanate and polyol, polyacryl, polyamide resin and the like.

(Olefin-based thermoplastic resin layer 11)
For the olefin-based thermoplastic resin layer 11, the same olefin-based thermoplastic resin used for the olefin-based thermoplastic resin film 10 can be used. Among them, as a flooring material, a resin made of homopolypropylene having excellent surface strength and wear resistance, particularly from the viewpoint of imparting caster resistance, such as surface physical properties, workability, economic efficiency, disposal (including incineration), preferably A resin composed of 70% by weight or more of homopolypropylene is desirable. In the present invention, homopolypropylene having a melting point of 150 to 170 ° C. is preferably used. More preferably, a homopolypropylene having a flexural modulus of 1000 MPa or more, a tensile yield strength of 30 MPa or more, and a Rockwell hardness of 75 or more is used. Homopolypropylene means a homopolymer of propylene monomer. The resin that may be contained in addition to the homopolypropylene is not particularly limited as long as no production problems occur in the process until the flooring is produced.

  The melting point is represented by JIS K7121, the flexural modulus is measured by JIS K7171, the tensile yield strength is measured by JIS K7161, and the Rockwell hardness is measured by JIS K7202.

  The polypropylene used in the present invention can be produced by a known polymerization method, and as a commercial product, trade name F-704NP: manufactured by Idemitsu Petrochemical Co., Ltd. is available.

  In the present invention, the olefinic thermoplastic resin layer 11 is configured to have a thickness of 300 μm or more. If the thickness is less than 300 μm, sufficient caster resistance cannot be imparted. The upper limit of the thickness is not particularly limited, but is set to a thickness of 500 μm or less from the viewpoint of productivity and cost. When a transparent resin is used as the olefinic thermoplastic resin, the thick olefinic thermoplastic resin layer 11 is present in the present invention, so that the transparent feeling is enhanced and the flooring material has a high-class feeling. To do.

(Adhesive layer 18)
The adhesive layer 18 functions to adhere the film 10 on which the printing layer 12 is formed and the olefinic thermoplastic resin layer 11. Examples of the lamination method with the olefin-based thermoplastic resin layer 11 include a dry lamination method or a wet lamination method with an adhesive layer 18, a thermal lamination method with or without an adhesive layer 18, a high frequency lamination method, and a transparent heat. An extrusion laminating method or the like in which a plastic resin is extruded in a molten state and laminated at the same time is applicable. In the extrusion laminating method, an adhesive resin layer such as an acid-modified olefin resin or an olefin- (meth) acrylate copolymer resin as the adhesive layer 18 is used for co-extrusion with the resin layer 11 as necessary. May be formed simultaneously. Further, prior to the lamination, the surface for adhesion to the resin layer 11, for example, corona discharge, ozone treatment, plasma treatment, ionizing radiation treatment, acid treatment, alkali treatment, anchor treatment, or the like Processing may be performed.

(Surface protective layer)
The surface protective layer 14 provided on the surface of the decorative sheet 100 will be described. This surface protective layer 14 is provided for imparting surface physical properties such as scratch resistance, abrasion resistance, water resistance, and stain resistance required for a flooring material (see FIG. 1). As a resin for forming the surface protective layer 14, a conventionally known thermosetting resin or curable resin such as ionizing radiation curable resin is used, and the thickness thereof is 1 to 100 μm, preferably 3 to 30 μm. It is appropriate to form. In more detail, since the technical matter regarding the surface protective layer described in Patent Document 1 specification Nos. 0031 to 0044 can be applied to the present invention as it is, the description is included here as a part of this specification. Quote. Preferred in the present invention is an ionizing radiation curable resin having a high surface hardness and excellent productivity.

(Recoat resin layer)
In providing the surface protective layer 14 made of an ionizing radiation curable resin on the surface of the decorative sheet 100, the surface of the surface protective layer 14, that is, the surface of the resin layer 11 in the example shown in FIG. 2, and the ionizing radiation curable resin are used. It is necessary to ensure sufficient adhesion with the surface protective layer 14 to be formed. For this purpose, surface activation treatment such as corona discharge treatment or ozone treatment is applied to the surface of the resin layer 11, or the ionizing radiation curing that constitutes the thermoplastic resin constituting the resin layer 11 and the surface protective layer 14. It is desirable to provide on the surface of the resin layer 11 a recoatable resin layer made of a resin composition having excellent adhesion to both the mold resin.

  As the recoatable resin layer, for example, it is desirable to use a thermosetting resin such as a urethane resin, an epoxy resin, a phenol resin, a urea resin, an alkyd resin, a polyester resin, among which a polyol compound and an isocyanate compound are used. It is most desirable to use a two-component curable urethane resin having the following composition. As the polyol compound, for example, an acrylic polyol compound, a polyether polyol compound, a polyester polyol compound, and the like can be used. Above all, from the viewpoint of the balance between adhesion to the thermoplastic resin and ionizing radiation curable resin and internal cohesive force. It is most desirable to use a polyester polyol compound.

The coating amount of the recoatable resin layer is desirably about 0.1 to 2.0 μm after drying. Examples of the method for forming the recoatable resin layer include various conventionally known coating methods such as a gravure coating method, a micro gravure coating method, a roll coating method, a knife coating method, an air knife coating method, a lip coating method, and a die coating method. It can be arbitrarily adopted.
Yes.

(Wood base)
The wood substrate 2 is not particularly limited. For example, veneer, wood veneer, wood plywood, particle board, medium density fiber made from various materials such as cedar, cocoon, temperament, pine, lawan, teak and melapie. A board (MDF) etc. are mentioned. For example, a moisture-proof layer may be formed on one surface of the wood substrate from the viewpoint of providing a moisture-proof effect.

  A flooring is provided by bonding the wooden substrate 2 and the decorative sheet 1 together. The method of sticking the decorative sheet to the woody base material or the laminating method is not limited. For example, a method of sticking the decorative sheet to the base material with an adhesive can be employed. What is necessary is just to select an adhesive agent suitably from well-known adhesive agents according to the kind etc. of a base material. Examples thereof include polyvinyl acetate, polyvinyl chloride, vinyl chloride / vinyl acetate copolymer, ethylene / acrylic acid copolymer, ionomer, butadiene / acrylonitrile rubber, neoprene rubber, natural rubber and the like.

  From the viewpoint of improving the adhesion between the wooden substrate and the decorative sheet, a primer layer may be provided on the other surface (back surface) opposite to the surface protective layer side of the decorative sheet of the present invention. The description regarding the primer layer (15) described above can be similarly applied to the back primer layer. In this case, extender pigments such as silica and barium sulfate may be added for the purpose of preventing blocking.

  The decorative sheet for flooring of the present invention can be used as a flooring material excellent in scratch resistance and caster resistance on the back surface of the resin film 10 without forming a conventionally provided backer. .

Examples Next, the present invention will be described in more detail with reference to examples. First, a decorative sheet to be laminated with a wooden substrate is manufactured.

Example 1
A two-part curable urethane primer layer and a two-part curable urethane primer layer and an acrylic urethane printing ink are provided on one side of a 60 μm-thick colored polypropylene film subjected to double-sided corona discharge treatment and the other side is provided with a two-part curable urethane primer layer and acrylic urethane type printing ink. A wood grain printed layer was formed.

  Next, a transparent homopolypropylene resin (melting point: 170 ° C.) having a flexural modulus of 1500 MPa, a tensile yield strength of 38 MPa, and a Rockwell hardness of 80 is formed on the printed layer through a urethane adhesive to a thickness of 300 μm using a T-die extruder. Thus, a polypropylene thermoplastic resin layer was extruded to produce a laminate.

  A urethane primer layer having a thickness of 2 μm was formed on the transparent homopolypropylene resin surface of the laminate. On the urethane-based primer layer, an ionizing radiation curable resin was applied and dried so as to have a thickness of 15 μm after drying by a gravure reverse coating method to form an uncured ionizing radiation curable resin layer. The uncured shadow radiation curable resin layer is cured by irradiating with an electron beam (acceleration voltage 175 keV, irradiation amount 5 Mrad) in an environment having an oxygen concentration of 200 PPM or less, and a surface protective layer made of an ionizing radiation curable resin is formed. At the same time, embossing was performed from the surface protective layer side with a grain conduit shape embossing plate having a plate depth of 50 μm to form a grain conduit-like uneven pattern. A decorative sheet was produced as described above.

Example 2
A transparent homopolypropylene resin (melting point: 170 ° C.) having a flexural modulus of 1500 MPa, a tensile yield strength of 38 MPa, and a Rockwell hardness of 80 is formed on a printed pattern with a wood pattern through a urethane adhesive to a thickness of 400 μm using a T-die extruder. A decorative sheet of the present invention was produced in the same manner as in Example 1 except that a laminate was produced by extrusion.

Comparative Example 1
A transparent random polypropylene resin (melting point: 145 ° C.) having a flexural modulus of 600 MPa, a tensile yield strength of 26 MPa, and a Rockwell hardness of 72 via a urethane adhesive on a wood-patterned printed layer is 300 μm in thickness using a T-die extruder. A decorative sheet as a comparative example was produced in the same manner as in Example 1 except that a laminate was produced by extrusion.
The random polypropylene resin used in this comparative example is a random copolymer of ethylene and propylene.

Comparative Example 2
A transparent homopolypropylene resin (melting point: 170 ° C.) having a flexural modulus of 1500 MPa, a tensile yield strength of 38 MPa, and a Rockwell hardness of 80 via a urethane adhesive on the printed pattern of wood pattern is 200 μm in thickness using a T-die extruder. A decorative sheet as a comparative example was produced in the same manner as in Example 1 except that a laminate was produced by extrusion.

Comparative Example 3
On the printed pattern of wood grain, urethane elastic adhesive is used, bending elastic modulus 1500MPa, tensile yield strength 38MPa, Rockwell hardness 80 transparent homopolypropylene resin (melting point 170 ° C) 50wt%, flexural modulus 600MPa, tensile yield strength Example 1 except that a laminate was produced by extruding a resin layer containing 50 wt% of a transparent random polypropylene resin (melting point 145 ° C.) of 26 MPa and Rockwell hardness 72 with a T-die extruder to a thickness of 400 μm. Similarly, a decorative sheet as a comparative example was produced.

Manufacturing method of flooring Using lauan plywood with a thickness of 12 mm as a wooden base material, and laminating decorative sheets obtained in Examples and Comparative Examples via a water-soluble urethane emulsion adhesive on a wood base material The flooring was produced by pasting.

Evaluation (caster resistant)
About the flooring obtained using the decorative sheet obtained in the above Examples and Comparative Examples, the caster resistance was evaluated using a caster resistance test apparatus L6-O4 (manufactured by Asano Machinery Co., Ltd.). .

  A schematic configuration diagram of the caster resistance test apparatus L6-O4 is shown in FIG. The caster-resistant test apparatus 1000 includes a load portion 1002 whose load can be changed by a weight 1001, an adjustment handle 1003, a rotatable caster fixing base 1010 (fixing base: diameter 320 mm, caster mounting portion diameter: 260 mm), and the caster. Three casters 1011 attached to a fixed base at equal intervals (vertical position when a regular triangle is drawn in a circular fixed base), a sample fixing base 1013 (diameter 80 cm, thickness 80 mm) (made of acrylic), Is provided. The caster used was 420SA-N (wheel: made of nylon) (average diameter 75 mm, thickness 25 mm) obtained from HAMMER CASTER.

A floor material (sample) (30 cm × 30 cm) to be tested is fixed to a sample fixing base 1013, a 30 kg weight 1001 is placed on a weighted portion 1002, and three pieces are placed on the surface of the floor material on the decorative layer side by an adjustment handle 1OO3. The caster 1011 was brought into contact (total load 70 kg / m ² ), the caster fixing base 1010 was operated, and was rotated counterclockwise at a speed of 20 rpm every 1000 minutes.

The caster resistance was evaluated based on the presence or absence of cracks generated on the floor material surface, and was ranked as follows.
○: Depression depth is less than 70 μm Δ: Depression depth is 70 μm or more and less than 100 μm ×: Depression depth is 100 μm or more

  The caster resistance can be evaluated by other testing machines as long as the evaluation can be equivalent to that of L6-O4 (manufactured by Asano Machinery Co., Ltd.).

The schematic sectional drawing of the flooring of this invention. The schematic sectional drawing of the decorative sheet (one aspect | mode) of this invention. The schematic block diagram of a caster resistance testing machine.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Decorative sheet 2 Woody material 10 Resin film 11 Resin layer 12 Print layer 14 Surface protective layer 15 Primer layer 16 Picture layer 17 Solid print layer 18 Adhesive layer 100 Cosmetic sheet 1000 Casting resistance test apparatus 1001 Weight 1002 Load part 1003 Adjustment handle 1010 Caster Fixing base 1011 Caster 1012 Sample 1013 Sample fixing base

Claims (6)

  A decorative sheet for flooring, which has at least an olefinic thermoplastic resin layer having a thickness of 300 to 500 μm and a surface protective layer having a thickness of 3 to 30 μm on an olefinic thermoplastic resin film on which the printing layer is printed.   The decorative sheet for flooring according to claim 1, wherein the olefinic thermoplastic resin of the olefinic thermoplastic resin layer is made of homopolypropylene.   The decorative sheet for flooring according to claim 1, wherein the olefinic thermoplastic resin of the olefinic thermoplastic resin layer comprises 70% by weight or more of homopolypropylene.   The decorative sheet for flooring according to any one of claims 1 to 3, wherein the homopolypropylene has a melting point of 150 to 170 ° C.   The decorative sheet for flooring according to any one of claims 1 to 4, wherein the olefinic thermoplastic resin film is a polypropylene resin film or a polyethylene resin film. The flooring material which affixes the decorative sheet for flooring materials in any one of Claims 1-5 on a wooden base material.

Images