JP2006062290A - Decorative sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a decorative sheet which is excellent in transparency and damage resistance, hard to be whitened and broken during processing and is also excellent in strength, durability, handleability and appearance or the like due to a surface sheet superior in oil resistance provided therewith. <P>SOLUTION: The decorative sheet 10A is provided with a surface sheet 14 comprising a resin composition containing 10 to 90 wt.% of an ionomer resin on at least one surface side of a substrate sheet 11. Preferably, the ionomer resin is prepared by partially neutralizing an ethylene-(meth)acrylic acid copolymer with a metal ion. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a decorative sheet used for an interior or exterior of an automobile.

For automobile interiors such as front panels, decorative sheets on which patterns such as wood grain are formed are widely used and variously developed. For example, Patent Document 1 discloses a sheet in which a pattern printing ink layer and a transparent acrylic resin sheet layer are sequentially laminated on an ABS resin layer (sheet layer and backer layer) as an excellent recyclable material. Yes. Further, Patent Document 2 includes a surface sheet in which a matting agent made of transparent light diffusing particles is added to a transparent sheet, and such a surface sheet and a back sheet are made of an adhesive layer made of a two-component curable resin. A bonded matte decorative sheet is described.
As described above, the decorative sheet is usually configured such that a pattern layer and the like are arranged on a sheet as a base material as necessary, and then a transparent surface sheet is arranged, and the surface sheet is made of an acrylic resin. Often used.
On the other hand, for parts used for automobile exteriors such as bumpers, mudguards, steps, etc., painted products in which a plastic substrate is coated are used.
JP 2001-334609 A JP 2002-283510 A

However, although the acrylic resin used for the surface sheet of the decorative sheet for automobile interiors is excellent in transparency, there is a problem that it is easily damaged and easily whitened during bending. In addition, the strength is not sufficient, and it sometimes breaks during trimming work. Furthermore, acrylic resin has insufficient oil resistance, and if a decorative sheet with a surface sheet made of acrylic resin is used in the interior of an automobile and spilled fragrance, the surface sheet may swell or become cloudy. There was a problem such as. In addition, even in automobile exterior materials having a surface layer made of such an acrylic resin, problems such as being easily damaged by hopping (so-called chipping) and insufficient solvent resistance have occurred.
In addition, when manufacturing a coated product for an automobile exterior, since a paint containing an organic solvent, which has a problem of adverse effects and harmfulness on the work environment, is used, so-called painting-less requirements are increasing.

  The present invention has been made in view of the above circumstances, and is provided with a surface sheet that is excellent in transparency and scratch resistance, is not easily whitened during processing, is not easily broken, and is also excellent in oil resistance. It is an object to provide a decorative sheet that is excellent in properties and appearance.

The decorative sheet of the present invention is characterized in that a top sheet made of a resin composition containing 10 to 90% by mass of an ionomer resin is provided on at least one side of the base sheet.
The ionomer resin is preferably a partially neutralized ethylene- (meth) acrylic acid copolymer with metal ions.
It is preferable that at least one of a pattern layer or a colored layer is formed between the base sheet and the top sheet.
The colored layer is preferably formed from a colored composition containing at least an ionomer resin and a pigment.

  The decorative sheet of the present invention comprises a resin composition containing 10 to 90% by mass of an ionomer resin, has excellent transparency and scratch resistance, is not easily whitened during processing, is not easily broken, and has excellent oil resistance. Since it is equipped with a sheet, it is excellent in strength, durability, handleability, and appearance. Therefore, it is particularly suitable for use in automobile interiors and automobile exteriors that require ease of integration with curved base materials, resistance to oil components such as fragrances, and resistance to scratches.

Hereinafter, the present invention will be described in detail.
The decorative sheet of the present invention is provided with a surface sheet formed from a resin composition containing 10 to 90% by mass of an ionomer resin on at least one side of a base sheet, and further to FIGS. As shown, at least one of the pattern layer 12 a or the colored layer 15 is formed between the base sheet 11 and the top sheet 14.

  The material of the base material sheet 11 is determined by design specifications such as base material materials and dimensions of panels for automobile interior and exterior, etc., which are molded using the decorative sheets 10A, 10B, and 10C of the present invention. Resin, PC resin, mixed resin of PC resin and ABS resin, PVC resin, PS resin, polyolefin resin such as PE resin and PP resin, and its elastomer resin, polyester resin, etc. can be used A laminated sheet of a plurality of resins may be used. The thickness of the base material sheet 11 is 0.05 mm to 1.00 mm, preferably 0.10 mm to 0.80 mm, considering the moldability at the time of molding.

  The pattern layer 12a of the decorative sheet 10A of FIG. 1 may be formed on the surface of the base sheet 11 by printing such as gravure printing or flexographic printing or various image forming methods, or printed on a biaxially stretched PET film or the like. It may be formed by transferring the formed pattern to the base material sheet 11 by a method such as heat transfer. Moreover, the pattern layer 12a may be provided in the form of the pattern sheet 12 provided with the pattern layer 12a on at least one side (in this example, only one side) of the resin sheet 12b, as shown in FIG. The thickness of the pattern layer 12a is formed in the range of 0.01 mm to 0.05 mm by the above printing method.

The base sheet 11 on which the pattern layer 12a is formed and the surface sheet 14 to be described later are attached and laminated via the adhesive layer 13 as in the example of FIG. 1 to improve the appearance quality of the pattern layer 12a. It is preferable that there is little damage.
As the adhesive layer 13, a film formed by applying a pressure-sensitive adhesive or an adhesive, a film or sheet made of a heat-sealable thermoplastic resin, and the like can be used. The former includes acrylic, vinyl acetate, and urethane. Acryl-urethane, ionomer, and the like. As the latter, ethylene-vinyl acetate copolymer resin, polyethylene resin, maleic acid-modified olefin resin, and ionomer resin can be used.
Further, as in the example of FIG. 3, a primer agent is applied on the base material sheet 11 to form a primer layer 17, a pattern sheet 12 is arranged on the primer layer 17, and the surface is further bonded via the adhesive layer 13. Sheets 14 may be laminated.

  The colored layer 15 of the decorative sheet 10B in FIG. 2 is formed from a colored composition containing at least an ionomer resin and a pigment, and the colored composition is colored using the decorative sheet 1010B. Based on the design of the molded panel or the like, it is performed by adjusting the color with a known pigment. The thickness of the colored layer 15 can be appropriately selected in the range of 0.05 mm to 0.50 mm from the color type and the concealability.

In the production of the decorative sheet 10B having the form shown in FIG. 2, the base sheet 11, the colored layer 15, and the surface sheet 14 are preferably laminated and bonded together by a coextrusion method equipped with a T die. At this time, the surface sheet 14 can be cooled by being sandwiched between cooling rolls having a mirror surface.
The thickness of the surface sheet 14 is 0.03 mm to 0.80 mm, and preferably 0.10 mm to 0.50 mm. If this thickness is less than 0.03 mm, scratch resistance cannot be obtained, and if it exceeds 0.80 mm, the surface of the decorative sheet becomes too flexible, making it unsuitable for applications such as panels.

The ionomer resin used for the top sheet 14 in the present invention is a partially neutralized ethylene- (meth) acrylic acid copolymer with a metal ion such as zinc, sodium, lithium, magnesium, etc., and an ethylene-methacrylic acid copolymer. Is preferably partially neutralized with zinc or sodium, more preferably partially neutralized with sodium in terms of transparency.
The resin composition forming the top sheet 14 contains an ionomer resin in the range of 10 to 90% by mass, preferably in the range of 20 to 80% by mass. Here, when the content of the ionomer resin in the resin composition is less than 10% by mass, the surface sheet 14 has insufficient transparency, scratch resistance, oil resistance, solvent resistance, and whitening, cracking, etc. during processing. The problem tends to occur. On the other hand, if it exceeds 90% by mass, the hardness of the resin composition decreases and becomes too soft, the thermal stability also decreases, the processability and handleability become insufficient, the adhesiveness becomes high, and it is molded into a sheet shape. It may not be possible.

  Examples of the resin component other than the ionomer resin contained in the resin composition include low density polyethylene, linear low density polyethylene, high density polyethylene, polypropylene, ethylene-vinyl acetate copolymer resin, and ethylene- (meth) acrylic acid copolymer resin. Of these, two or more of these may be used. What contains 20-80 mass% of ionomer resin and 80-20 mass% of polyethylene-type resin is preferable at the point of transparency, workability, scratch resistance, oil resistance, and solvent resistance. Examples of components other than the resin component contained in the resin composition include processing aids such as antioxidants, ultraviolet absorbers, ultraviolet reflectors, and lubricants.

The decorative sheets 10A, 10B, and 10C of the present invention as illustrated in FIGS. 1 to 3 are surface sheets made of a resin composition containing 10 to 90% by mass of an ionomer resin on at least one side of the base sheet 11. 14, and at least one of the pattern layer 12 a or the colored layer 15 is formed between the base sheet 11 and the top sheet 14. As a manufacturing method of the decorative sheets 10A, 10B, and 10C, the following methods can be given.
In the case of having the pattern layer 12a as illustrated in FIG. 1, as described above, the pattern layer 12a is formed directly on the surface of the base sheet 11 or by a transfer method. Next, the base sheet 11 and the top sheet 14 are bonded together via the adhesive layer 13. As a specific method at that time, a method by continuous hot pressing may be mentioned. At this time, by continuously pressing the top sheet 14 with a mirror surface, a decorative sheet 10 </ b> A with a high gloss and a smooth surface appearance can be obtained.
As illustrated in FIG. 3, in the case of having the pattern sheet 12, after forming the primer layer 17 on the base sheet 11, the pattern sheet 12 is arranged, and then the same as in the case of FIG. 1 through the adhesive layer 13. The top sheet 14 is bonded together.
In the case of the one having the colored layer 15 as shown in FIG. 2, a method of directly forming the topsheet 14, the colored layer 15, the adhesive layer 13, and the base material sheet 11 by a multilayer coextrusion method can be mentioned.

(1) Configuration of decorative sheet A decorative sheet 10B having the configuration shown in FIG. 2 was produced by a multilayer coextrusion method.
Base sheet 11: ABS resin, thickness 300 μm
Colored layer 15: 250 μm thick
Adhesive layer 13: 75 μm thick
Top sheet 14: 125 μm thick
(2) Evaluation As a result of integrally molding the decorative sheet 10B having the above-described structure by insert molding with a base material (made of ABS resin) for the interior member, it is excellent in transparency, scratch resistance, oil resistance, etc., and has an appearance and design. A good molded article was obtained. Moreover, whitening and a crack did not generate | occur | produce at the time of processing of this decorating sheet 10B and a molded object.

It is sectional drawing which shows an example of the decorating sheet of this invention. It is sectional drawing which shows another example of the decorating sheet of this invention. It is sectional drawing which shows another example of the decorating sheet of this invention.

Explanation of symbols

10A, 10B, 10C Decorative sheet 11 Substrate sheet 12a Pattern layer 14 Surface sheet 15 Colored layer

Claims (4)

A decorative sheet comprising a surface sheet made of a resin composition containing 10 to 90% by mass of an ionomer resin on at least one side of a base sheet. The decorative sheet according to claim 1, wherein the ionomer resin is obtained by partially neutralizing an ethylene- (meth) acrylic acid copolymer with a metal ion. The decorative sheet according to claim 1 or 2, wherein at least one of a pattern layer or a colored layer is formed between the base sheet and the top sheet. The decorative sheet according to claim 3, wherein the colored layer is formed from a colored composition containing at least an ionomer resin and a pigment.

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