JP2012210792A - Mirror surface decorative panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a mirror surface decorative panel in which curved small surface working such as corner R is applied to an edge part, and which has high mirror surface properties.SOLUTION: In the mirror surface decorative panel in which a surface decorative sheet is disposed on a base material, a transparent resin film having a thickness of 50 to 300 μm and a haze value of <1% and a resin film layer having a thickness of 200 to 900 μm are laminated via a decorative layer, the total thickness is 400 to 1,000 μm, and at least one edge is subjected to curved surface working by direct post form working, and thus high mirror surface properties can be achieved even when small curved face working has been applied.

Description

  The present invention relates to a mirror surface decorative plate having a curved surface processed at an end.

  For decorative panels used in kitchens for home interiors and storage doors, high-grade door materials are preferred, especially for high-grade door materials. It is used. In order to enhance the high specularity, the image reflected on the sheet is highly transparent without being clouded, and the surface has no irregularities and the contour of the reflected image is sharply expressed. Is required. In addition, these decorative decorative boards are often subjected to a corner radius process on the edge of the decorative panel depending on the mode of installation. In particular, the corner radius portion has a sharper design as the diameter is smaller, and a high-class design can be obtained.

  As a decorative sheet having high specularity, for example, a high-definition decorative sheet in which a transparent resin film and a resin film are laminated is disclosed (for example, see Patent Document 1). The decorative sheet is a decorative sheet that has been enhanced by using a transparent resin film having a constant haze and light transmittance as a surface layer. The decorative sheet is affixed to various flat plates, curved plates, etc. It is disclosed that it can be applied to the interior of a product. Further, it is disclosed that a bending process or the like can be performed by pasting on a plate-like substrate and performing a V-cut or U-cut process.

  However, the decorative sheet can be bent by V-cut or U-cut after being applied to the base material on the plate, but when it is directly applied to the plate-like base material having a small corner radius at the end. In some cases, the sheet cannot be satisfactorily stuck due to the repulsion of the sheet or the high mirror surface cannot be maintained.

  On the other hand, as a method of forming a curved surface with a small corner radius on a decorative plate used for a kitchen counter of a residential facility, a round processing of 2 mm to 4 mm is performed using a resin plate of about 0.1 to 0.8 mm. The direct post-form processing method which performs is disclosed (for example, refer patent document 2). Although the said processing method is a method which can manufacture the decorative board of a small round process, about the decorative board structure which can form a small round process while holding a high mirror surface in the decorative board using the high mirror surface decorative sheet of another layer structure Was not disclosed at all.

JP-A-10-258488 JP-A-2005-271489

  The problem to be solved by the present invention is to provide a mirror surface decorative plate having a high specularity and having a small curved surface process such as a corner radius at the end.

  The mirror surface decorative sheet of the present invention is a mirror surface decorative sheet in which a mirror surface decorative sheet is provided on a substrate, and the mirror surface decorative sheet has a thickness of 50 to 300 μm and a haze value of less than 1.0%. And a resin film layer having a thickness of 200 to 900 μm is laminated through a decorative layer, the total thickness is 400 to 1000 μm, and at least one end of the mirror surface decorative plate is curved by direct post-form processing The decorative board solves the above-mentioned problems.

  The mirror surface decorative plate of the present invention has high mirror surface properties even when a minute curved surface processing such as a corner radius is applied to the end portion, and thus can be suitably used for house interior materials such as kitchen and storage door materials. .

It is a schematic sectional drawing which shows an example of the mirror surface decorative sheet used for the mirror surface decorative board of this invention. It is a schematic sectional drawing which shows an example of the mirror surface decorative sheet used for the mirror surface decorative board of this invention. It is a schematic sectional drawing which shows an example of the mirror surface decorative sheet used for the mirror surface decorative board of this invention. It is a schematic sectional drawing which shows the laminated structure of the mirror surface decorative board before the direct post-form process manufactured in the Example. It is a schematic sectional drawing of the mirror surface decorative board of this invention manufactured in the Example. It is a schematic sectional drawing of the decorative board which gave the edge part curved surface process manufactured in the comparative example.

  The mirror surface decorative board of the present invention has a transparent resin film having a thickness of 50 to 300 μm and a haze value of less than 1.0%, and a resin film layer having a thickness of 200 to 900 μm laminated via a decorative layer. A mirror surface decorative sheet obtained by using a mirror surface decorative sheet having a thickness of 400 to 1000 μm and processing at least one end of a mirror surface decorative sheet provided with the mirror surface decorative sheet on a base material by direct post-form processing.

[Mirror finish sheet]
The mirror surface decorative sheet used in the present invention has a transparent resin film having a thickness of 50 to 300 μm and a resin film layer having a thickness of 200 to 900 μm laminated via a decorative layer, and the total thickness is 400 to 1000 μm. This is a decorative sheet. In the present invention, by using the mirror surface decorative sheet having the above configuration, a highly specular decorative sheet can be obtained, and when the end portion is subjected to curved surface processing, the curved surface processed portion has high mirror surface properties. Can hold.

(Transparent resin film)
As the transparent resin film, a transparent resin film having a thickness of 50 to 300 μm, preferably 100 to 200 μm is used. By setting the thickness of the transparent resin film to the thickness, suitable surface smoothness can be ensured, and high specularity of the resulting decorative board can be realized. In addition, the transparent resin film having the thickness makes it easy to ensure a good surface hardness as an interior material, facilitates material procurement, and is effective in reducing costs. As the resin used for the transparent resin film, a thermoplastic resin can be preferably used. For example, PET (polyethylene terephthalate), PVC (polyvinyl chloride), PP (polypropylene), PETG (glycol-modified polyethylene terephthalate), acrylic, etc. A plastic resin can be used. Among these, PET and acrylic are preferable as resins having higher transparency, and it is more preferable to use PET from the viewpoint of preventing cracking (crazing) due to a cleaning solvent or a surfactant.

  With regard to the transparency of the transparent resin film, by setting the haze value to less than 1%, preferably 0.9% or less, a particularly suitable specular decorative board without white turbidity can be obtained.

(Resin film layer)
The resin film layer is a layer made of a resin film and has a thickness of 200 to 900 μm, preferably 300 to 700 μm, and more preferably 300 to 500 μm. The resin film layer is a layer provided in the lower layer of the transparent resin film, and by setting the thickness of the resin film layer to the thickness, the mirror surface of the decorative sheet can be used when cutting the decorative sheet during curved surface processing by direct post-form processing. Therefore, cutting can be performed without impairing the properties, and suitable bending workability can be realized while maintaining high specularity, so that high specularity can be maintained even in a curved surface processed portion. As the resin of the resin film used for the resin film layer, a thermoplastic resin can be suitably used, and a thermoplastic resin such as PET, PVC, PP, PETG, or acrylic can be used.

  The resin film layer may be a layer made of a single resin film or a layer in which a plurality of resin films are laminated. In addition, the resin film used for the resin film layer may have transparency, may have concealment properties, or may be colored, but is made of a colored resin film. A resin film layer is preferred because it is easy to improve the design properties of the decorative layer.

(Decoration layer)
The decorative layer is provided to give a desired design such as a wood grain pattern or an abstract pattern. Examples of the decorative layer include those by various types of printing including gravure printing, and those by vapor deposition. However, gravure printing is preferable because various color patterns can be easily printed. .

(Layer structure)
The specular decorative sheet used in the present invention is a specular decorative sheet in which the transparent resin film and the resin film layer are laminated via a decorative layer, and the total thickness is 400 to 1000 μm. In the present invention, by setting the thicknesses of the transparent resin film and the resin film layer within the above range and the total thickness within the above range, suitable curved surface processing can be performed while maintaining high design properties.

  Lamination of the transparent resin film and the resin film layer through the decorative layer is performed on the surface of the transparent resin film laminated with the resin film layer or on the surface of the resin film layer laminated with the transparent resin film. It is preferable to laminate the transparent resin film and the resin film layer. Especially, it is preferable to provide a decorative layer on the surface to be laminated with the resin film layer of the transparent resin film and to laminate the transparent resin film and the resin film layer because the design property by the decorative layer is easily visually recognized.

  There is no particular limitation on the method for laminating the transparent resin film and the base resin film, and a heat laminating method and a dry laminating method in which a heat bonding type adhesive layer or a printing ink layer is used to bond together by heat can be used.

  The mirror surface decorative sheet may be provided with an adhesive layer for laminating each layer and a hard coat layer for increasing the surface hardness as a layer other than the above-described layers as necessary. Moreover, in order to improve the adhesiveness of each layer, easy adhesion processes, such as a corona treatment and a primer process, may be performed.

  As a preferable configuration example of the mirror surface decorative sheet, a configuration in which a decorative layer is provided on the surface to be laminated with the resin film layer of the transparent resin film and the resin film layer is laminated via an adhesive (FIG. 1), the configuration in FIG. A configuration in which a hard coat layer is provided on the surface layer of the transparent resin film (FIG. 2), a configuration in which the resin film layer in the configuration in FIG. 1 is composed of a plurality of resin films (FIG. 3), and the like can be exemplified.

[Base material]
The base material used for the mirror surface decorative board of the present invention is not particularly limited as long as it is a base material applicable to direct post-form processing, but a wood base material can be preferably used, plywood, particle board (PB), medium density fiber board ( MDF) can be preferably used. In particular, it is preferable to use MDF because the surface smoothness is high and high specularity is easily obtained.

[Mirror surface veneer]
The mirror surface decorative plate of the present invention is a mirror surface decorative plate in which the resin film layer side of the mirror surface decorative sheet and a base material are laminated, and at least one end portion thereof is subjected to curved processing by direct post-form processing. It is.

  The method for laminating the mirror surface decorative sheet and the base material is not particularly limited, and can be bonded using various adhesives. For the adhesive used for bonding, emulsion adhesives such as vinyl acetate resins and ethylene / vinyl acetate copolymer resins, solvent-based urethane resin adhesives, reactive hot-melt urethane adhesives, etc. can be used. However, from the viewpoint of surface smoothness, a reactive hot-melt urethane adhesive is preferable.

  There is no limitation on the adhesive coating method, and a sheet coating method using an extrusion type coating machine such as a die coater or a substrate coating method using a roll coater or the like can be used.

  The mirror surface decorative plate of the present invention is provided with curved surface processing at the end portion by cutting and bending at least one end portion of the decorative plate with a direct post-form processing machine. The mirror surface decorative plate may have any shape according to various uses, but as an interior material, a square shape such as a square or a rectangle is often used. At least one end of these decorative plates, if the shape is square, the curved surface processing provided on at least one side of the surrounding four sides is a decorative plate when only one side is curved, when two or more sides are processed, etc. A desired end portion is appropriately processed according to the location to which is applied.

  The curved surface processing provided at the end is preferably corner radius processing. The mirror surface decorative plate of the present invention can maintain suitable mirror surface properties even when the radius of curvature of the rounded process is small. The curvature radius is preferably 3 mm or less, more preferably 2 mm or less, and particularly preferably 1.5 mm or less.

The example of a suitable process process of the curved surface process by a direct post-form process is shown.
Cutting is performed leaving a part of the base material of the decorative sheet and the decorative sheet. At this time, in order to facilitate the bending process, the curved surface processing part is provided with a wedge processing part that leaves only the specular decorative sheet.

  An adhesive, preferably a hot melt adhesive, is used for the wedged portion and the end bonding surface. As the adhesive, an ethylene / vinyl acetate copolymer hot melt adhesive or a urethane resin reactive hot melt adhesive can be used.

  Thereafter, bending is performed along the cut shape. In this processing method, since the same type of base materials are bonded to each other at the side surface portion (the end surface) of the decorative plate end portion, sufficient adhesive strength can be obtained. Further, in the curved surface processed portion, only the mirror-finished decorative sheet is bent from the time of bending until the end of bending, so that unevenness (duck) derived from the wooden base material does not occur and curved surface processing with excellent design can be performed.

  The mirror surface decorative sheet of the present invention obtained above has a mirror surface decorative sheet 10 laminated on a base material 6 with an adhesive 5 interposed therebetween, and the rounded curved surface portion is cut leaving a remaining thickness t. The decorative sheet 10 is bonded to the substrate 6 through the adhesive 7. Then, the side surface portion (the end surface) of the edge portion of the decorative board subjected to the round processing has a configuration in which the remaining base material 6 ′ at the time of cutting is bonded to the base material 6 by the adhesive 7 (FIG. 5).

  At the time of direct post-form processing in the mirror surface decorative plate of the present invention, it is preferable that the cutting thickness of the decorative sheet to be bent has a remaining thickness of the decorative sheet of 100 to 500 μm.

  The mirror surface decorative plate of the present invention has high mirror surface properties even when a minute curved surface processing such as a corner radius is applied to the end portion, and thus can be suitably used for house interior materials such as kitchen and storage door materials. .

Example 1
A two-component curable urethane gravure ink for gravure printing was gravure-printed on one side of a transparent PET film having a thickness of 100 μm and a haze of 0.9% to form a decoration layer. After applying a polyurethane heat sealant on the decorative layer surface, 450-μm thick PET-G (1,4-cyclohexanedimethanol copolymer polyethylene terephthalate) is stacked on the heat sealant application surface, A mirror-finished decorative sheet having a total thickness of 550 μm was prepared by heat lamination (FIG. 1).

  A reactive hot-melt urethane adhesive is applied to a rectangular MDF substrate having a thickness of 18 mm × width of 945 mm (short side) × length of 1850 mm (long side) by a roll coater, and the mirror surface decorative sheet is applied to the application surface. The PET-G side was laminated and bonded together to obtain a mirror-coated decorative board (FIG. 4). The edge part of the two long sides of the obtained mirror surface decorative plate was rounded at the edge part of the mirror surface decorative plate using a direct post-form processing machine to obtain a mirror surface decorative plate subjected to the edge rounding process ( FIG. 5). The remaining thickness of the mirror surface decorative plate cutting part (remaining thickness of the decorative sheet) at the time of direct post-form processing was 400 μm, and the radius of curvature R of the rounded processing was 1.5 mm.

(Example 2)
In the same manner as in Example 1, except that an acrylic film having a thickness of 125 μm and a haze of 0.9% was used in place of the transparent PET film having a thickness of 100 μm and a haze of 0.9% as the transparent resin film. A mirror-finished decorative board was made.

(Example 3)
As a transparent resin film, a PET film having a thickness of 50 μm and a haze of 0.9% is used instead of a transparent PET film having a thickness of 100 μm and a haze of 0.9%, and a PET-G having a thickness of 450 μm is used as the resin film. Then, a mirror-finished decorative board subjected to rounded edge processing was prepared in the same manner as in Example 1 except that PET-G having a thickness of 350 μm was used.

(Comparative Example 1)
As a resin film, instead of PET-G having a thickness of 450 μm, PETG having a thickness of 60 μm was used, and a decorative sheet and a decorative board were prepared in the same manner as in Example 1 except that the R portion was left to have a thickness t of 130 μm. Created.

(Comparative Example 2)
The edge R is the same as in Example 1 except that a transparent PET film having a thickness of 100 μm and a haze of 0.9% was used instead of a transparent PET film having a thickness of 100 μm and a haze of 7.2%. A mirror-finished decorative board was made.

(Comparative Example 3)
A round process having a radius of curvature of 1.5 mm was formed at the ends of two long sides of a rectangular MDF base material having a thickness of 18 mm × width of 945 mm (short side) × length of 1850 mm (long side). Next, a reactive hot-melt urethane adhesive was applied to the PET-G surface of the mirror-finished decorative sheet obtained in the same manner as in Example 1, and the decorative plate was obtained by simultaneously laminating the surface and the mouth end surface by a laminating method. Created (FIG. 6).

(Comparative Example 4)
An MDF substrate was obtained in the same manner as in Comparative Example 3. Next, a solvent-based urethane resin adhesive was applied to the PET-G surface of the mirror-finished decorative sheet obtained in the same manner as in Example 1, and the decorative plate was prepared by simultaneously bonding the surface and the mouth end surface by a vacuum forming method. (FIG. 6).

  The following evaluation was performed about the decorative board of the said Example and the comparative example. The obtained results are shown in Table 1.

<Surface smoothness>
The decorative board was arrange | positioned on the desk, the distance from a fluorescent lamp to a decorative board was 1800 mm, and the image of the fluorescent lamp reflected on the decorative board surface was observed. The fluctuation of the image at this time was visually observed and evaluated according to the following criteria. In addition, surface smoothness (circle) or more was set as the pass.
◎: The image is reflected neatly and there is almost no fluctuation. ○: The outline of the image is not broken, but there is a slight fluctuation. △: The outline of the image is slightly broken and the fluctuation is conspicuous. ×: The outline of the image cannot be recognized.

<Transparency>
The degree of white turbidity on the decorative board surface was visually observed and evaluated according to the following criteria. In addition, the transparency (circle) or more was set as the pass.
○: not cloudy ×: cloudy

<Postform processing aptitude>
Lifting due to sheet repulsion during bending and cracking at the rounded portion were evaluated according to the following criteria. In addition, the workability ○ or more was regarded as acceptable.
○: Can be processed without problems.
X: The sheet is lifted or cracked due to repulsion and cannot be processed.

<Curved surface design>
Ducks and irregularities in the rounded portion and the side surface of the mouth end were visually observed and evaluated according to the following criteria. In addition, the curved surface design ○ or more is accepted.
◎: The curved surface portion is smooth and the smoothness of the lip portion is good. ○: The level difference between the curved surface portion and the lip of the lip portion can be confirmed slightly. : Cannot be evaluated because bending is not possible

  As shown in Table 1, the decorative plates of Examples 1 and 2 of the present invention obtained good results in surface smoothness, transparency, suitability for R processing, and R part design. In particular, the decorative board of Example 1 had the best balance and was excellent in balance, such as not affected by crazing.

  In Comparative Example 1, since the resin film was thin, the irregularities on the surface of the wooden substrate were reflected on the surface, resulting in poor surface smoothness. In Comparative Example 2, although the surface smoothness was good, since the haze value of the transparent resin film was high, the surface lacked transparency and the surface became cloudy. In Comparative Example 3, the sheet could not be processed due to strong sheet repulsion. In Comparative Example 4, good surface smoothness was not obtained, and in the R part, duck at the time of cutting the substrate was reflected on the surface, resulting in lack of design.

1. Transparent resin film Decorative layer Adhesive layer 4. Resin film layer 5. Adhesive layer 6. Base material layer 7. Adhesive layer (Kiguchi)
8). Adhesive layer (R part)
9. Hard coat layer 10. Mirror surface decorative sheet

Claims (3)

A mirror surface decorative plate provided with a mirror surface decorative sheet on a substrate,
The mirror surface decorative sheet is formed by laminating a transparent resin film having a thickness of 50 to 300 μm and a haze value of less than 1% and a resin film layer having a thickness of 200 to 900 μm via a decorative layer, and a total thickness of 400 to A specular decorative plate having a thickness of 1000 μm, wherein at least one end of the specular decorative plate is curved by direct post-form processing. The mirror surface decorative board according to claim 1, wherein the resin film layer is a layer made of a thermoplastic resin film. The mirror surface decorative board according to claim 1 or 2, wherein the curved surface processing is corner radius processing with a radius of 1.5 mm or less.

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