JP2021041542A - Resin laminate - Google Patents

Abstract

To provide a resin laminate which can suppress interlayer peeling.SOLUTION: A resin laminate 10 includes a surface material 1, a base material 3 and a decorative layer 2. The surface material 1 is formed of a transparent thermoplastic resin material. The base material 3 is formed of a resin material. The decorative layer 2 is arranged between the surface material 1 and the base material 3, and is formed by an inkjet printing method. The thickness of the surface material 1 is 0.1 mm or more and 3 mm or less. The thickness of the base material 3 is 1 mm or more and 5 mm or less. The elastic modulus of the base material 3 is larger than the elastic modulus of the surface material 1.SELECTED DRAWING: Figure 2

Description

The present invention relates to a resin laminate.

In recent years, many techniques for decorating building materials with ink have been developed (see, for example, Patent Document 1).

For example, Patent Document 1 discloses a patent relating to a decorative sheet in which a transparent resin layer and a surface protective layer are laminated in this order, and at least a backer layer is laminated on the back surface of the base sheet.

Further, for example, Patent Document 2 discloses a patent in which a convex portion is provided on one surface of a metal base material and a molten resin composition is injected onto the convex surface of the metal base material to mechanically exhibit an anchor effect. ing.

Japanese Unexamined Patent Publication No. 2016-64629 Japanese Unexamined Patent Publication No. 2009-51131

However, when the resin laminate is dimensionally changed by heat or water, peeling may occur between the layers when a shearing force in the direction perpendicular to the direction of the laminate is applied.

When a dimensional change occurs due to heat or water, the amount of the dimensional change is proportional to the size of the object. In a laminate of two types of materials with different linear expansion coefficients and dimensional change rates due to water absorption, assuming that one is a fixed end and the other is a self-end, the difference in the amount of dimensional change is the largest at the end on the free end side. It will increase and the largest shear force will be generated. The force is also generated at the bonding interface of the two materials.

An object of the present invention is to provide a resin laminate capable of suppressing peeling between layers.

In order to achieve the above object, the resin laminate according to the first invention includes a surface material, a base material, and a decorative layer. The surface material is made of a transparent resin material. The base material is made of a resin material. The decorative layer is arranged between the surface material and the base material and is formed by an inkjet printing method. The thickness of the surface material is 0.1 mm or more and 3 mm or less. The thickness of the base material is 1 mm or more and 5 mm or less. The elastic modulus of the base material is larger than the elastic modulus of the surface material.

By making the elastic modulus of the base material larger than the elastic modulus of the surface material in this way, the surface material follows the deformation of the base material even when the base material undergoes a dimensional change.

Therefore, peeling between the base material and the decorative layer or between the decorative layer and the surface material can be suppressed.

The resin laminate according to the second invention is the resin laminate according to the first invention, and the elastic modulus of the surface material is 1.5 GPa or less.

As a result, the surface material can be made to follow the dimensional change of the base material, and peeling between layers can be suppressed.

The resin laminate according to the third invention is the resin laminate according to the first invention, and the elastic modulus of the surface material is 1.0 GPa or less.

As a result, the surface material can be made to follow the dimensional change of the base material, and peeling between layers can be suppressed.

The resin laminate according to the fourth invention is the resin laminate according to the first invention, and the thickness of the decorative layer is 10 μm or more and 100 μm or less.

In this way, it is possible to suppress peeling of the decorative layer provided with a predetermined thickness from the surface material or the base material.

The resin laminate according to the fifth invention is the resin laminate according to the first invention, and the surface material is at least one selected from an acrylic resin, a polyolefin resin, a polycarbonate resin, or a polyester resin. It is made of a material containing.

Thereby, a transparent surface material having a predetermined elastic modulus can be formed.

According to the present invention, it is possible to provide a resin laminate capable of suppressing peeling between layers.

The perspective view of the resin laminate of embodiment which concerns on this invention. FIG. 3 is a cross-sectional view of the decorative panel of FIG. A partially enlarged view of FIG. A perspective view of the surface material of the resin laminate of FIG. 1 as viewed from the first surface side. A perspective view of the surface material of the decorative panel of FIG. 1 as viewed from the second surface side. FIG. 3 is a cross-sectional view of a surface material in the decorative panel of FIG. FIG. 3 is a perspective view of the base material in the decorative panel of FIG. 1 as viewed from the side on which the surface material is arranged. A perspective view of the base material in the decorative panel of FIG. 1 as viewed from the opposite side of FIG. 7. The flow chart which shows the manufacturing method of the resin laminate of embodiment which concerns on this invention. (A) (b) is a cross-sectional view for explaining the manufacturing method of the resin laminate of FIG. (A) (b) is a cross-sectional view for explaining the manufacturing method of the resin laminate of FIG. FIG. 9 is a cross-sectional view for explaining a method of manufacturing the resin laminate of FIG. The figure which shows the table of the result of Examples 1 to 3 and Comparative Example 1. FIG. 5 is a cross-sectional view of a resin laminate in a modified example of the embodiment according to the present invention.

Hereinafter, the resin laminate of the present invention will be described in detail with reference to the drawings.
<Structure>
(Overview of resin laminate)
FIG. 1 is a perspective view of the resin laminate 10 of the present embodiment. FIG. 2 is a cross-sectional view of the resin laminate 10 of the present embodiment. FIG. 3 is an enlarged view of part S in FIG.

Further, in the following description, the vertical direction coincides with the vertical direction in FIG. 2, but the direction is not limited to this, and the direction changes depending on the position where the resin laminate 10 is arranged.

The resin laminate 10 of the present embodiment is, for example, a tile, a panel, a sheet, or the like, and is used as a decorative or decorative panel, a decorative or decorative tile, a decorative or decorative sheet, or the like. Further, the resin laminate 100 may be used as a flooring material or the like.

The resin laminate 10 includes a surface material 1, a decorative layer 2, and a base material 3.

The surface material 1 is made of a transparent resin material. The base material 3 is made of a resin material. The decorative layer 2 is arranged between the surface material 1 and the base material 3. Note that FIG. 2 shows the stacking direction F.

(Surface material)
FIG. 4 is a perspective view of the surface material 1 as viewed from above. FIG. 5 is a perspective view of the surface material 1 as viewed from below. FIG. 6 is a cross-sectional view of the surface material 1.

The surface material 1 is not particularly limited as long as it is made of a transparent resin material, and it is more preferable that the surface material 1 is made of a highly transparent resin material.

The material of the surface material 1 is, for example, from acrylic resin such as acrylonitrile-styrene copolymer, polymethylmethacrylate resin, polyolefin resin such as polyethylene, polycarbonate resin, polyester resin such as polyethylene terephthalate, and polystyrene. It can be formed from a material containing at least one selected.

The surface material 1 has a plate-shaped main body portion 11 and a side wall portion 12. The main body 11 is formed in a rectangular shape. The side wall portion 12 is formed so as to be inclined from the peripheral edge of the main body portion 11 to the hem. The main body portion 11 and the side wall portion 12 are integrally formed. The surface material 1 has a first surface 1a (which can also be called an upper surface or a front surface) and a second surface 1b (which can also be said to be a lower surface or a back surface).

The second surface 1b of the surface material 1 includes an inner surface 11b (which can also be said to be a lower surface or a back surface) of the main body portion 11 and an inner wall surface 12b of the side wall portion 12.

A recess 1c surrounded by an inner surface 11b and an inner wall surface 12b is formed on the second surface 1b of the surface material 1. As shown in FIG. 6, the side wall portion 12 has an end surface 12e facing the base material 3.

The decorative layer 2, which will be described later, is provided on the inner surface 11b, the inner wall surface 12b, and the end surface 12e.
The thickness W1 of the surface material 1 is set to 0.1 mm or more and 3 mm or less, but the thickness W1 of the surface material 1 is preferably 0.1 mm or more and 1 mm or less.

Further, the elastic modulus of the surface material 1 is smaller than the elastic modulus of the base material 3. The elastic modulus of the surface material is preferably 1.5 GPa or less, more preferably 1.0 GPa or less.

For example, assuming an object having a length of 150 mm, a width of 10 mm, a thickness of 5 mm, and a longitudinal elastic modulus of 2.25 GPa, the force applied in the length direction when extended by 3 mm is calculated using Hooke's law. It becomes 1600N.

On the other hand, if the shape is the same and the longitudinal elastic modulus is 1 GPa, the force applied in the length direction is 710 N. By reducing the elastic modulus in this way, the force applied in the length direction becomes small.

Further, if the same length is the width and the thickness is halved to 2.5 mm, the force applied in the length direction is halved. In this way, the force applied in the length direction can be halved by reducing the thickness.

Further, by making the elastic modulus of the surface material 1 smaller than the elastic modulus of the base material 3, it is possible to relax the shearing force in the direction perpendicular to the stacking direction F within a certain section.

The surface material 1 can be produced by injection molding, press molding, vacuum forming, or the like.

(Decorative layer)
The decorative layer 2 is formed by various patterns, colors, and the like to decorate the resin laminate 10. As shown in FIGS. 2 and 3, the decorative layer 2 is formed on the second surface 1b (including the inner surface 11b and the inner wall surface 12b) and the end surface 12e of the surface material 1. The decoration by the decorative layer 2 can be visually recognized from the outside through the transparent surface material 1.

The decorative layer 2 can be printed on the second surface 1b of the surface material 1 in a non-contact manner by an inkjet printing machine. The decorative layer 2 is formed of ink that can be ejected by an inkjet printing machine.

In this case, printing may be performed directly on the second surface 1b and the end surface 12e of the surface material 1, or the second surface 1b and the end surface 12e of the surface material 1 are subjected to primer treatment or discharge treatment in order to improve the adhesiveness. You may print on. Further, these treatments may be performed on the decorative layer 2 after printing.

As the ink discharged by the inkjet printing machine, ink produced by a known technique is used. For example, a UV or EB curable ink containing a monomer as a main component and one or more of other additives such as an oligomer, a coloring material, a dispersant, a photopolymerization initiator, and a surfactant (cited by the Journal of the Imaging Society of Japan). Vol. 49, No. 5, UV Inkjet Curing Properties and Polymers, Vol. 34, November (1985) Electron beam-curing resin).

Alternatively, for example, permeation, evaporation, drying, acid polymerization drying, and thermosetting ink obtained by dissolving (or dispersing) a known colorant (dye or pigment) in a solvent (or dispersion medium) together with a binder resin. You may use it. These may be used in combination.

The decorative layer 2 is formed by printing on the second surface 1b and the end surface 12e of the surface material 1 by an inkjet printing machine.

The thickness W2 (see FIG. 3) of the decorative layer 2 is preferably set to 10 μm or more and 100 μm or less, and more preferably 10 μm or more and 40 μm or less.

(Base material)
FIG. 7 is a perspective view of only the base material 3 as viewed from above. FIG. 8 is a perspective view of the base material 3 as viewed from below.

As shown in the figure, the base material 3 supports the surface material 1. As shown in FIG. 3, the base material 3 is arranged on the surface 2b of the decorative layer 2 opposite to the surface 2a on the surface material 1 side.

The base material 3 is formed by insert molding on the surface 2b of the decorative layer 2.

The base material 3 has a base portion 31 and a convex portion 32. The base portion 31 is formed in the shape of a rectangular plate. The convex portion 32 has a rectangular shape and is formed on one surface (the surface or the upper surface on the surface material 1 side) of the base portion 31.

The convex portion 32 is formed in a shape that fits into the concave portion 1c of the surface material 1, and is formed in a trapezoidal shape in a cross-sectional view. The convex portion 32 has a surface 321 (upper surface) having the same shape as the inner surface 11b of the main body portion 11 of the surface material 1, and a side surface 322 extending downward from the surface 321 to the hem.

The side surface 322 is formed in the same shape as the inner wall surface 12b of the side wall portion 12 of the surface material 1, and in detail, is formed in the same shape as the decorative layer 2 formed on the surface of the inner wall surface 12b. A raised portion is formed on the resin laminate 10 by such a convex portion 32 and the concave portion 1c of the surface material 1.

Further, a groove-shaped concave portion 311 is formed on the surface of the base portion 31 around the convex portion 32. In the groove-shaped recess 311, an end portion 2e (see FIG. 2) formed on the end surface 12e of the side wall portion 12 of the surface material 1 of the decorative layer 2 is arranged.

The base material 3 is made of a resin material, and the resin material is not particularly limited, but for example, a material that is easily elastically deformed in order to absorb the impact received by the resin laminate 10 is preferable.

Such a material can be formed from at least one resin material selected from, for example, a vinyl chloride resin such as PVC, an olefin resin such as polyethylene, and a styrene resin such as ABS resin. Further, from the viewpoint of the adhesiveness of the decorative layer 2 with the ink, it is preferable that the decorative layer 2 is made of a polar resin material.

The thickness W3 of the base material 3 is set to 1 mm or more and 5 mm or less, but 2 mm or more and 5 mm or less is preferable.

<Manufacturing method of resin laminate>
Next, a method for manufacturing the resin laminate 10 of the present embodiment will be described.

FIG. 9 is a flow chart showing a method of manufacturing the resin laminate 10 of the present embodiment. 10 (a), 10 (b), 11 (a), 11 (b) and 12 are cross-sectional views for explaining a method of manufacturing the resin laminate 10.

First, in step S10, the surface material 1 as shown in FIGS. 4 to 6 is produced by injection molding, press molding, vacuum forming, or the like.

Next, in step S20, as shown in FIG. 10A, the ink 130 is ejected from the inkjet printing machine 120 to the second surface 1b and the end surface 12e of the surface material 1, and the ink is discharged to the second surface 1b and the end surface 12e. When applied, the decorative layer 2 is formed as shown in FIG. 10 (b).

Next, in step S30, the base material 3 is formed on the decorative layer 2 by insert molding.

Specifically, as shown in FIG. 11A, the surface material 1 and the decorative layer 2 are arranged in the mold 200. The mold 200 has a first mold 201 and a second mold 202.

The first mold 201 is formed with a gate 210 for injecting a resin material into the mold. The surface material 1 and the decorative layer 2 are arranged on the second mold 202. In this embodiment, two gates 210 are formed.

As shown in FIG. 11B, after the surface material 1 and the decorative layer 2 are arranged in the second mold 202, the first mold 201 and the second mold 202 are closed. After that, the resin material is ejected from the gate 210 into the mold 200, and the base material 3 is formed as shown in FIG. Then, the created resin laminate 10 is taken out from the mold 200.

<Example>
Next, the resin laminate 10 of the present embodiment will be described with reference to Examples.

The resin laminate in which the elastic modulus of the surface material was changed was immersed in water to verify the occurrence of peeling between the surface material and the decorative layer or between the decorative layer and the base material.

In both Examples 1 to 3 and Comparative Example 1, a decorative layer was formed using ink.
The base materials used in Examples 1 to 3 and Comparative Example 1 had a thickness of 2 mm and an elastic modulus of 2.3 GPa, and were formed of AES (acrylonitrile / ethylene-propylene-diene / styrene) resin. Used.

The surface materials used in Examples 1 to 3 and Comparative Example 1 are both made of PMMA (Polymethylcrylic) resin, are transparent, and have a thickness of 0.5 mm, but each has an elastic modulus. The rates are different. The elastic modulus of the surface material of Example 1 is 0.5 GPa, the elastic modulus of the surface material of Example 2 is 0.9 GPa, and the elastic modulus of the surface material of Example 3 is 1.5 GPa. The elastic modulus of the surface material of Comparative Example 1 is 3.3 GPa.

In Examples 1 and 2, there was no initial peeling, and peeling occurred on the 14th day after the resin laminate was immersed in water. The peeling site occurred between the decorative layer and the base material (indicated as C in FIG. 13).

In Example 3, there was no initial peeling, and peeling occurred on the 7th day after the resin laminate was immersed in water, and the location where the peeling occurred could not be determined.

In Comparative Example 1, there was an initial peeling, and the peeling portion was between the surface material and the decorative layer (indicated as A in FIG. 13).

As described above, when the elastic modulus of the base material is larger than the elastic modulus of the surface material, initial peeling does not occur and the result of immersion in water can be secured for 7 days or more.

<Other embodiments>
Although the embodiment of the resin laminate and the method for producing the resin laminate according to the present invention has been described above, the present invention is not limited to the above embodiment and is appropriately modified without departing from the spirit of the present invention. It is possible.

(A)
In the above embodiment, the side wall portion 12 is formed on the surface material 1, but the side wall portion may not be provided and the surface material 1 may be plate-shaped. In this case, the decorative panel may not have a raised center. FIG. 14 is a cross-sectional view showing a resin laminate 20 that is not raised.

As shown in FIG. 14, the resin laminate 20 has a surface material 21, a decorative layer 22, and a base material 23. The surface material 21 has a plate shape and is not provided with a recess 1c as compared with the surface material 1.

Further, the decorative layer 22 is formed over the entire surface of the surface material 21 on the base material 23 side of both sides. The base material 23 is formed in a plate shape, and is not provided with a convex portion 32 or the like as compared with the base material 23.

(B)
In the above embodiment, the decorative layer 2 is also formed on the end surface 12e of the side wall portion 12, but the decorative layer 2 is not formed on the end surface 12e, and the decorative layer 2 is formed on the inner surface 11b and the inner wall surface 12b. It may be formed.

(C)
In the above embodiment, the base material 3 is in direct contact with the decorative layer 2, but in order to suppress peeling between the decorative layer 2 and the base material 3, an adhesive layer is formed between the decorative layer 2 and the base material 3. May be provided.

(D)
In the above embodiment, the two gates 210 are formed, but the location is not limited to the two, and the location is not limited to the location shown in FIG. 11B.

(E)
Further, it is possible to replace the constituent elements in the above-described embodiment with well-known constituent elements as appropriate without departing from the spirit of the present invention.

The resin laminate of the present invention has an effect of suppressing peeling between layers, and is useful as a decorative tile, a decorative panel, a decorative tile, a decorative panel, and the like.

1: Surface material 2: Decorative layer 3: Base material 10: Resin laminate

Claims (5)

A surface material made of a transparent resin material and
A base material formed of a resin material and
A decorative layer disposed between the surface material and the base material and formed by an inkjet printing method is provided.
The thickness of the surface material is 0.1 mm or more and 3 mm or less.
The thickness of the base material is 1 mm or more and 5 mm or less.
The elastic modulus of the base material is larger than the elastic modulus of the surface material.
Resin laminate. The elastic modulus of the surface material is 1.5 GPa or less.
The resin laminate according to claim 1. The elastic modulus of the surface material is 1.0 GPa or less.
The resin laminate according to claim 1. The thickness of the decorative layer is 10 μm or more and 100 μm or less.
The resin laminate according to claim 1. The resin laminate according to claim 1, wherein the surface material is formed of a material containing at least one selected from an acrylic resin, a polyolefin resin, a polycarbonate resin, and a polyester resin.

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