JP2022144460A - Decorative sheet - Google Patents

Abstract

To provide a technique capable of improving a quality when applying a decorative sheet to a curved surface part.SOLUTION: A decorative sheet 1A (decorative board) includes a metal layer 10, an adhesive layer (A) 20 laminated on the metal layer 10, a film layer 30 laminated on the adhesive layer (A) 20, and a coat layer 40 containing a melamine resin laminated on the film layer 30.SELECTED DRAWING: Figure 1

Description

The present invention relates to decorative laminates.

2. Description of the Related Art Decorative sheets (also referred to as "decorative boards") are sometimes applied to improve the design of walls in the interior construction of railway trains and buses, and the construction of interior walls and exteriors of houses and buildings. The surface of the decorative sheet is imparted with scratch resistance and antifouling properties.

Decorative sheets have conventionally been produced by molding using a press machine. Due to the characteristics of the press machine, the maximum length of the decorative sheet is limited to 10 shaku (3 m), and the surface to be applied is limited to a flat surface, making it difficult to apply (apply to a curved surface) to a curved surface. In recent years, decorative sheets that can be applied to curved surfaces have also been developed, but the radius of curvature that can be applied is large, and the application surface has been limited.
In Patent Document 1, a metal-based melamine resin is used as an interior material for vehicles such as railway trains and buses, in which a surface layer made of melamine resin-impregnated paper and a plurality of thin metal plates are arranged in the lowest layer and intermediate layer in the decorative board structure. A decorative board is disclosed.

Japanese Patent Application Laid-Open No. 2002-137327

However, in the technique disclosed in Patent Document 1, there is room for improvement in applying the decorative sheet to the curved surface portion. In particular, the interior of railway trains has many curved surfaces due to the characteristics of passenger car structures, and there are issues such as the small radius of curvature required during construction.

According to the invention, a metal layer and
an adhesive layer (A) laminated on the metal layer;
a film layer laminated on the adhesive layer (A);
a coat layer containing a melamine resin laminated on the film layer;
A decorative laminate is provided.

ADVANTAGE OF THE INVENTION According to this invention, the quality at the time of applying a decorative sheet to a curved-surface part can be improved.

1 is a schematic cross-sectional view of a decorative sheet according to a first embodiment; FIG. It is a figure which compares and explains the application method of the conventional decorative sheet and the application method of a new decorative sheet which concern on 1st Embodiment. BRIEF DESCRIPTION OF THE DRAWINGS It is a schematic process flow figure which shows the manufacturing method of the decorative sheet which concerns on 1st Embodiment. FIG. 5 is a schematic cross-sectional view of a decorative sheet according to a second embodiment; FIG. 4 is a schematic process flow diagram showing a method for manufacturing a decorative sheet according to a second embodiment; FIG. 11 is a schematic cross-sectional view of a decorative sheet according to a third embodiment; FIG. 11 is a schematic cross-sectional view of a decorative sheet according to a fourth embodiment; FIG. 11 is a schematic cross-sectional view of a decorative sheet according to a fifth embodiment;

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of the present invention will be described with reference to the drawings. In addition, in all the drawings, the same constituent elements are denoted by the same reference numerals, and the description thereof will be omitted as appropriate. In addition, "~" represents "more than" to "less than" unless otherwise specified.
In the following embodiments, first, the basic configuration of the decorative sheet will be described in the first embodiment. More specific configurations of the decorative sheet (especially variations of the configuration of the film layers) will be described in the second to fifth embodiments.

<<First embodiment>>
<Overview of decorative sheet>
FIG. 1 shows a schematic cross-sectional view of the decorative material sheet of this embodiment. The decorative sheet 1A is used for interiors of railway trains, interior walls and exteriors of houses, buildings, and the like. The decorative sheet 1A is used with a design attached as necessary. A decorative sheet 1A is obtained by manufacturing a long strip-shaped decorative sheet and cutting it into a predetermined length in the final step. In addition, the long strip-shaped decorative sheet may be provided to the market as a roll without being cut.

As illustrated, the decorative sheet 1A includes a metal layer 10, an adhesive layer 20, a film layer 30, and a coat layer 40 in this order.
Each layer constituting the decorative sheet 1A will be described below.

(metal layer 10)
The metal layer 10 is made of a metal material such as a metal compound, and functions as a so-called core material and a masking layer. More specifically, aluminum (including aluminum alloy), stainless steel, and steel plate can be preferably used as the metal layer 10 . The metal layer 10 can hide the construction surface located from the front side to the back side.

When the metal layer 10 is viewed from the coat layer 40 side, the metal layer 10 can be combined with the film layer 30 (to be described later) to allow the pattern of the metal layer 10 itself to be visually recognized or to have a desired color.

By including the metal material component in the metal layer 10 in this manner, heat resistance and fire resistance can be achieved.

The thickness of the metal layer 10 can be appropriately set depending on the required flexibility (flexibility). It is about 1 mm (0.8 mm).

A product α·t (mm·GPa) of the elastic modulus α (Young's modulus) of the metal forming the metal layer 10 and the thickness t of the metal layer 10 is 30 mm·GPa or more and 400 mm·GPa or less. The lower limit of the product α·t is preferably 40 mm·GPa or more, more preferably 50 mm·GPa or more. The upper limit is preferably 270 mm·GPa or less, more preferably 250 mm·GPa or less. By setting the product α·t (mm·GPa) within the above range, the balance between the strength and flexibility of the decorative sheet 1A can be ensured, and good workability and work quality can be achieved.

For example, the elastic modulus α of aluminum is 70.3 GPa, and if the thickness t is 1 to 3 mm, the product α·t is 70.3 to 210.9 mm·GPa. The elastic modulus α of stainless steel (SUS430) is 200, and if the thickness t is 0.5 to 1 mm, the product α·t is 100 to 200 mm·GPa. In either case, the product α·t (mm·GPa) satisfies a suitable range (30 mm·GPa or more and 300 mm·GPa or less).

(Adhesive layer (A) 20)
Examples of the adhesive layer (A) 20 include thermoplastic polyimide adhesives such as acrylic adhesives, urethane adhesives, silicone adhesives, polyimides, polyimide amides, polyimide amide ethers, polyester imides, polyimide ethers, etc. Hot-melt adhesives (polyester-based, modified olefin-based), polyvinyl acetate (VA), polyethylene vinyl acetate (EVA)-based adhesives, and the like are included.

(Film layer 30)
The film layer 30 is made of a resin material such as a transparent or opaque thermoplastic resin or a curable resin material. Specifically, the resin material includes polyethylene, polypropylene, ethylene-propylene copolymer, polyolefin such as ethylene-vinyl acetate copolymer (EVA), cyclic polyolefin (COP), modified polyolefin, polyvinyl chloride, and polyvinylidene chloride. , Polystyrene, Polyamide (e.g. Nylon 6, Nylon 46, Nylon 66, Nylon 610, Nylon 612, Nylon 11, Nylon 12, Nylon 6-12, Nylon 6-66), Polyimide, Polyamideimide, Polycarbonate (PC), Poly -(4-methylpentene-1), ionomer, acrylic resin, polymethyl methacrylate, acrylonitrile-butadiene-styrene copolymer (ABS resin), acrylonitrile-styrene copolymer (AS resin), butadiene-styrene copolymer , polyoxymethylene, polyvinyl alcohol (PVA), ethylene-vinyl alcohol copolymer (EVOH), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polycyclohexane terephthalate (PCT) polyester, polyether, polyether Ketone (PEK), polyetheretherketone (PEEK), polyetherimide, polyacetal (POM), polyphenylene oxide, modified polyphenylene oxide, polysulfone, polyethersulfone, polyphenylene sulfide, polyarylate, aromatic polyester (liquid crystal polymer), Polytetrafluoroethylene, polyvinylidene fluoride, other fluorine resins, styrene, polyolefin, polyvinyl chloride, polyurethane, polyester, polyamide, polybutadiene, trans-polyisoprene, fluororubber, chlorinated polyethylene Various thermoplastic elastomers such as epoxy resins, phenolic resins, urea resins, melamine resins, unsaturated polyesters, silicone resins, urethane resins, poly-para-xylylene, polymonochloroparaxylylene (poly -monochloro-para-xylylene), poly-dichloro-para-xylylene, poly-monofluoro-para-xylylene, poly-monoethyl-para-xylylene par a-xylylene) and other polyparaxylylene resins, copolymers, blends, and polymer alloys mainly composed of these, and at least one selected from these can be included. In this embodiment, a polyvinyl chloride film or a polyethylene terephthalate film is preferred.

The thickness of the film layer 30 is approximately 10 μm to 300 μm. As a result, it is possible to make the decorative sheet 1A thin while ensuring good workability, durability, reliability, and the like. For example, if the thickness of the film layer 30 is too small, the inner layer (for example, the metal layer 10 such as aluminum) is likely to be exposed when receiving an impact. exposure can be greatly suppressed. In addition, since the metal layer 10 is harder than the film layer 30, the thinner the film layer 30, the better the scratch resistance. In addition, since the metal layer 10 is nonflammable, it is preferable that the film layer 30 is thin in terms of achieving good nonflammability.
Further, if the thickness of the film layer 30 is too large, it becomes difficult to reduce the thickness of the decorative sheet 1A, and the workability of the decorative sheet 1 is deteriorated.
By setting the thickness of the film layer 30 within the above range, the above characteristics can be achieved in a well-balanced manner.

In addition, the film layer 30 may contain one or more selected from the group consisting of silver, copper, titanium, or metal ions of these metals as an antibacterial agent or antiviral agent.

(Coating layer 40)
The coat layer 40 is made of a hard resin material containing a thermosetting resin or a thermoplastic resin, and has functions such as good scratch resistance and stain resistance (stain resistance). Moreover, the hard resin material forming the coat layer 40 generally has high transparency. Therefore, the light reflected by the film layer 30 and the metal layer 10 is preferably transmitted. Thereby, the transmitted light can be visually recognized by an observer, and the decorative sheet 1A having excellent aesthetics can be realized.

The layer thickness of the coat layer 40 can be 20 μm or less, preferably 10 μm or less. The lower limit of the layer thickness of the coat layer 40 is, for example, 1 μm or more, preferably 5 μm or more.

Examples of the resin constituting the coat layer 40 include the resins exemplified for the film layer 30, and melamine resin is preferable.

A melamine resin is a resin containing a melamine compound and an aldehyde compound as constituent components. A melamine compound is a compound having a 1,3,5-triazine skeleton, in which three amino groups are introduced into the triazine ring. Formaldehyde is particularly preferred as the aldehyde compound. The hardness of the decorative sheet 1A can be further improved, and the melamine-based resin constituting the decorative sheet 1A can be synthesized more efficiently.

Among various hard resin materials, melamine resin has a particularly high surface hardness, is particularly excellent in scratch resistance and stain resistance (difficulty in adhesion of dirt), and enhances the aesthetics and durability of the decorative sheet 1. contribute to improvement.

Coat layer 40, like film layer 30, may contain one or more selected from the group consisting of silver, copper, titanium, or metal ions of these metals as an antibacterial or antiviral agent.

The coat layer 40 may be embossed on its surface. By having embossing, it is difficult for fingerprints and the like to adhere, and the antifouling effect can be improved.

Alternatively, the coat layer 40 may contain a matting filler, and the surface thereof may be provided with projections following the shape of the matting filler. By providing the coating layer 40 having the convex portions, the luster is suppressed, the aesthetics are excellent, and fingerprints and the like are difficult to adhere, and the antifouling effect is also excellent.

The average particle diameter of the matte filler is preferably larger than the average film thickness of the coat layer 40 (12 μm or less). The matte filler has an average particle size of 3 μm to 100 μm, preferably 5 to 70 μm, more preferably 5 to 50 μm.

The surface roughness (arithmetic mean height (μm) Sa) of the surface of the coat layer 40 is 0.1 to 10 μm, preferably 0.2 to 7 μm, more preferably 0.5 to 5 μm. If the surface roughness of the surface of the coat layer 40 is within the above range, it is possible to provide a decorative sheet having an excellent surface luster suppressing effect and an antifouling effect.

Furthermore, in the decorative sheet 10 of the present embodiment, the ratio of the area of the matte filler to the area (100%) of the surface of the coat layer 40 (area occupied by the matte filler ratio) is 5 to 60%, preferably 10 to 50%, more preferably 15 to 40%. If the area ratio of the matting filler is within the above range, it is possible to provide a decorative sheet which is excellent in the effect of suppressing surface luster and the antifouling effect.

The area ratio of the matte filler can be obtained by binarizing the image of the surface of the coat layer 40 obtained by a laser microscope and calculating the area ratio of the matte filler in the coat layer 40 (100%).

The matting filler contains at least one selected from acrylic resins, melamine resins and silica. Examples of the matting filler include acrylic resin particles, melamine resin particles, polystyrene resin particles, silica particles, composite particles of these resins and silica, and the like. Considering the visibility of the printed layer, it is preferable to contain an acrylic resin or a melamine resin.

Examples of matting fillers include Metabrene (acrylic resin particles, manufactured by Mitsubishi Chemical Corporation), Tuftic (acrylic resin particles, manufactured by Toyobo), Techpolymer (acrylic resin particles, manufactured by Sekisui Plastics Co., Ltd.), Techpolymer (polystyrene resin particles , manufactured by Sekisui Plastics Co., Ltd.), silica particles (manufactured by Denka), Optobeads (manufactured by Nissan Chemical Industries, Ltd., melamine resin/silica composite particles), Eposter (melamine resin particles, manufactured by Nippon Shokubai Co., Ltd.), etc. can be done.

If the refractive index of the matte filler is significantly different from the refractive index of the resin layer constituting the coat layer 40 (the portion of the coat layer 40 other than the matte filler), the transparency of the coat layer 40 is reduced. The matting effect of the coat layer 40 is not sufficiently exhibited, and the design of the appearance is deteriorated. Therefore, from the viewpoint of improving the design of the appearance, it is preferable to use a matte filler made of a transparent material having a refractive index difference of 0.2 or less with respect to the resin forming the coat layer 40 .

The refractive index of the resin constituting the coating layer 40 is about 1.4 to 1.7, and the preferably used melamine resin is about 1.6. ~1.8.

The difference between the linear expansion coefficient of the resin forming the coat layer 40 and the linear expansion coefficient of the matting filler is 5×10 ⁻⁵ /° C. or less. Within this range, the difference in degree of expansion and contraction between the matting filler and the resin constituting the coat layer 40 due to temperature changes is small, and the plurality of protrusions of the coat layer 40 can be maintained, which in turn has the effect of suppressing luster. An antifouling effect can be stably obtained.

In the present embodiment, the coat layer 40 is a combination in which the base resin is a melamine resin and the resin contained in the matting filler is an acrylic resin, or the base resin is a thermoplastic resin and the resin contained in the matting filler. is preferably a melamine resin.

<Construction method of decorative sheet 1A>
A method of applying the decorative sheet 1 will be briefly described.
Here, regarding the construction of the interior (floor, ceiling, wall surface) of railway vehicles and bus vehicles, referring to FIG. We will compare and explain the construction method (new construction) that becomes possible by using . FIG. 2(a) is a diagram explaining a conventional construction method, and FIG. 2(b) is a diagram explaining a construction method according to this embodiment.

As shown in FIG. 2(a), in construction using a conventional decorative sheet, the decorative sheet is divided into a plurality of parts in order to correspond to the portion having a shape that cannot be folded. (pressing surface member) was required, and a large number of separate members were required. In addition, there are restrictions on the design due to the inability to bend outward, and it was necessary to consider the characteristic that the top of the decorative sheet cannot be bent outward when designing the vehicle. Furthermore, in the construction of the end portion of the decorative sheet, it was not possible to carry out winding construction, and warping was likely to occur at this portion, and other members such as a pressing surface member were required.

On the other hand, the decorative sheet 1 of the present embodiment has characteristics in which strength and flexibility are well balanced, and can be bent outward. Therefore, for example, even if there is a concave shape as a structure for attaching a lighting device, the decorative sheet 1 can be easily applied to the inside of the concave shape by bending appropriately. In addition, since warping or the like is prevented from occurring at the ends, other members such as pressing surface members are not required. Moreover, even if the wall surface has an outwardly curved shape, the decorative sheet 1 can be applied without causing wrinkles or cracks. In addition, members such as screws are required to attach the pressing surface member, and the installation position is sometimes limited in consideration of the contact of passengers with it. Also from this point of view, the degree of freedom in design is improved.

<Method for manufacturing decorative sheet 1A>
(Process Overview)
In the following manufacturing method, an example using aluminum as the metal layer 10 will be described with reference to FIG.

The manufacturing process of the decorative sheet 1 includes a surface film manufacturing process S10 for manufacturing a surface film by laminating the film layer 30 and the coat layer 40, an AL bonding process S20 for providing an adhesive layer (A) 20 on the metal layer 10, and a surface It has a surface film bonding step S30 for bonding the surface fill manufactured in the film manufacturing step S10 and the metal layer 10 provided with the adhesive layer (A) 20 in the AL bonding step S20. These steps (S10, S20, S30) are performed as continuous steps, and further downstream, the masking step S40 and the cutting step S50 can be performed continuously with the above steps (S10, S20, S30).

(Surface film manufacturing step S10)
In the surface film manufacturing step S10, first, a transparent film (material for the film layer 30) is supplied from a long transparent film roll, and a printing layer and a concealing layer (colored layer) are formed as necessary. . The configuration of the decorative sheet having a printed layer and a concealing layer (colored layer) will be described in second to fifth embodiments. A method for manufacturing a decorative sheet having a printed layer will be described in a second embodiment.

A coat layer 40 having a predetermined thickness is formed on one surface of a transparent film (material of the film layer 30). Specifically, a coating liquid containing a thermosetting resin or a thermoplastic resin is prepared (coating liquid preparation step), and this coating liquid is applied to one surface of a transparent film (material of the film layer 30) to a predetermined thickness. (coating layer applying step), and then cured by drying (drying treatment step).

Various methods can be used as the coating method, and specific examples include die coating, lip coating, gravure coating, ink jet, spin coating, bar coating, roll coating, and wire bar coating. method, dip coating method, and the like. The film layer 30 is continuously supplied from the long roll, and the coating liquid coating and curing steps are continuously performed to obtain the first laminate (the film layer 30 laminated with the coat layer 40). be done.

(AL bonding step S20)
In the AL bonding step S20, the metal layer 10 (AL base material) is supplied from the wound body of the metal layer 10 made of aluminum, and pretreatment S21 is performed to provide an adhesive layer (A) 20 on one surface of the metal layer 10. Then, the metal layer 10 to which the adhesive layer (A) 20 is applied is heat-treated S23.

(Surface film joining step S30, masking step S40 and cutting step S50)
In the surface film bonding step S30, the adhesive layer (A) 20 manufactured in the AL bonding step S20 is applied to the first laminate (the film layer 30 laminated with the coat layer 40) manufactured in the surface film manufacturing step S10. The metal layers 10 thus formed are joined. At this time, the adhesive layer (A) 20 is bonded to the film layer 30 .

As a result, a long decorative sheet 1A is manufactured, and then in a masking step S40, the coat layer 40 of the decorative sheet 1 is masked, and in a cutting step S50, the decorative sheet 1 is cut into a predetermined length.

<Summary of Features of Decorative Sheet 1A>
As described above, the features (effects) of the present embodiment are summarized as follows.
(1) Decorative sheet 1A (decorative board)
a metal layer 10;
an adhesive layer (A) 20 laminated on the metal layer 10;
a film layer 30 laminated on the adhesive layer (A) 20;
a coat layer 40 containing a melamine resin laminated on the film layer 30;
have
According to the decorative sheet 1A, a balance between strength and flexibility can be ensured, and good workability and work quality can be realized. Moreover, since the metal layer 10 functions as a core material, good nonflammability (fire resistance) can be ensured. In particular, as in the case of the interior of a train car, there are many curved surfaces, etc., and even when the construction conditions are severe, it is possible to deal with it. Specifically, conventional decorative sheets often cannot be folded, and in particular, have problems such as being unable to be bent outwards or being unable to be rolled up. In addition, there is also the problem that warping is likely to occur, and that a stamping surface member or the like for pushing the warp is required separately. However, according to the present embodiment, the above-described problems are solved, the outer bending is possible, the restrictions on construction are greatly eased, and the degree of freedom in design is increased. In addition, it is possible to realize construction that does not require a pressing surface, and it is possible to reduce the number of parts, improve maintainability, and improve design.

(2) The thickness T of the coat layer 40 is 1 μm or more and 20 μm or less.
By setting the thickness T of the coat layer 40 within the above range, the strength and flexibility of the decorative sheet 1 can be well balanced.

(3) The product α·t of the elastic modulus α of the metal forming the metal layer 10 and the thickness t of the metal layer 10 is 30 mm·GPa or more and 400 mm·GPa or less.
By setting the thickness T of the metal layer 100 within the above range, the strength and flexibility of the decorative sheet 1 can be well balanced.

(4) The decorative sheet 1 does not cause wrinkles or cracks in the coat layer 40 when bent 90 degrees. Flexibility of construction and restrictions on design can be greatly relaxed.

<<Second Embodiment>>
<Overview of Decorative Sheet 1B>
The configuration of the decorative sheet 1B will be described with reference to the cross-sectional structure of FIG. The decorative sheet 1B of the present embodiment shows the film layer 30 of the decorative sheet 1A of the first embodiment as a plurality of layers, and the difference from the first embodiment (that is, the film layer 30B) will be noted below. , and the description of the same configuration will be omitted as appropriate.

As shown in FIG. 4, the decorative sheet 1B includes a metal layer 10, an adhesive layer 20, a film layer 30B, and a coat layer 40 in this order.
Each layer constituting the film layer 30B of the decorative sheet 1B will be described below.

<Film layer 30B>
The film layer 30B has a colored layer 31, an adhesive layer (C) 34, a printed layer 35, a receiving layer 36, and a transparent layer 37 from the metal layer 10 (adhesive layer (A) 20) side.

(Colored layer 31)
The colored layer 31 is a layer that is bonded to the adhesive layer (A) 20 and can hide the surface of the metal layer 10 so that the metal layer 10 is not visible from the resin coat layer 18 side. When viewed from the coat layer 40 side, the colored layer 31 can improve the visibility of the pattern of the printed layer 35 and change the color by combining with the printed layer 35 described later.
Examples of the constituent material of the colored layer 31 include the materials exemplified for the film layer 30 of the first embodiment, specifically, resin materials, metal materials, metal compounds such as metal oxides, and the like.

(Adhesive layer (C) 34)
The adhesive layer (C) 34 is a layer for closely bonding the colored layer 31 and the printed layer 35, and the same material as the adhesive layer (A) 20 can be used.

(Print layer 35)
The print layer 35 has various patterns such as a wood grain pattern, a stone pattern, and a geometric pattern, and the patterns are visually recognized when the user views the printed layer 35 from the coat layer 40 side.

The print layer 35 can contain a resin and a colorant such as a pigment or a dye, and various patterns are formed by the colorant. Examples of the resin contained in the print layer 35 include the resins exemplified for the film layer 30 . The layer thickness of the print layer 35 is about 1 μm to 10 μm as a whole.

(Receiving layer 36)
The receiving layer 36 (ink receiving layer) functions as a base for the printing layer 35 . The receiving layer 36 preferably allows the ink used for forming the printing layer 35 to penetrate inside and improves the adhesion between the printing layer 35 and the transparent layer 37 .

Although the material of the receiving layer 36 is not particularly limited, for example, various resin materials such as various thermoplastic resins and cured products of curable resin materials can be suitably used. As a specific example of the resin material forming the receiving layer 36, the same material as the film layer 30 described above can be used.

The thickness of the receiving layer 36 is not particularly limited, but by setting it to 20 nm or more and 50 μm or less, it is possible to achieve a good balance between thinning of the decorative sheet 1 and ink permeability.

(Transparent layer 37)
The transparent layer 37 is composed of a material containing polyethylene terephthalate. Stability against bending external force, etc., and ease of handling are further improved.

According to the decorative sheet 1B having such a configuration, construction similar to that of the first embodiment is possible. In addition, since the printed layer 35 is provided, it is possible to further improve the design in the application of the decorative sheet 1B.

<Method for manufacturing decorative sheet 1B>
A method for manufacturing the decorative sheet 1B will be described with reference to FIG. The manufacturing method of the decorative sheet 1B is the manufacturing method of the decorative sheet 1A of the first embodiment, in which the surface film manufacturing step S10 is replaced with a method of manufacturing the film layer 30B composed of a plurality of layers (surface film manufacturing step S10B). It is.

(Surface film manufacturing step S10B)
In the surface film manufacturing step S10B, first, a transparent film (transparent layer 37) is supplied from a roll of a long transparent film, and the receiving layer 36 and the printing layer 35 are formed. As a method for forming the print layer 35, for example, gravure printing, inkjet printing, offset printing, or the like can be used.

Subsequently, an adhesive layer (C) 34 is applied to the print layer 35 side (adhesive applying process S11). Further, the coat layer 40 is formed with a predetermined thickness on the surface of the transparent layer 37 opposite to the side of the printed layer 35 (coat layer imparting process S12). Next, it is cured by a drying process (drying process step S13).
As a result, a first laminate in which the adhesive layer (C) 34, the print layer 35, the receiving layer 36 and the transparent layer 37 are laminated is obtained.

Next, a colored layer 31 (concealing base material) is separately prepared and laminated on the surface of the printed layer 35 (adhesive layer (C) 34) of the first laminate obtained in the previous step (lamination processing S40), The obtained second laminate is supplied to the surface film joining step S30.

In the surface film bonding step S30, the metal layer 10 provided with the adhesive layer (A) 20 supplied by the same treatment as in the AL bonding step S20 of the first embodiment and the surface film manufacturing step (S10B) obtained in the The second laminate is joined. At this time, the adhesive layer (A) 20 is bonded to the colored layer 31 of the film layer 30B.

As a result, a long decorative sheet 1B is manufactured, and then in a masking step S40, the coat layer 40 of the decorative sheet 1 is masked, and in a cutting step S50, the decorative sheet 1 is cut into a predetermined length.

Also in the method for manufacturing the decorative sheet 1B, all the steps can be realized by continuous steps as in the first embodiment.

<<Third Embodiment>>
<Overview of decorative sheet>
The configuration of the decorative sheet 1C will be described with reference to the cross-sectional structure of FIG. The decorative sheet 1C of this embodiment has a film layer 30C in which a metal deposition layer 33C is provided between the colored layer 31 and the adhesive layer (C) 34 shown in the film layer 30B of the decorative sheet 1B of the second embodiment. It is configured. The following description focuses on the differences from the first and second embodiments (that is, the metal deposition layer 33C of the film layer 30C), and the description of the same configurations is omitted as appropriate.

As shown in FIG. 6, the decorative sheet 1C includes a metal layer 10, an adhesive layer 20, a film layer 30C, and a coat layer 40 in this order.
Each layer constituting the film layer 30C of the decorative sheet 1C will be described below.

<Film layer 30C>
The film layer 30C includes, from the metal layer 10 (adhesive layer (A) 20) side, a colored layer 31, a metal deposited layer 33C, an adhesive layer (C) 34, a printed layer 35, a receiving layer 36, and a transparent layer. 37.

The metal deposition layer 33C is a layer in which aluminum oxide, silicon oxide, silicon nitride, or silicon oxynitride is deposited on the colored layer 31 . By having the metal deposition layer 33C, the decorative sheet 1C can have a metallic design. Other features are the same as those of the first and second embodiments. In the case where the metal vapor deposition layer 33C is provided on the entire surface of the colored layer 31, the color tone exhibited by the colored layer 31 is not necessary, so a layer that simply functions as a base material instead of the colored layer 31 may be used. good.

As for the manufacturing method, in the manufacturing method of the second embodiment (FIG. 5), the metal vapor deposition layer 33C is supplied to the surface film manufacturing process as the colored layer 31 vapor-deposited.

<<Fourth Embodiment>>
<Overview of Decorative Sheet 1D>
The configuration of the decorative sheet 1D will be described with reference to the cross-sectional structure of FIG. The decorative sheet 1D of the present embodiment has a metal foil layer 33D through an adhesive layer (B) 32 instead of the metal vapor deposition layer 33C shown in the film layer 30C of the decorative sheet 1C of the third embodiment. The configuration is set to The following description focuses on the differences from the third embodiment (that is, the metal foil layer 33D of the film layer 30D), and the description of the same configurations is omitted as appropriate.

As shown in FIG. 7, decorative sheet 1D includes metal layer 10, adhesive layer 20, film layer 30D, and coat layer 40 in this order.
Each layer constituting the film layer 30D of the decorative sheet 1D will be described below.

<Film layer 30D>
The film layer 30D includes a colored layer 31, an adhesive layer (B) 32, a metal foil layer 33D, an adhesive layer (C) 34, and a printed layer 35 from the metal layer 10 (adhesive layer (A) 20) side. , a receiving layer 36 and a transparent layer 37 .

The metal foil layer 33D is a metal foil made of aluminum, copper, or the like, and is attached to the colored layer 31 with an adhesive layer (B) 32 . By having the metal foil layer 33D, the decorative sheet 1D can have a metallic design. Other features are the same as those of the first to third embodiments.

As for the manufacturing method, in the manufacturing method of the second embodiment (FIG. 5), the colored layer 31 to which the metal foil layer 33 is adhered is supplied to the surface film manufacturing step S20.

<<Fifth Embodiment>>
<Overview of Decorative Sheet 1E>
The configuration of the decorative sheet 1E will be described with reference to the cross-sectional structure of FIG. The decorative sheet 1D of this embodiment has a configuration in which the colored layer 31 provided in the second to fourth embodiments is omitted. The following description focuses on the differences from the first to fourth embodiments, and descriptions of the same configurations are omitted as appropriate.

As shown in FIG. 8, the decorative sheet 1C includes a metal layer 10, an adhesive layer 20E, a film layer 30E, and a coat layer 40 in this order. In this embodiment, the adhesive layer 20E is made of a transparent adhesive.
Each layer constituting the film layer 30C of the decorative sheet 1E will be described below.

<Film layer 30E>
30 C of film layers have the printing layer 35, the receiving layer 36, and the transparent layer 37 from the metal layer 10 (adhesion layer (A) 20) side.

In this embodiment, there is no colored layer 31, and the adhesive layer (A) 20E is made of a transparent adhesive.

Although the embodiments of the present invention have been described above, these are merely examples of the present invention, and various configurations other than those described above can be employed within the scope that does not impair the effects of the present invention.

EXAMPLES The present invention will be described in more detail below with reference to Examples, but the present invention is not limited to these.

[Example 1]
A sample of the decorative laminate of Example 1 was manufactured by the manufacturing method illustrated in FIG. Specifically, it is as follows.
While continuously supplying a PET film from a roll of a long polyethylene terephthalate (PET) film (base material layer) with a thickness of 38 μm, a film having a thickness of 3 μm was applied to one surface of the PET film by gravure printing. A printing layer was formed continuously. At the same time, a coating liquid containing a melamine resin (resin: manufactured by Sumitomo Bakelite Co., Ltd., solvent: water) was prepared, and the coating liquid was applied to the surface of the PET film (substrate layer) opposite to the surface provided with the printed layer. was continuously coated by a die coating method and then cured to laminate a resin coating layer having a thickness of 6 μm. As described above, a long first laminate in which the printed layer, the PET film (base material layer), and the resin coat layer were laminated in order was obtained.
On the other hand, the PVC was continuously supplied from a separately wound body in which a long polyvinyl chloride (PVC) film (base material layer) with a thickness of 25 μm was wound, and a urethane resin was applied to one surface of the roll. and continuously laminated to the printed layer of the first laminate via the adhesive layer to obtain a long second laminate.
Next, a metal layer is supplied from a wound body of a metal layer made of aluminum (A3003PH16 defined in JIS H 4000, thickness 1.0 mm) and subjected to pretreatment, and an adhesive layer (A) is formed on one surface of the metal layer. The metal layer to which the adhesive layer (A) was applied was heat-treated.
A long decorative sheet is manufactured by bonding a metal layer provided with an adhesive layer (A) to the second laminate, and then the coating layer of the decorative sheet is masked and cut into a fixed length. Thus, a sample of Example 1 was obtained.

[Comparative Example 1]
As Comparative Example 1, the following melamine decorative plate with aluminum plate was manufactured. Specifically, it is as follows. First, 80 g/m ² unbleached kraft paper was used as a base material, and 50 g/m ² of phenolic resin was impregnated into the unbleached kraft paper to form a core layer with a thickness of 0.10 mm. This core layer was laminated on an aluminum plate (A3003PH16 defined in JIS H 4000) having a thickness of 1.0 mm as a metal base plate. In this case, a sample of Comparative Example 1 having a total thickness of 1.20 mm was laminated on the core layer with a decorative paper containing titanium oxide impregnated with 20 g/m ² of melamine resin and having a thickness of 0.10 mm. got

[Comparative Example 2]
A sample of Comparative Example 2 was obtained by coating one surface of a 1 mm thick aluminum plate (A3003PH16 defined in JISH4000) with paint (acrylic resin baked finish) to a film thickness of 30 μm.

[Comparative Example 3]
A 125 μm thick polyvinyl chloride (PVC) film (base layer) is used as the surface layer material, an acrylic adhesive layer is applied to the back surface, and aluminum (A3003PH16 specified in JIS H 4000, thickness 1.0 mm) is used. A sample of Comparative Example 3 was obtained by laminating the metal layer on one side with a squeegee.

<Evaluation>
For Example 1 and Comparative Examples 1-3, (1) scratch resistance, (2) abrasion resistance, (3) pencil hardness, (4) wipeability, (5) chemical resistance, (6) smoothness, (7) The workability was tested and evaluated for 7 items. Table 1 shows the evaluation results.

[1. Scratchability]
Steel wool was attached to the tribostation, and after 50 reciprocating scratches with a load of 250 g, the degree of damage was visually observed and evaluated as "conspicuous" or "inconspicuous."
In Example 1 and Comparative Example 1, the degree of scratches was inconspicuous and high scratch resistance was exhibited.

[2. Abrasion resistance]
It was carried out based on the "thermosetting resin high pressure decorative board test method" specified in JIS K 6902.
Evaluation criteria are as follows.
A: 500 times or more B: 100 times or more and less than 500 times C: Less than 100 times Example 1, Comparative Examples 1 and 3 exhibited high abrasion resistance. In particular, Example 1 exhibited extremely high wear resistance.

[3. pencil hardness]
It was carried out based on the "pencil hardness test" specified in JIS K 5600.
Evaluation criteria are as follows.
◎: 6H~
○: 3H to 5H
×: ~2 hours
Example 1, Comparative Example 1 and Comparative Example 2 exhibited high wear resistance.

[4. Wipeability]
A mark was made with a rubber (black natural rubber) and a crayon under a load of 3 kg, and the appearance after wiping with a waste cloth under a load of 3 kg was evaluated in three grades of "inconspicuous", "substantially inconspicuous" and "conspicuous".
As for rubber marks, Example 1 and Comparative Example 2 exhibited high wiping properties.
As for crayon marks, Example 1 showed high wiping ability.

[5. chemical resistance]
After wiping with three types of chemicals (“acetone,” “methyl ethyl ketone,” and “gasoline”), the state was confirmed and evaluated.
Example 1, Comparative Example 1 and Comparative Example 2 showed sufficient chemical resistance. In Comparative Example 3, dissolution was observed on the surface.

[6. Smoothness]
After drying in an oven at 50° C. for 2 hours, the state of warpage was confirmed and evaluated.
In Example 1, Comparative Example 2, and Comparative Example 3, warpage did not occur and high smoothness was exhibited.

[7. workability]
The state when bent outward by 3R was visually observed, and the presence or absence of cracks was evaluated as "no cracks" or "cracks present."
In Example 1, Comparative Example 2, and Comparative Example 3, cracks did not occur during outward bending, and high workability was exhibited.
[Evaluation summary]
Example 1 showed satisfactory results for the above seven items. According to the decorative sheet (decorative board) having such characteristics, even if there are many curved surfaces due to the characteristics of the passenger car structure, such as the interior of a railway train, and the radius of curvature required during construction is small, the It was confirmed that construction could be performed with quality. In addition, it was confirmed that, because of its high strength (wear resistance, etc.) and chemical resistance, it is possible to reduce the frequency of repairs by cleaning and realize a good usage environment (clean vehicle environment).

1A, 1B, 1C, 1D, 1E decorative sheet 10 metal layer 20 adhesive layer (A)
30, 30B, 30C, 30D, 30E film layer 31 colored layer 32 adhesive layer (B)
33C metal deposition layer 33D metal foil layer 34 adhesive layer (C)
35 printing layer 36 receiving layer 37 transparent layer 40 coating layer

Claims (12)

a metal layer;
an adhesive layer (A) laminated on the metal layer;
a film layer laminated on the adhesive layer (A);
a coat layer containing a melamine resin laminated on the film layer;
A veneer having a The decorative board according to claim 1, wherein the coating layer has a thickness T of 1 µm or more and 20 µm or less. The decorative board according to claim 1 or 2, wherein the product α·t of the elastic modulus α of the metal forming the metal layer and the thickness t of the metal layer is 30 mm·GPa or more and 400 mm·GPa or less. The decorative board according to any one of claims 1 to 3, wherein the coating layer does not wrinkle or crack when bent 90 degrees. 5. Any one of claims 1 to 4, wherein the film layer comprises a colored layer, an adhesive layer (B), a receiving layer and a transparent layer in this order from the adhesive layer (A) side. Decorative board of description. 6. The decorative laminate of Claim 5, comprising a printing layer between said receiving layer and said colored layer. The film layer comprises a substrate layer, a metal deposition layer, an adhesive layer (B), a printing layer, a receiving layer, and a transparent layer in this order from the adhesive layer (A) side. The decorative board according to any one of 1 to 4. The film layer includes a substrate layer, an adhesive layer (C), a metal foil, an adhesive layer (B), a printing layer, a receiving layer, and a transparent layer, which are arranged from the adhesive layer (A) side. 5. A decorative laminate according to any one of claims 1 to 4, provided in sequence. The film layer comprises a receiving layer and a transparent layer in this order from the adhesive layer (A) side,
5. Decorative laminate according to any one of claims 1 to 4, wherein said adhesive layer (A) is a transparent adhesive. 10. Decorative laminate according to claim 9, comprising a printing layer between the receiving layer and the adhesive layer (A). The decorative laminate according to any one of claims 1 to 10, wherein the surface of said coat layer is embossed. The coat layer contains a matting filler,
The surface of the coat layer is provided with a convex portion that follows the shape of the matte filler,
A decorative laminate according to any one of claims 1 to 11.

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