JP2023184333A - Decorative sheet - Google Patents

Abstract

To provide a decorative sheet which can achieve thinning of a transparent resin layer as an upper layer while suppressing discoloration of a pattern.SOLUTION: A decorative sheet includes a raw fabric layer, a pattern layer which is formed on one surface side of the raw fabric layer and contains an inorganic pigment, and a transparent resin layer formed on the pattern layer by a transparent resin so as to have a thickness of 70 μm or less. The thickness of the transparent resin layer is preferably 50 μm or more and 60 μm or less. The inorganic pigment preferably contains at least one of an iron oxide, a chromium oxide, a titanium oxide, a carbon black, ocher, malachite and ultramarine.SELECTED DRAWING: Figure 1

Description

The present disclosure relates to decorative sheets.

2. Description of the Related Art Conventionally, a decorative sheet has been used which includes a picture pattern layer on which a desired picture pattern is formed using ink on an original fabric layer. In such decorative sheets, patterns are created using inks containing organic pigments that have excellent coloring properties and can express vivid colors, such as red pigments such as quinacridone and polyazo, and yellow pigments such as isoindolinone and monoazo. is formed.

JP2008-080518A

However, since organic pigments have low light resistance, in decorative sheets that are often used in environments exposed to ultraviolet rays, the upper layer of the pattern layer formed using ink containing organic pigments is It was necessary to form a transparent resin layer having a thickness greater than or equal to the thickness of the pattern layer to suppress deterioration of the picture pattern layer. For this reason, it has been difficult to reduce the thickness of the transparent resin layer, and it has been difficult to reduce the amount of transparent resin used when forming the decorative sheet.
The present disclosure has been made in view of such problems, and an object of the present disclosure is to provide a decorative sheet that can realize a thinner transparent resin layer as an upper layer while suppressing fading of a pattern.

In order to solve the above-mentioned problems, a decorative sheet according to one embodiment of the present disclosure includes a raw fabric layer, a picture pattern layer formed on one side of the raw fabric layer and containing an inorganic pigment, and a picture pattern layer. A transparent resin layer made of transparent resin and having a thickness of 70 μm or less is provided thereon.

According to the present disclosure, it is possible to obtain a decorative sheet that can realize a thinner transparent resin layer as an upper layer while suppressing fading of a pattern.

FIG. 1 is a cross-sectional view showing a configuration example of an embodiment of a decorative sheet according to the present disclosure. FIG. 3 is a cross-sectional view showing a configuration example of a modified example of the embodiment of the decorative sheet according to the present disclosure.

Embodiments of the present disclosure will be described below with reference to the drawings. However, the embodiments described below are merely examples, and there is no intention to exclude the application of various modifications and techniques not specified below. The present disclosure can be implemented in various ways (for example, by combining the embodiments) without departing from the spirit thereof.

[Basic composition of decorative sheet]
Hereinafter, with reference to FIG. 1, a decorative sheet 1 according to the present disclosure will be described.
The decorative sheet 1 includes a raw fabric layer 11, a picture pattern layer 12 formed on one side (front side) of the raw fabric layer 11, and a transparent resin layer 13 formed on the picture pattern layer 12. We are prepared. Further, the decorative sheet 1 may include a surface protection layer 14 formed on the transparent resin layer 13 and a primer layer 15 formed on the other side (back side) of the raw fabric layer 11.

The primer layer 15 is a layer provided to improve the adhesion between the decorative sheet 1 and a surface to which the decorative sheet 1 is adhered, such as a wall surface, a building material, a base material, or the like. The raw fabric layer 11 is a layer that serves as the base material of the decorative sheet 1, and it absorbs irregularities and steps on the surface to which it is applied, improving the finish of the decorative sheet 1, and also changing the color and pattern of the surface to which it is applied. This is a layer for concealment. Further, the raw fabric layer 11 is a layer for suppressing scratches occurring on the decorative sheet 1 and giving the decorative sheet a design and a soft and comfortable touch. The pattern layer 12 is a layer that imparts a desired color to the decorative sheet 1. The surface protection layer 14 is a layer provided on the uppermost surface of the decorative sheet 1 to protect the decorative sheet 1 and adjust the gloss of the surface of the decorative sheet 1.

Each layer of the original fabric layer 11, picture pattern layer 12, transparent resin layer 13, surface protection layer 14, and primer layer 15 will be described in detail below.
In addition, in the decorative sheet 1, the primer layer 15 may be omitted. For example, if the surface to which the decorative sheet 1 is attached has a function as a primer layer, the primer layer 15 can be omitted. Further, for example, if the transparent resin layer 13 also has a function as the surface protection layer 14, the surface protection layer 14 can be omitted.
That is, the decorative sheet 1 only needs to have the surface protection layer 14 formed on at least one side of the raw fabric layer 11.

<Original fabric layer>
The raw fabric layer 11 is a layer formed by mixing a resin material with a pigment for coloring. The raw fabric layer 11 only needs to have the strength required as the base material of the decorative sheet 1, and is formed of a resin material. In addition, the raw fabric layer 11 also has a function as a concealing layer to prevent the color and pattern of the construction surface from penetrating the surface of the decorative sheet 1, and to hide the color and pattern of the construction surface. Preferably, it is colored. It is preferable that the raw fabric layer 11 is formed of, for example, colored polyethylene.

The thickness of the raw fabric layer 11 is, for example, preferably 40 μm or more and 200 μm or less, more preferably 100 μm or more and 160 μm or less. When the thickness of the original fabric layer 11 is 40 μm or more, it can sufficiently exhibit the hiding properties required for the decorative sheet 1 and has sufficient strength as a base material. On the other hand, when the thickness of the original fabric layer 11 is 200 μm or less, it is possible to suppress problems such as whitening and cracking during bending.

(resin material)
Examples of the resin material constituting the raw fabric layer 11 include thermoplastic resin. The thermoplastic resin is not particularly limited, and materials similar to thermoplastic resins used as base layers and the like in conventional decorative sheets can be used. Examples of the thermoplastic resin include polyolefin resins such as polyethylene, polypropylene, polymethylpentene, polybutene, ethylene-propylene copolymer, ethylene-α-olefin copolymer, propylene-α-olefin copolymer, polyethylene terephthalate, Polybutylene terephthalate, polytetramethylene terephthalate, polyethylene naphthalate, polyethylene terephthalate-isophthalate copolymer, 1,4-cyclohexanedimethanol copolymerization Polyester resins such as polyethylene terephthalate, polyarylate, polycarbonate, ethylene-vinyl acetate copolymer olefin copolymer resins such as ethylene-vinyl alcohol copolymers, ethylene-(meth)acrylic acid (ester) copolymers, ethylene-unsaturated carboxylic acid copolymers, metal neutralized products (ionomers), etc. Polyolefin resins, poly(meth)acrylonitrile, polymethyl(meth)acrylate, polyethyl(meth)acrylate, polybutyl(meth)acrylate, acrylic resins such as polyacrylamide, 6-nylon, 6,6-nylon, 6,10- Polyamide resins such as nylon, styrene resins such as polystyrene, AS resins, ABS resins, vinyl resins such as polyvinyl chloride, polyvinyl acetate, polyvinyl alcohol, polyvinyl acetal, polyvinyl butyral, polyvinyl fluoride, polyvinylidene fluoride, Fluororesins such as polytetrafluoroethylene, ethylene-tetrafluoroethylene copolymer, ethylene-perfluoroalkyl vinyl ether copolymer, etc., or mixtures, copolymers, composites, laminates, etc. of two or more thereof. Can be used.

In particular, in view of the growing social concern about environmental issues in recent years, it is not desirable to use thermoplastic resins that contain chlorine (halogen), such as polyvinyl chloride resin, and it is preferable to use non-halogen-based thermoplastic resins. Preference is given to using thermoplastic resins. In particular, polyester resins (amorphous or biaxially oriented) or polyolefin resins, especially polyolefin resins, are used as non-halogen thermoplastic resins from the viewpoint of various physical properties, processability, versatility, economic efficiency, etc. Most preferably. For example, as the polyolefin resin, it is preferable to use a polypropylene resin containing 30% by mass or more and 100% by mass or less of a highly crystalline homopolypropylene resin having an isotactic pentad fraction (mmmm fraction) of 95% or more.

The raw fabric layer 11 may contain, as necessary, a coloring agent, a filler, an ultraviolet absorber, a light stabilizer, a heat stabilizer, an antioxidant, an antistatic agent, a lubricant, a flame retardant, an antibacterial agent, and an anti-mold agent. One or more kinds of additives selected from various additives such as a lubricant, a lubricant, a light scattering agent, and a gloss modifier may be added. In addition, it is preferable that the original fabric layer 11 has a concealing property to hide the surface to which the decorative sheet 1 is attached, such as a wall surface, from the surface (upper surface) of the decorative sheet 1.
It is preferable that the raw fabric layer 11 contains a monochromatic colorant. As the colorant, it is preferable to use a known inorganic pigment represented by titanium oxide, which is a white pigment for imparting hiding properties. If the concealment property is low, the pattern on the surface to which the decorative sheet 1 is attached will be transparent, which is not preferable. By containing an inorganic pigment, a decorative sheet 1 with good hiding properties can be obtained.

<Picture pattern layer>
The picture pattern layer 12 is formed on the original fabric layer 11 using ink containing an inorganic pigment. The pattern layer 12 is formed to improve the design of the decorative sheet 1 by decorating the surface side with a pattern such as a wood grain pattern.
The ink used to form the picture pattern layer 12 contains a pigment including an inorganic pigment and a binder resin. As the binder resin, known resins can be used, but urethane resins and acrylic resins are preferably used. Furthermore, resins such as vinyl chloride resin and vinyl acetate resin may be mixed as the binder resin.

The ink containing an inorganic pigment forming the pattern layer 12 may contain only an inorganic pigment as a pigment, or may contain an inorganic pigment as a main component and an organic pigment mixed therein. Here, the "main component" refers to the component contained in the resin in the largest amount, and when an inorganic pigment and an organic pigment are mixed, the inorganic pigment contains more than 50% by mass. It means that
When an inorganic pigment and an organic pigment are mixed, the inorganic pigment is preferably contained in an amount of more than 50% by mass, more preferably 70% by mass or more of the total pigment. If the organic pigment to be mixed has high weather resistance, the content of the inorganic pigment may be relatively low; if the organic pigment to be mixed has low weather resistance, the content of the inorganic pigment may be relatively low. It is necessary to aim high.

Inorganic pigments may be selected depending on the desired color tone, including synthetic inorganic pigments that are metal compounds using zinc, titanium, lead, iron, copper, chromium, etc., and natural pigments obtained from natural minerals and soil. Preferably, it contains at least one mineral pigment. Specifically, inorganic pigments include iron oxide (red pigment, yellow pigment, black pigment), chromium oxide (green pigment), titanium oxide (white pigment), carbon black (black pigment), loess, malachite (green pigment), pigment) and ultramarine (blue pigment).

The organic pigment used together with the inorganic pigment is preferably a material with high light resistance among organic pigments, and for example, phthalocyanine (blue pigment) is preferably used.
The method of forming the picture pattern layer 12 is not particularly limited, but it is preferably formed by, for example, a printing method. Examples of printing methods include gravure printing, offset printing, screen printing, flexographic printing, and inkjet printing. Furthermore, the printing method is not limited to the printing method described above, and any conventionally known pattern forming method such as a transfer method or a photosensitive resin method can be applied.
The type of pattern of the picture pattern layer 12 is arbitrary, and may be, for example, a wood grain pattern, a stone grain pattern, an abstract pattern, etc., or may be full-surface solid printing.

<Transparent resin layer>
The transparent resin layer 13 is a layer formed on the picture pattern layer 12.
The thickness of the transparent resin layer 13 is 70 μm or less, preferably 40 μm or more and 60 μm or less. The transparent resin layer 13 is formed to have a thickness of 70 μm or less, which is thinner than the transparent resin layer formed on the pattern layer formed with a conventional ink containing an organic pigment, due to the improved light resistance of the pattern layer 12. be able to. As a result, the amount of resin used for forming the transparent resin layer 13 can be reduced, and the bendability of the decorative sheet 1 can be appropriately reduced, so that even when the construction surface of the decorative sheet 1 is not flat, the adhesion of the decorative sheet 1 can be improved. It is possible to reduce manufacturing costs while improving performance. In addition, by forming the transparent resin layer 13 with a thickness of 40 μm or more and 60 μm or less, the fading effect of the pattern layer 12 is significantly improved, and the scratch resistance of the surface of the decorative sheet 1 against wear and scratches is improved, and the transparent resin layer The amount of resin used to form No. 13 is further reduced.

(resin material)
As the resin material constituting the transparent resin layer 13, for example, thermoplastic resin can be used. The thermoplastic resin is not particularly limited, and examples thereof include polyolefins such as polyethylene, polypropylene, polymethylpentene, polybutene, ethylene-propylene copolymer, ethylene-α-olefin copolymer, propylene-α-olefin copolymer, etc. Resins, ethylene-vinyl acetate copolymers, ethylene-vinyl alcohol copolymers, ethylene-(meth)acrylic acid (ester) copolymers, ethylene-unsaturated carboxylic acid copolymers metal neutralized products (ionomers), etc. Polyolefin resins such as olefin copolymer resins of , polyester resins such as polyarylate and polycarbonate, acrylic resins such as poly(meth)acrylonitrile, polymethyl(meth)acrylate, polyethyl(meth)acrylate, polybutyl(meth)acrylate, and polyacrylamide, 6-nylon, 6,6 - Polyamide resins such as nylon and 6,10-nylon, styrene resins such as polystyrene, AS resin, and ABS resin, vinyl resins such as polyvinyl chloride, polyvinyl acetate, polyvinyl alcohol, polyvinyl acetal, and polyvinyl butyral, and polyfluoride resins. Fluororesins such as vinyl chloride, polyvinylidene fluoride, polytetrafluoroethylene, ethylene-tetrafluoroethylene copolymer, ethylene-perfluoroalkyl vinyl ether copolymer, etc., or mixtures, copolymers, and composites of two or more thereof A body, a laminate, etc. can be used.

Here, a large number of thermoplastic resins have been mentioned as thermoplastic resins that can be used for the transparent resin layer 13, but in view of the growing social concern about environmental issues in recent years, chlorine (halogenated resin) such as polyvinyl chloride resin ) It is undesirable to use a thermoplastic resin containing halogen-free thermoplastic resins, and it is desirable to use non-halogen thermoplastic resins. In particular, from the viewpoint of various physical properties, processability, versatility, economic efficiency, etc., it is best to use polyolefin resins or polyester resins (amorphous or biaxially oriented) as non-halogen thermoplastic resins. desirable.

The polyolefin resin may be appropriately selected from the many types listed above depending on the intended use of the decorative sheet 1 and the like. In particular, the most suitable resin for general use is a polypropylene resin, that is, a homopolymer or a copolymer containing propylene as a main component. Here, the term "main component" refers to the component contained in the resin in the largest amount.
More specifically, as the polypropylene resin, homopolypropylene resin, random polypropylene resin, block polypropylene resin, etc. may be used singly or appropriately blended, or resins in which atactic polypropylene is further blended as appropriate are used. Can be done. It may also be a copolymer containing an olefin monomer other than propylene, for example, an α-olefin having a polypropylene crystal part and having 2 to 20 carbon atoms other than propylene, preferably ethylene, butene, etc. Examples include propylene-α-olefin copolymers containing 15 mol% or more of one or more comonomers of 1,4-methylpentene-1, hexene-1, or octene-1. In addition, low-density polyethylene, ethylene-α-olefin copolymer, ethylene-propylene copolymer rubber, ethylene-propylene-nonconjugated diene copolymer rubber, and styrene-butadiene copolymer are commonly used to soften polypropylene resins. Modifiers such as coalescing or hydrogenated products thereof can be added as appropriate.

The transparent resin layer 13 may contain, as necessary, a colorant, a filler, an ultraviolet absorber, a light stabilizer, a heat stabilizer, an antioxidant, an antistatic agent, a lubricant, a flame retardant, an antibacterial agent, and a fungicide. One or more kinds of additives selected from various additives such as a lubricant, a lubricant, a light scattering agent, and a gloss modifier may be added. The transparent resin layer 13 preferably has transparency (colorless transparent, colored transparent, translucent) to the extent that the pattern of the pattern layer 12 can be seen through from the surface (upper surface) of the decorative sheet 1.

Further, the transparent resin layer 13 may contain an antiviral agent that improves antiviral properties. Since the transparent resin layer 13 contains an antiviral agent, it has antiviral properties even if the transparent resin layer 13 is exposed due to abrasion of the surface protection layer 14.

Preferably, the antiviral agent is a silver-based material. Antiviral agents include antibacterial zeolite, antibacterial apatite, and antibacterial zirconia, which are formed by incorporating metal ions such as silver ions, copper ions, and zinc ions into inorganic compounds such as zeolite, apatite, and zirconia. Inorganic antibacterial agents can be used, and antiviral agents include zinc pyridione, 2-(4-thiazolyl)-benzimidazole, 10,10-oxybisphenoxanodine, organic sulfur halogens, and pyridine-2-thiol. Although oxides and the like can be used, silver-based antiviral agents are superior in terms of antiviral effects.
Further, the antiviral agent may have a structure in which a silver-based material is supported on an inorganic material. Thereby, the decorative sheet 1 with excellent durability of the virus effect can be obtained.

<Surface protective layer>
The surface protection layer 14 is made of a resin material. The main component of the resin material constituting the surface protective layer 14 is, for example, polyurethane-based, acrylic silicone-based, fluorine-based, epoxy-based, vinyl-based, polyester-based, melamine-based, aminoalkyd-based, urea-based resin, etc. Appropriate selection of materials is used. The form of the resin material is not particularly limited, and may be water-based, emulsion, solvent-based, or the like. The curing method for the resin material can be appropriately selected from one-component type, two-component type, ionizing radiation (for example, ultraviolet) curing method, thermosetting method, photocuring method, etc.

As the resin material used as the main component of the surface protective layer 14, a urethane-based resin material using isocyanate is suitable from the viewpoints of workability, cost, cohesive force of the resin itself, and the like. Isocyanates include, for example, tolylene diisocyanate (TDI), xylylene diisocyanate (XDI), hexamethylene diisocyanate (HMDI), diphenylmethane diisocyanate (MDI), lysine diisocyanate (LDI), isophorone diisocyanate (IPDI), and bis(methyl isocyanate). The curing agent can be appropriately selected from adducts, burettes, and isocyanurates of derivatives such as cyclohexane (HXDI) and trimethylhexamethylene diisocyanate (TMDI). Among these, from the viewpoint of weather resistance, it is preferable to use hexamethylene diisocyanate (HMDI) or isophorone diisocyanate (IPDI), which have a linear molecular structure. In addition, in order to improve the surface hardness, it is preferable to use an ionizing radiation-curable resin that is cured by active energy rays such as ultraviolet rays and electron beams. Note that these resins can be used in combination with each other. For example, by using a hybrid type of thermosetting type and photocuring type, it is possible to improve surface hardness, suppress curing shrinkage, and improve adhesion. can be achieved. Furthermore, by using a hybrid type of thermosetting type and ionizing radiation curing type, it is possible to satisfy the scratch resistance and at the same time make it difficult for the surface protective layer 14 to whiten or crack during bending.

The surface protective layer 14 may contain a gloss adjuster for gloss adjustment. As the gloss modifier, any commercially known material may be used, and for example, fine particles made of inorganic materials such as silica, glass, alumina, calcium carbonate, barium sulfate, etc. may be used. Furthermore, fine particles made of an organic material such as acrylic can also be used as the gloss modifier. However, when high transparency is required, it is preferable to use fine particles of highly transparent silica, glass, acrylic, etc. as the gloss modifier. In particular, among fine particles such as silica and glass, a gloss modifier with a low bulk density, which is made up of secondary agglomerations of fine primary particles rather than solid spherical particles, has a high matting effect depending on the amount added. Therefore, by using a gloss modifier with a low bulk density, the amount of the gloss modifier added can be reduced.

Further, the gloss adjusting agent contained in the surface protective layer 14 is preferably adjusted so that the glossiness of the decorative sheet 1 is 10 or less. As described above, when the original fabric layer 11 contains a gloss adjuster, it is necessary to adjust the glossiness of the entire decorative sheet 1 to 10 or less. When the glossiness of the decorative sheet 1 is 10 or less, the decorative sheet 1 can have a calm appearance. Here, the value of glossiness indicates, for example, the value of 60 degree specular gloss according to JIS Z 8741. This improves the harmony with patterned furniture and fittings, giving it a more desirable appearance as a decorative sheet used for door frames, window frames, baseboards, partitions, and surrounding edges that are pre-assembled into buildings. .

Furthermore, in order to impart various functions to the surface protective layer 14, the surface protective layer 14 may contain functional additives such as antibacterial agents and antifungal agents. Furthermore, the surface protective layer 14 may contain an ultraviolet absorber and a light stabilizer as necessary. Examples of the ultraviolet absorber include benzotriazole-based, benzoate-based, benzophenone-based, triazine-based, and cyanoacrylate-based ultraviolet absorbers. Examples of the light stabilizer include hindered amine light stabilizers.

The thickness of the surface protective layer 14 is preferably within the range of 3 μm or more and 15 μm or less. When the thickness of the surface protective layer 14 is 3 μm or more, the effect of improving scratch resistance becomes high. Moreover, when the thickness of the surface protective layer 14 is 15 μm or less, it is possible to suppress the occurrence of cracks and cracks during bending, and it is possible to suppress deterioration of the design and weather resistance of the decorative sheet 1.

Furthermore, like the transparent resin layer 13, the surface protective layer 14 may contain an antiviral agent that improves antiviral properties. By including an antiviral agent in the surface protective layer 14, antiviral properties can be maintained on the surface of the decorative sheet 1. For this reason, it is more preferable that both the surface protection layer 14 and the transparent resin layer 13 contain an antiviral agent. Note that the antiviral agent has the same structure as the antiviral agent contained in the transparent resin layer 13 of the decorative sheet 1, so a description thereof will be omitted.

<Primer layer>
The primer layer 15 is provided on the surface of the original fabric layer 11 opposite to the picture pattern layer 12. As the primer layer 15, for example, polyester resin, polyurethane resin, a mixture thereof, etc. can be used. Furthermore, by using a two-component type using polyol and isocyanate, the adhesion between the primer layer 15 and the surface to which the decorative sheet 1 is attached is improved, and the cohesive force of the primer layer 15 itself is improved.

Examples of polyols include acrylic polyols and polyester polyols. Examples of isocyanates include aromatic ones such as tolylene diisocyanate and 4,4' diphenylmethane diisocyanate, and aliphatic ones such as hexamethylene diisocyanate, isophorone diisocyanate and xylene diisocyanate. For the primer layer 15, it is preferable to use an aromatic polyol in terms of quick reactivity and heat resistance.

The thickness of the primer layer 15 is preferably 1 μm or more. By setting the thickness of the primer layer 15 to 1 μm or more, it is possible to prevent the adhesive from being dissolved by the solvent, the primer layer 15 disappearing, and the adhesion to the base material decreasing.
In addition, when the construction surface has large irregularities, it is preferable to seal the construction surface with putty or the like in advance, and apply a primer if necessary.

<Modified example>
A modified example of the decorative sheet according to this embodiment will be explained using FIG. 2. FIG. 2 is a schematic cross-sectional view for explaining a configuration example of the decorative sheet 2 according to a modification of the present embodiment.
As shown in FIG. 2, embossed portions 26 are formed on the surface of the decorative sheet 2 in order to impart a given design. The embossed portions 26 may include, for example, wood grain conduit grooves, stone plate surface irregularities (granite cleavage surfaces, etc.), cloth surface textures, satin finish, sand grain, hair lines, line grooves, etc., depending on the design of the picture pattern layer 12. Alternatively, various uneven shapes can be formed depending on the desired design.

The embossed portion 26 is formed by, for example, providing unevenness to the transparent resin layer 13 and the surface protection layer 14 by embossing. The embossing method is not particularly limited, and examples thereof include a method of imparting irregularities using a known single-wafer type or rotary type embossing machine.

<Effects of this embodiment>
The decorative sheet according to the present embodiment described above has the following effects.
(1) The decorative sheet according to the present disclosure includes a raw fabric layer, a picture pattern layer formed on one side of the raw fabric layer and containing an inorganic pigment, and a transparent resin on the picture pattern layer to a thickness of 70 μm or less. A transparent resin layer formed of.
As a result, the decorative sheet can suppress the fading of the pattern while making the upper transparent resin layer thinner, moderately reducing the bendability of the decorative sheet, and improving the adhesion of the decorative sheet to the construction surface. It is possible to reduce manufacturing costs while improving performance.

(2) In the decorative sheet according to the present disclosure, the thickness of the transparent resin layer is 50 μm or more and 60 μm or less.
As a result, in the decorative sheet, the fading effect of the picture pattern layer is significantly improved, the scratch resistance of the decorative sheet surface against wear and scratches is improved, and the amount of resin used for forming the transparent resin layer is further reduced.

(3) The decorative sheet according to the present disclosure contains at least one of iron oxide, chromium oxide, titanium oxide, carbon black, loess, malachite, and ultramarine blue as an inorganic pigment in the picture pattern layer.
Thereby, the decorative sheet can have a thin transparent resin layer.

Hereinafter, the decorative sheet according to the present disclosure will be explained using Examples. Note that the decorative sheet according to the present disclosure is not limited to these examples.

<Example 1>
A colored original fabric made of polyethylene (PE), which is a thermoplastic resin, and having a thickness of 55 μm was used as the original fabric layer. On one side of this colored original fabric, a wood grain pattern was printed using urethane resin ink by gravure printing to form a picture pattern layer. At this time, the urethane resin ink contains iron oxide (ochre/brown pigment), which is an inorganic pigment, and phthalocyanine (blue pigment), which is an organic pigment with high weather resistance, and contains urethane resin as a binder resin. Ink was used. At this time, the mixing ratio of the inorganic pigment and the organic pigment was 70:30 by mass.

Subsequently, polypropylene resin (PP) was applied and cured to a thickness of 50 μm on the picture pattern layer to form a transparent resin layer.
Furthermore, a thermosetting resin (manufactured by DIC Graphics Co., Ltd., urethane acrylate resin) was applied and cured to a thickness of 6 μm on the transparent resin layer to form a surface protective layer. In this way, the decorative sheet of Example 1 was formed.

<Example 2>
A decorative sheet of Example 2 was formed using the same materials and procedures as in Example 1, except that the thickness of the transparent resin layer was 40 μm.

<Example 3>
A decorative sheet of Example 3 was formed using the same materials and procedures as in Example 1 except that the thickness of the transparent resin layer was 60 μm.

<Example 4>
A decorative sheet of Example 3 was formed using the same materials and procedures as in Example 1, except that the thickness of the transparent resin layer was 30 μm.

<Example 5>
A decorative sheet of Example 4 was formed using the same materials and procedures as in Example 1, except that the thickness of the transparent resin layer was 70 μm.

<Comparative example 1>
The pattern layer is formed using a urethane resin ink that uses organic pigments polyazo pigment (red pigment) and isoindolinone (yellow pigment) instead of iron oxide and phthalocyanine as the ink pigments forming the pattern layer. A decorative sheet of Comparative Example 1 was formed using the same materials and procedures as in Example 1 except for the following.

<Comparative example 2>
A decorative sheet of Comparative Example 2 was formed using the same materials and procedures as Comparative Example 1 except that the thickness of the transparent resin layer was 70 μm.

<Comparative example 3>
A decorative sheet of Comparative Example 3 was formed using the same materials and procedures as Comparative Example 1 except that the thickness of the transparent resin layer was 80 μm.

[evaluation]
(fading)
The decorative sheets of each Example and Comparative Example were set in a sunshine weather meter, and after 2000 hours, they were taken out from the test period and the degree of discoloration of each decorative sheet was evaluated.
Discoloration was visually evaluated as follows.
"○"...No change in the color of the picture pattern layer "△"...Slight fading of the color of the picture pattern layer was confirmed "×"...Significant discoloration of the color of the picture pattern layer was confirmed

(Scratch hardness test)
The hardness of the decorative sheets of each example and comparative example was determined by measuring the hardness of the hardest pencil (pencil hardness) that did not cause any scratches on the surface of the decorative sheet in a scratch hardness (pencil method) test based on JIS K5600. evaluated.
The scratch hardness was evaluated as follows.
"○"...The hardness of the hardest pencil that did not cause any scars on the surface of the decorative sheet was H to 6H.
"△"...The hardness of the hardest pencil that did not cause any scars on the surface of the decorative sheet was 2B to F.
"×"...Hardness of the hardest pencil that did not cause any scars on the surface of the decorative sheet was 6B to 3B

(Hoffman scratch test)
A scratch test was conducted on the decorative sheets of each example and comparative example using a Hoffman scratch hardness tester (manufactured by GARDCO). In the scratch test, the heaviest load that did not cause any tears or scratches on the surface of the decorative sheet was measured. After the test, areas with changes in gloss, tears, etc. on the surface were confirmed.
The Hoffman scratch test was evaluated as follows.
"○"...Minimum load at which the surface protective layer peels off is 400g or more "△"...Minimum load at which the surface protection layer peels off is 200g or more and less than 400g "×"...Minimum load at which the surface protection layer peels off is less than 200g

(manufacturing cost)
The manufacturing cost of the decorative sheets of each Example and Comparative Example was evaluated.
The manufacturing cost was evaluated as follows by combining the amount of resin used in forming the transparent resin layer (thickness of the transparent resin layer) and the cost of the pigment.
“◎”: Improved than the conventional product (Comparative Example 1) “○”: Equivalent to the conventional product (Comparative Example 1) “△”: Better than the conventional product (Comparative Example 1) “×”: Significantly worse than conventional product (Comparative Example 1)

Table 1 below shows the evaluation results of each evaluation.

As shown in Table 1, in the decorative sheets of Examples containing more than 50% by mass of inorganic pigments, there was almost no fading of the picture pattern layer, and the scratch resistance and manufacturing cost were also good.
On the other hand, in the decorative sheets of comparative examples containing only organic pigments, when the thickness of the transparent resin layer was 50 μm, the pattern layer was discolored, and when the thickness of the transparent resin layer was 70 μm, the transparent resin layer was formed. As the amount of resin used increased and expensive organic pigments were used in large quantities, manufacturing costs increased.

Furthermore, in the decorative sheets of each example containing more than 50% by mass of inorganic pigments, in Examples 2 to 5 in which the thickness of the transparent resin layer was 40 μm or more, there was no slight discoloration in the pattern layer. . Further, in Examples 1 to 4 in which the thickness of the transparent resin layer was 60 μm or less, the manufacturing cost was better.
From the above, when the pattern layer contains more than 50% by mass of inorganic pigments and the thickness of the transparent resin layer is 70 μm or less, it is preferable from the viewpoint of suppressing discoloration of the pattern layer and manufacturing cost characteristics, and the transparent resin layer The thickness of 40 μm or more and 60 μm or less is particularly preferable from the viewpoint of suppressing discoloration of the picture pattern layer and manufacturing cost characteristics.

The embodiments of the present disclosure have been described above, but the embodiments described above illustrate devices and methods for embodying the technical idea of the present disclosure, and the technical idea of the present disclosure It does not specify the material, shape, structure, arrangement, etc. The technical idea of the present disclosure can be modified in various ways within the technical scope defined by the claims.

1, 2 Decorative sheet 11 Original fabric layer 12 Picture pattern layer 13 Transparent resin layer 14 Surface protection layer 15 Primer layer 26 Embossed part

Claims (7)

A raw fabric layer,
a pattern layer formed on one side of the original fabric layer and containing an inorganic pigment;
A transparent resin layer formed of a transparent resin with a thickness of 70 μm or less on the picture pattern layer;
A decorative sheet with. The decorative sheet according to claim 1, wherein the transparent resin layer has a thickness of 40 μm or more and 60 μm or less. The decorative sheet according to claim 1, wherein the inorganic pigment contains at least one of iron oxide, chromium oxide, titanium oxide, carbon black, loess, malachite, and ultramarine blue. The decorative sheet according to claim 1, wherein the original fabric layer is formed of colored polyethylene. The decorative sheet according to claim 1, further comprising a surface protection layer formed on the transparent resin layer. The decorative sheet according to claim 1, wherein the transparent resin layer has an uneven surface. The decorative sheet according to claim 1, further comprising a primer layer formed on the other side of the original fabric layer.

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