JP2024032830A - Decorative sheet for recoat and method for producing decorative sheet for recoat - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorative sheet for recoat having good expansion/contraction preventing property and high dimensional stability.

SOLUTION: A decorative sheet for recoat includes a base material 10 and a recoat layer 20 which is provided on at least one surface side of the base material 10, contains non-woven fabric containing a thermoplastic resin fiber as a fiber of a component and has a gap between fibers, in which the non-woven fabric has a difference in breaking strength between a flow direction and a width direction of 40.0 N or less.

SELECTED DRAWING: Figure 1

COPYRIGHT: (C)2024,JPO&INPIT

Description

The present invention relates to a decorative sheet for recoating and a method for manufacturing a decorative sheet for recoating.

BACKGROUND OF THE INVENTION For surface finishing of furniture, architectural interior materials, home appliances, etc., a decorative sheet having a base material with a wood grain pattern etc. is laminated on the surface of the above products by means such as lamination. There are two types of decorative sheets: those that are already colored and those that are not colored and are coated with paint such as stain afterwards.The latter is a decorative sheet for recoating. being called. Here, the term "stain" refers to a paint for coloring the surface of wood, which is made by adding pigments, dyes, etc. to linseed oil, resin, etc. in the form of liquid, gel, spray, or the like. There are water-based ones and oil-based ones, and they are called oil stains, stain varnishes, water-based stains, etc. After assembling a product using materials laminated with a recoat decorative sheet for surface finishing, the product is colored in a desired color by applying paint such as stain to the decorative sheet on the surface of the product. It's easy to do.

As a conventional decorative sheet for recoating, one has been proposed in which a pattern is printed on a base material using printing ink and then a top coat is applied (for example, see Patent Document 1). However, since the conventional decorative sheet for recoating has a smooth surface, even if a thick coating of stain or the like is attempted, it will sag, making it difficult to obtain a surface with excellent texture.
Therefore, in order to obtain a surface with excellent durability when applying a thick coat of stain, etc., we printed a pattern on the base material using printing ink, and then recoated the surface using a nonwoven fabric for the recoat layer located on the surface. Decorative sheets have been proposed (for example, see Patent Document 2). The decorative sheet for recoating proposed in Patent Document 2 reliably retains colorants such as stains in the voids of the nonwoven fabric, prevents the paint from dripping from the surface of the decorative sheet, and provides a coating with excellent durability. can carry out construction work.

Japanese Unexamined Patent Publication No. 149457/1983 Japanese Patent Application Publication No. 9-262934

However, in decorative sheets for recoating, heat lamination is applied to bond the recoat layer of nonwoven fabric made of thermoplastic resin fibers to the base material, but heat lamination causes the nonwoven fabric to expand and contract. Therefore, it was difficult to obtain a decorative sheet for recoating of a desired size.

In view of the above problems, an object of the present invention is to provide a decorative sheet for recoating and a method for manufacturing the decorative sheet for recoating, which has good anti-expansion properties and high dimensional stability.

In order to solve the above problem, the present inventors conducted extensive research and found that the above problem can be solved by ensuring that the difference in breaking strength between the machine direction and the width direction of the nonwoven fabric used for the recoat layer is below a certain value. I found it. That is, the present invention provides the following [1] to [6].
[1] A base material, and a recoat layer provided on at least one side of the base material, containing a nonwoven fabric containing thermoplastic resin fibers as a constituent fiber, and having voids between the fibers, The nonwoven fabric is a decorative sheet for recoating, and the difference in breaking strength between the machine direction and the width direction is 40.0N or less.
[2] The decorative sheet for recoating according to [1], wherein the nonwoven fabric is a non-oriented nonwoven fabric.
[3] The decorative sheet for recoating according to [1] or [2], wherein the recoating layer has a resin coating film on the surface of at least a portion of the fibers while maintaining at least some voids.
[4] The decorative sheet for recoating according to any one of [1] to [3], wherein the recoat layer has a colorant in the voids and at least a portion of the surface of the fibers.
[5] The decorative sheet for recoating according to any one of [1] to [4], wherein the base material is a resin base material.
[6] A step of preparing a base material; a step of preparing a nonwoven fabric containing thermoplastic resin fibers as a constituent fiber and having a difference in breaking strength of 40.0 N or less in the machine direction and width direction; a step of obtaining a laminate in which the nonwoven fabric is arranged on a material; a step of thermally laminating the laminate to bond the base material and the nonwoven fabric under heat and laminating a recoat layer on the base material; A method for producing a decorative sheet for recoating, including:

According to the present invention, it is possible to provide a decorative sheet for recoating and a method for producing a decorative sheet for recoating, which has good anti-expansion properties and high dimensional stability.

1 is a schematic cross-sectional view (part 1) of a decorative sheet for recoating according to an embodiment of the present invention. FIG. 2 is a schematic cross-sectional view (Part 2) of the decorative sheet for recoating according to the embodiment of the present invention.

Embodiments of the present invention will be described below with reference to the drawings. In the description of the drawings below, the same or similar parts are represented by the same or similar symbols. However, the drawings are schematic, and the relationship between the thickness and planar dimensions, the ratio of the thickness of each layer, etc. are different from the reality. Therefore, the specific thickness and dimensions should be determined in reference to the following explanation. Furthermore, it goes without saying that the drawings include portions with different dimensional relationships and ratios.

(Embodiment)
[Decorative sheet for recoating]
As shown in FIG. 1, the recoat decorative sheet 1 according to the embodiment of the present invention includes a base material 10, and is provided on at least one surface side of the base material 10, and includes thermoplastic resin fibers as constituent fibers. and a recoat layer 20 including a nonwoven fabric containing the fibers and having voids between the fibers.
Note that the recoat decorative sheet 1 according to the embodiment of the present invention does not have an adhesive layer using an adhesive between the base material 10 and the recoat layer 20.

<Base material>
The base material 10 is not particularly limited as long as it is normally used as a decorative sheet, and resin base materials, metal base materials, ceramic base materials, fibrous base materials, wood base materials, etc. may be used depending on the purpose. It can be selected as appropriate. The base material 10 is preferably a resin base material or a metal base material from the viewpoint of good thermal conductivity, and more preferably a resin base material from the viewpoint of a balance between tensile strength and elongation characteristics.
Each of the above base materials may be used alone, but for example, a laminate made of any combination such as a composite of a resin base material and a wood base material, a composite of a resin base material and a metal base material, etc. Good too. When the base material 10 is a laminate, an adhesive layer and a primer layer may be further provided between each layer of the laminate.

Examples of the resin base material used as the base material 10 include those made of various synthetic resins. Examples of synthetic resins include polyethylene, polypropylene, polymethylpentene, olefin resins such as various olefin thermoplastic elastomers, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, vinyl chloride-vinyl acetate copolymer, and ethylene-vinyl acetate copolymer. vinyl resins such as ethylene-vinyl alcohol copolymers, polyester resins such as polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, ethylene glycol-terephthalic acid-isophthalic acid copolymers, various polyester thermoplastic elastomers, Acrylic resins such as methyl methacrylate, polyethyl methacrylate, and polybutyl acrylate, polyamide resins such as nylon 6 or nylon 66, cellulose resins such as cellulose triacetate and cellophane, polystyrene, polycarbonate resins, polyarylate resins, and Examples include polyimide resin.

Examples of the metal base material used as the base material 10 include those made of aluminum, duralumin aluminum alloy, iron, iron alloys such as stainless steel, titanium, copper, or copper alloys such as brass. Further, as the base material 10, it is also possible to use a base material made of another material and coated with these metals by plating or the like.

Examples of the ceramic base material used as the base material 10 include ceramic building materials such as gypsum, calcium silicate, cement, and wood chip cement, ceramics, glass, enamel, and fired tiles.

As the fibrous base material used as the base material 10, for example, paper base materials such as tissue paper, kraft paper, titanium paper, linter paper, paperboard, and base paper for gypsum board can be used. These paper base materials are made of acrylic resin, styrene-butadiene rubber, melamine resin, urethane resin, etc., in order to increase the strength between the fibers of the paper base material or between other layers and the paper base material, and to prevent fuzzing. It is also possible to add a resin (resin impregnation after papermaking, or internal filling during papermaking). Examples of the paper base material to which resin is added include interpaper reinforced paper, resin-impregnated paper, and the like.
Examples of the fibrous base material used as the base material 10 include raw vinyl wallpaper, which is a paper base material with a vinyl chloride resin layer provided on the surface, which is often used in the field of building materials.
Examples of the fibrous base material used as the base material 10 include coated paper, art paper, parchment paper, glassine paper, parchment paper, paraffin paper, and Japanese paper used in the office field or for ordinary printing and packaging. .
Examples of the fibrous base material used as the base material 10 include woven fabrics and non-woven fabrics made of various fibers that have an appearance and properties similar to paper. Examples of various fibers include inorganic fibers such as glass fibers, asbestos fibers, potassium titanate fibers, alumina fibers, silica fibers, and carbon fibers. Further, various types of fibers include synthetic resin fibers such as polyester fibers, acrylic fibers, and vinylon fibers.

Examples of the wood base material used as the base material 10 include veneers of various woods such as cedar, pine, cypress, oak, oak, lauan, and teak, plywood, laminated wood, particle board, and medium density fiberboard (MDF). ) etc.

The thickness of the base material 10 is not particularly limited, but in consideration of physical properties such as strength, mass, and flexibility of the decorative sheet 1 for recoating, it is preferably 30 μm or more and 250 μm or less, and 50 μm or more and 230 μm or less. More preferably, the thickness is 80 μm or more and 200 μm or less.

For the purpose of improving the design, it is preferable that the decorative sheet 1 for recoating further includes a pattern ink layer 11 and a colored concealing layer 12 between the base material 10 and the recoat layer 20, as shown in FIG. .

《Picture ink layer》
The picture (pattern) of the picture ink layer 11 can be arbitrarily selected depending on the desired design appearance, such as a wood grain pattern, a stone grain pattern, a cloth grain pattern, a leather grain pattern, a geometric pattern, etc. In the recoating decorative sheet 1, for example, when expressing a wood grain design appearance, a wood grain pattern may be selected as the pattern ink layer 11.
The pattern ink layer 11 may be formed anywhere on the base material 10, and may be formed on the entire surface of the base material 10.
The pattern ink layer 11 can be formed, for example, by printing. The pattern ink layer 11 may be a single layer, or may be formed from two or more layers.

The ink used to form the pattern ink layer 11 is a mixture of a binder component, coloring components such as pigments and dyes, extender pigments, solvents, stabilizers, plasticizers, catalysts, curing agents, etc. as appropriate.
There are no particular restrictions on the binder component, and examples include acrylic resin, urethane resin, vinyl chloride-vinyl acetate copolymer, styrene resin, polyester resin, chlorinated polyolefin resin, polyvinyl butyral resin, alkyd resin, petroleum resin, and ketone. Examples include resins, epoxy resins, melamine resins, fluororesins, silicone resins, cellulose derivatives, and rubber resins. These resins as binder components can be used alone or in combination of two or more.
Coloring components include, for example, inorganic pigments such as titanium white, lead white, carbon black, iron black, yellow lead, titanium yellow, Bengara, cadmium red, ultramarine blue, and cobalt blue; quinacridone red, isoindolinone yellow, and nickel azo complex. , organic pigments or dyes such as phthalocyanine blue; metal pigments made of scaly foil pieces such as aluminum and brass; known pearlescent pigments made of scaly foil pieces such as titanium dioxide-coated mica and basic lead carbonate; It can be appropriately selected and used from the following.

The thickness of the pattern ink layer 11 is not particularly limited, but from the viewpoint of exhibiting good design by the pattern, it is preferably 0.1 μm or more and 10 μm or less, and 0.5 μm or more and 7.5 μm or less. is more preferable, and even more preferably 1.0 μm or more and 5.0 μm or less. When the pattern ink layer 11 is formed of two or more layers, it is preferable that the total thickness of each pattern ink layer 11 is within the above range.

The pattern ink layer 11 may contain additives such as antioxidants and ultraviolet absorbers to the extent that the effects of the present invention are not impaired.
As a means for applying the pattern ink layer 11, gravure printing, silk screen printing, gravure offset printing, flexo printing, inkjet printing, etc. are preferable, and gravure printing is more preferable for large lots, and inkjet printing is more preferable for small lots. preferable.

《Colored concealing layer》
As shown in FIG. 2, the recoating decorative sheet 1 preferably has a form in which a colored concealing layer 12 is further provided on the resin base material 10 side as a part of the pattern ink layer 11.
The colored concealing layer 12 can give an intended color to the base material 10 when there is color unevenness, adjust the surface color, and can improve the design of the decorative sheet 1 for recoating. The colored concealing layer 12 is often formed in an opaque color for the purpose of hiding the base material 10, but it can also be formed in a colored transparent color to take advantage of the pattern that the base material 10 has.

The colored concealing layer forming composition used for forming the colored concealing layer 12 is a binder component mixed with coloring components such as pigments and dyes, extender pigments, solvents, stabilizers, plasticizers, catalysts, curing agents, etc. things are used.
The binder component and coloring component of the colored concealing layer 12 may be appropriately selected based on the use of the decorative sheet for recoating 1 and compatibility with the pattern ink layer 11. Can be used.

The thickness of the colored hiding layer 12 is not particularly limited, but from the viewpoint of good design by hiding the base material 10, it is preferably 0.1 μm or more and 10 μm or less, and 0.25 μm or more It is more preferably 0.5 μm or less, and even more preferably 0.5 μm or more and 5.0 μm or less. When the colored hiding layer 12 is formed of two or more layers, it is preferable that the total thickness of each colored hiding layer 12 is within the above range.

<Recoat layer>
The recoat layer 20 contains thermoplastic resin fibers as the constituent fibers, and is preferably configured with thermoplastic resin fibers as a main component. Here, the main component refers to a component exceeding 50% by mass of the components constituting the recoat layer 20, preferably exceeding 60% by mass, more preferably exceeding 70% by mass, and more preferably 80% by mass. More preferably, the content exceeds % by mass.

The thermoplastic resin fibers constituting the recoat layer 20 are not particularly limited, but include, for example, (meth)acrylic resins such as poly(meth)acrylic acid ester; polyvinyl acetal (butyral resin) such as polyvinyl butyral; polyethylene terephthalate. , polyester resins such as polybutylene terephthalate; polyolefin resins such as polyethylene and polypropylene; styrene resins such as polystyrene and α-methylstyrene; acetal resins such as polyoxymethylene; polyolefin thermoplastic elastomers, polystyrene thermoplastic elastomers, polydienes Thermoplastic elastomers such as thermoplastic elastomers, polyurethane thermoplastic elastomers, polyester thermoplastic elastomers, and fluororesin thermoplastic elastomers; fluororesins such as vinyl chloride resins, polyurethane resins, and ethylene-tetrafluoroethylene copolymers; Examples include polyamide resin, polyimide resin, polylactic acid resin, polycarbonate resin, polyvinyl acetal resin, liquid crystalline polyester resin, and the like. Among these, in consideration of morphological stability, (meth)acrylic resins, polyolefin resins, polyurethane resins, etc. are preferred.

Other fibers constituting the recoating layer 20 include, for example, biodegradable fibers made from lactic acid obtained from starch such as corn, cellulose-based artificial fibers such as rayon, polynosic, cupro, acetate, and triacetate, glass fibers, Examples include inorganic fibers such as carbon fibers, ceramic fibers, and asbestos fibers, and recycled fibers obtained from textile products using these fibers. These fibers constituting the recoat layer 20 can be used alone or in combination of two or more.

The nonwoven fabric constituting the recoat layer 20 is characterized in that the difference in breaking strength between the machine direction (MD) and the width direction (TD) is 40.0 N or less. If the difference in breaking strength between the flow direction and the width direction exceeds 40.0 N, the stress applied during thermal lamination or the like will cause expansion and contraction to differ depending on the direction, resulting in a loss of dimensional stability. In this specification, the machine direction (MD) of a nonwoven fabric is the machine direction at the time of manufacture, and the width direction (TD) is the direction perpendicular to the machine direction at the time of manufacture.
The difference in breaking strength between the flow direction and the width direction is preferably 35.0 N or less, more preferably 30.0 N or less, and 25.0 N or less from the viewpoint of high dimensional stability. More preferably, it is 20.0N or less, even more preferably, and the closer it is to 0N, the better.
Note that the method for measuring the breaking strength in this specification is as described in the Examples described later.

The non-woven fabric constituting the recoat layer 20 is a non-oriented non-woven fabric in which the constituent fibers do not have orientation in order to improve the anti-stretching property and to keep the difference in breaking strength between the machine direction and the width direction below the above value. It is preferable.

The nonwoven fabric constituting the recoat layer 20 preferably has a breaking strength in the flow direction of 5.0 N or more, more preferably 10.0 N or more, and even more preferably 15.0 N or more. When the breaking strength in the flow direction of the nonwoven fabric satisfies the above range, it has strength against stress applied during thermal lamination, etc., and can prevent breakage during manufacturing.

The nonwoven fabric constituting the recoat layer 20 preferably has a breaking strength in the width direction of 1.0 N or more, more preferably 1.5 N or more, and even more preferably 2.0 N or more. When the breaking strength in the width direction of the nonwoven fabric satisfies the above range, it has strength against stress applied during thermal lamination, etc., and can prevent breakage during manufacturing.

The basis weight of the nonwoven fabric constituting the recoat layer 20 is not particularly limited, but from the viewpoint of obtaining mechanical strength of the recoat layer 20, it is preferably 5 g/m ² or more, and preferably 10 g/m ² or more. More preferably, it is 15 g/m ² or more. In addition, the basis weight of the nonwoven fabric constituting the recoat layer 20 is preferably 40 g/m ² or less, and 35 g/m ² from the viewpoint of being able to perform coating with excellent ink receptivity while retaining the colorant. It is more preferably at most 30 g/m ² , even more preferably at most 30 g/m 2 .

- Dimensional Stability The nonwoven fabric constituting the recoat layer 20 preferably has high dimensional stability even when subjected to heating conditions such as thermal lamination. To measure the dimensional stability of the nonwoven fabric, measure the dimensions of the nonwoven fabric in the machine direction and width direction at five locations before and after thermal lamination (160°C, 50 kg/cm ² ), and calculate the rate of change from the average value. do.
The rate of change in the machine direction of the nonwoven fabric is preferably 10% or less, more preferably 8% or less, even more preferably 5% or less, and the closer it is to 0%, the better. The rate of change in the width direction of the nonwoven fabric is preferably 10% or less, more preferably 8% or less, even more preferably 5% or less, and the closer it is to 0%, the better. When the rate of change in the flow direction and the width direction of the nonwoven fabric is within the above range, it is possible to obtain a decorative sheet 1 for recoating of a desired size without considering shrinkage.

The recoat layer 20 is preferably one that allows the pattern of the pattern ink layer 20 to be visually recognized, and is preferably a transparent layer such as transparent paper or semi-transparent paper. Specifically, the transparency of the recoat layer 20 is preferably 50% or less, and 40% It is more preferably at most 30%, even more preferably at most 30%. Note that the lower limit of opacity is about 10%. The recoat layer 20 can be formed by, for example, a method in which paper is made transparent by treating it with concentrated sulfuric acid, a method in which paper is made by highly beating chemical pulp, a method in which base paper is impregnated with a clarifying agent such as wax and synthetic resin, or a method in which synthetic fibers are impregnated with a clarifying agent such as wax and synthetic resin. It can be obtained by a well-known manufacturing method such as a method of heating and pressurizing synthetic pulp mixed paper to make it transparent, and it may be obtained by any manufacturing method.

There is no particular limit to the thickness of the recoat layer 20, but it ensures that the recoat paint such as stain is retained, prevents the paint from dripping, and provides a coating with excellent adhesive properties that retains the colorant. From the viewpoint that it can be used, it is preferably 50 μm or more and 200 μm or less, more preferably 60 μm or more and 180 μm or less, and even more preferably 70 μm or more and 150 μm or less.

On the surface side of the recoating layer 20 in which the base material 10 is provided in the thickness direction, there is a filling portion (not shown) formed by melting and filling at least a portion of thermoplastic resin fibers into some of the fiber voids. ). The filling portion ensures adhesion between the base material 10 and the recoat layer 20.

A fiber portion (not shown) in which fiber voids and at least a portion of the surface are present is provided on the side opposite to the surface on which the base material 10 is provided in the thickness direction of the recoat layer 20 . The fiber portion of the recoating layer 20 has a recoating property that retains the coloring agent (recoating paint) in the voids and surfaces of the fibers. can have.

《Resin coating》
Preferably, the recoat layer 20 has a resin coating (not shown) on the surface of at least a portion of the fibers while maintaining at least some voids. The resin coating improves the function of the recoat layer 20 as a stain paint receiving layer. The resin coating film exists on some of the fibers of the recoat layer 20, and by improving the wettability of the fibers, it prevents the stain paint from dripping and provides a coating with excellent ink receptivity that retains the colorant. can do.

Examples of the resin used as the resin coating include thermoplastic resins, thermosetting resins, and ionizing radiation-curable resins. The resin used as the resin coating can be used as a coating composition by adding crosslinking agents, curing agents such as polymerization initiators, polymerization accelerators, solvents, viscosity modifiers, extender pigments, etc., as necessary. .

Examples of thermoplastic resins include cellulose derivatives such as ethyl cellulose, cellulose nitrate, cellulose acetate, ethyl hydroxyethyl cellulose, and cellulose acetate propionate, styrene resins or styrene copolymers such as polystyrene and polyα-methylstyrene, and polymethacrylic acid. Methyl, acrylic resins such as polyethyl methacrylate, polyethyl acrylate, and polybutyl acrylate, vinyl polymers such as polyvinyl chloride, polyvinyl acetate, vinyl chloride-vinyl acetate copolymer, polyvinyl butyral, rosin, rosin modified Examples include natural or synthetic resins such as maleic acid resin, rosin-modified phenol resin, rosin ester resin such as polymerized rosin, coumaron resin, vinyltoluene resin, and polyamide resin.

Examples of thermosetting resins include phenol resin, urea resin, diallyl phthalate resin, melamine resin, guanamine resin, unsaturated polyester resin, polyurethane resin, epoxy resin, aminoalkyd resin, melamine-urea cocondensation resin, silicone resin, and polyester resin. Examples include siloxane resin.

As the ionizing radiation-curable resin, resins conventionally used as ionizing radiation-curable resins can be used, such as (meth) having an ionizing radiation-curable functional group (meth)acryloyl group. Acrylate resin can be used. In addition, "(meth)acrylate" means "acrylate or methacrylate."
Examples of the (meth)acrylate resin include monomers, oligomers, and prepolymers such as urethane (meth)acrylate, acrylic (meth)acrylate, polyester (meth)acrylate, and epoxy (meth)acrylate. Among these (meth)acrylate resins, acrylate resins with acryloyl groups such as urethane acrylate, acrylic acrylate, polyester acrylate, and epoxy acrylate are preferred from the viewpoint of adhesion with the heat seal layer and balance of coating film strength. Among these, urethane (meth)acrylate is preferred.
Note that ionizing radiation refers to electromagnetic waves or charged particle beams that have energy quantum that can polymerize or crosslink molecules, and ultraviolet rays (UV) or electron beams (EB) are usually used, but other Electromagnetic waves such as X-rays and γ-rays, and charged particle beams such as α-rays and ion beams can also be used.

When the ionizing radiation curable resin is UV curable, the ionizing radiation curable resin composition preferably contains additives such as a photopolymerization initiator and a photopolymerization accelerator.
Examples of the photopolymerization initiator include one or more selected from acetophenone, benzophenone, α-hydroxyalkylphenone, Michler's ketone, benzoin, benzyl methyl ketal, benzoyl benzoate, α-acyloxime ester, thioxanthone, and the like.
In addition, the photopolymerization accelerator can reduce polymerization inhibition caused by air during curing and accelerate the curing speed, and includes, for example, p-dimethylaminobenzoic acid isoamyl ester and p-dimethylaminobenzoic acid ethyl ester. One or more types may be selected.

-Heat shrinkage rate The recoating decorative sheet 1 has a low heat shrinkage rate, so it can suppress expansion, contraction and curling even when used in a high-temperature environment.
Even when used in a high temperature environment of about 60°C, from the viewpoint of suppressing expansion, contraction and curling of the decorative sheet 1 for recoating, the average of the machine direction and width direction after curing in an environment of 60°C for 72 hours. The heat shrinkage rate obtained from good. The lower limit of the heat shrinkage rate of the recoating decorative sheet 1 after curing in a 60° C. environment for 72 hours is 0%.
Note that the method for measuring the heat shrinkage rate in this specification is as described in Examples described later.

[Method for manufacturing decorative sheet for recoating]
The method for manufacturing the decorative sheet for recoating 1 of the present invention will be described by taking as an example the decorative sheet for recoating shown in FIG. 1, which is one of the preferred embodiments of the decorative sheet for recoating of the present invention.
First, the base material 10 is prepared. A nonwoven fabric constituting the recoat layer 20 is prepared that contains thermoplastic resin fibers and has a difference in breaking strength of 40.0 N or less in the machine direction and the width direction.
Next, a nonwoven fabric is placed on the base material 10.
Next, the laminate in which the base material 10 and the nonwoven fabric are laminated is thermally laminated to bond the base material 10 and the nonwoven fabric together by thermocompression, thereby producing the decorative sheet 1 for recoating in which the recoat layer 20 is laminated on the base material 10. Can be done.
Through the above steps, it is possible to manufacture the decorative sheet 1 for recoating in which the base material 10 and the recoat layer 20 are sequentially laminated. The produced decorative sheet 1 for recoating has high dimensional stability because the nonwoven fabric constituting the recoat layer 20 can disperse stress applied during the lamination process and prevent expansion and contraction by breaking the fibers little by little. have

The method for producing the decorative sheet for recoating 1 preferably further includes the step of applying the above-described composition for forming a resin coating film from the surface side of the recoat layer 20 of the decorative sheet for recoating 1. By including this step, it is possible to manufacture the decorative sheet for recoating 1 having a resin coating film on the surface of at least a portion of the fibers while maintaining voids in at least a portion of the recoat layer 20.

As described above, according to the decorative sheet for recoating 1 according to the present embodiment, the dimensional stability can be increased due to the good anti-expansion property.

[How to color the decorative sheet for recoating]
The method for coloring the decorative sheet for recoating 1 according to the embodiment of the present invention is to apply a recoating paint to the recoating layer 20 of the decorative sheet for recoating 1 using a general coating method, and then coloring the recoating layer 20. It is something.
The recoating layer 20 of the decorative sheet 1 for recoating has a fiber part that maintains the fiber voids and surface on the coated surface side, so the recoat layer 20 has a fiber part that maintains the fiber voids and surface, so it has a fiber part that maintains the fiber voids and surface. Fleshness can be guaranteed. Therefore, the recoat decorative sheet 1 according to the embodiment of the present invention can be easily colored in any desired color by applying a coloring agent such as a stain to the recoat layer 20.

Next, the present invention will be explained in more detail with reference to examples, but the present invention is not limited to these examples in any way.

[evaluation]
The following evaluations were performed on the decorative sheets for recoating obtained in Examples and Comparative Examples. The results are shown in Table 1.

<Tensile test>
The nonwoven fabrics used for the decorative sheets for recoating prepared in Examples and Comparative Examples were cut into a size of 150 mm x 50 mm, and used as test pieces for a tensile test. Using JIS7127:1999 as a reference, the flow direction and The breaking strength (N) was measured in each width direction.

<Dimensional stability>
The dimensional stability of the decorative sheets for recoating produced in Examples and Comparative Examples was evaluated.
A: The rate of change in dimensions in the machine direction and width direction before and after thermal lamination is 5% or less B: The rate of change in dimensions in the machine direction and width direction before and after thermal lamination is more than 5% and 10% or less C: Heat The change rate of dimensions in the machine direction and width direction before and after lamination is more than 10%

<Heating shrinkage rate>
The heat shrinkage rate was measured in accordance with JIS7133:1999. Specifically, the decorative sheets for recoating prepared in Examples and Comparative Examples were cut into a size of 120 mm x 120 mm, and used as test pieces for the heat shrinkage rate test. Marked lines were drawn in the vertical and horizontal directions of the test piece, and the distance between the marked lines was measured. Next, the test piece was placed in an oven at a temperature of 60°C and cured for 72 hours. After taking out the test piece from the oven, the distance between the gauge lines in the machine direction and the width direction of the test piece was measured, and the shrinkage rate (%), which is the average of the dimensional changes in the machine direction and the width direction, was measured.

(Example 1)
A colored polyvinyl chloride sheet having a thickness of 100 μm was prepared as a base material. Then, by gravure printing the composition for forming a pattern ink layer on the base material, a pattern ink layer having a thickness of 4 μm was formed.
Next, a non-oriented nonwoven fabric having a basis weight of 25 g/m ² and a thickness of 60 μm and containing acrylic/polyester resin fibers as fibers was prepared. Then, the prepared nonwoven fabric was placed on the pattern ink layer placed on the base material and heat-pressed by thermal lamination (160° C., 50 kg/cm ² ) to obtain a laminate in which a recoat layer was formed.
Next, a composition for forming a resin coating film containing a urethane resin was applied from the surface side of the recoat layer to form a resin coating film on the recoat layer to obtain a decorative sheet for recoat.
Table 1 shows the evaluation results for the obtained decorative sheet for recoating.

(Comparative example 1)
A colored polyvinyl chloride sheet with a thickness of 100 μm was prepared as a base material. Then, by gravure printing the composition for forming a pattern ink layer on the base material, a pattern ink layer having a thickness of 4 μm was formed.
Next, an oriented nonwoven fabric having a basis weight of 25 g/m ² and a thickness of 60 μm and containing acrylic/polyester resin fibers as fibers was prepared. Then, the prepared nonwoven fabric was placed on the pattern ink layer placed on the base material and heat-pressed by thermal lamination (160° C., 50 kg/cm ² ) to obtain a laminate in which a recoat layer was formed.
Next, a composition for forming a resin coating film containing a urethane resin was applied from the surface side of the recoat layer to form a resin coating film on the recoat layer to obtain a decorative sheet for recoat.
Table 1 shows the evaluation results for the obtained decorative sheet for recoating.

From Table 1, in Example 1, the results of dimensional stability and heat shrinkage rate were good by using a nonwoven fabric with a difference in breaking strength of 40.0 N or less in the machine direction and width direction.
On the other hand, in Comparative Example 1, a nonwoven fabric having a difference in breaking strength in the machine direction and width direction of more than 40.0 N was used, and the results of dimensional stability and heat shrinkage rate were not good.

The decorative sheet for recoating of the present invention has good anti-expansion properties and high dimensional stability, and can be used for interior or exterior materials of buildings such as walls, ceilings, and floors, window frames, doors, In addition to fittings and fixtures such as handrails, skirting boards, edges, and moldings, it is also suitable as a decorative surface board for kitchen equipment, furniture or light electrical appliances, cabinets such as OA equipment, and layers constituting interior or exterior parts of vehicles. used for.

1: Decorative sheet for recoating 10: Base material 11: Pattern ink layer 12: Colored concealing layer 20: Recoat layer

Claims (1)

base material and
a recoat layer provided on at least one surface side of the base material, comprising a nonwoven fabric containing thermoplastic resin fibers as constituent fibers, and having voids between the fibers,
The nonwoven fabric is a decorative sheet for recoating, wherein the difference in breaking strength between the machine direction and the width direction is 40.0 N or less.