JP2553982B2 - Laminated sheet and molded product with it - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION The present invention relates to floors, decorative walls and decorative boards,
The present invention also relates to a laminated sheet obtained by joining sheets of a plurality of layers for use as a table top and the like, and a molded body to which the laminated sheet is attached.

[0002]

2. Description of the Related Art Recently, among laminated sheets used for decorative boards and the like, there is a laminated sheet having a concavo-convex pattern (that is, embossing) under a transparent (including semi-transparent. is there. Although the surface is smooth, the internal pattern is not flat, so it is used as a high-grade plate material with a deep aesthetic appearance. Such a laminated sheet is disclosed, for example, in Japanese Utility Model Publication No. 56-69435, in which a transparent upper layer sheet is thermocompressively laminated on a lower layer sheet having an upper surface embossed.

In such a conventional laminated sheet, the upper layer sheet needs to be hot pressed against the lower layer sheet having an embossed surface so as not to break the embossing. Therefore, the upper layer sheet must be softer than the lower layer sheet, and the upper layer sheet must be softened. There are inconveniences such as not being able to impart sufficient abrasion resistance to the surface of the sheet.

Therefore, the present inventors have invented a laminated sheet in which upper and lower two layers are joined by an ultraviolet curable adhesive and have already filed a patent application (Japanese Patent Application No. 3-321167).
According to the invention, the upper and lower two layers are bonded via an ultraviolet curable adhesive (heating and pressure bonding) (the adhesive is cured by irradiation with ultraviolet rays), so that the sheet is heated to a high temperature. No need. That is, for example, even if the mating sheet that is in contact with it has a higher hardness than the sheet with an embossed surface, the embossment will not collapse, so the material of each layer sheet can be used for durability (including abrasion resistance) and aesthetics. Can be selected according to the request of. Further, it is not difficult to make the laminated sheet of the present invention into a long product.

[0005]

However, regarding the above-mentioned laminated sheet according to the invention of the present inventors, there has been a demand for improvement in the following points. That is, (a) The surface layer is preferably one having high transparency and gloss in order to make the internal uneven pattern clear and enhance the appearance. Furthermore, in order to keep its aesthetic appearance for a long time, it becomes dirty and cracked,
Alternatively, it is preferable that it is not easily affected by chemicals.

C) If the laminated sheet has an excellent appearance,
Not only floors and walls but also table tops and various racks (shelf)
・ I want to use it for cabinets. For that purpose, it must be able to be attached to a curved surface without impairing its aesthetic appearance.

PET is used as the material of the surface layer satisfying the above (a).
There is (polyethylene terephthalate), but normal PE
With T (biaxially stretched PET), it is difficult to satisfy the above requirement (c). This is because such a PET has a small elongation and does not have appropriate flexibility at a general molding temperature, and therefore, when formed into a laminated sheet and then bent and formed, wrinkles may occur.

The object of the present invention is to improve the above-mentioned laminated sheet so as to satisfy both the above requirements (a) and (c), and further, to provide a molded article having the improved sheet stuck on the surface thereof, such as a table top or a rack. Is to be provided as.

[0009]

The laminated sheet according to claim 1 of the present invention comprises an amorphous polyethylene terephthalate (hereinafter referred to as amorphous PET) sheet as an upper layer and a vinyl chloride (hereinafter referred to as PVC) sheet. As the lower layer, the inner surface that is the bonding surface (that is, amorphous PE
At least one of the lower surface of the T sheet or the upper surface of the PVC sheet) is embossed, and both sheets are joined by an ultraviolet curable adhesive.

According to a second aspect of the present invention, in the molded article, the laminated sheet of the above (first aspect) and the amorphous PET sheet are directed outward (P
The VC sheet is made to be on the side of the base material described below), molded along the surface of the base material including the curved surface portion, and bonded on the surface.

[0011]

The laminated sheet according to claim 1 of the present invention has a deep aesthetic appearance because the embossed pattern under the layer is visible through the surface layer, but the surface layer is an amorphous PET sheet. The aesthetics are especially remarkable. This is because, similar to ordinary PET (the above-mentioned biaxially stretched type), amorphous PET has remarkably excellent transparency and gloss (luster) compared with, for example, PVC and OPS. Therefore, the visual sense of high quality is further amplified such that the uneven pattern inside is clearly observed. Amorphous PET is also excellent in stain resistance (hard to stain) and chemical resistance (hard to be chemically affected), so that the surface is always kept beautiful. The high impact resistance makes it difficult to break, which also contributes to the longevity of the original aesthetics. It should be noted that the fact that the amorphous PET is odorless is also convenient when it is applied in a highly hermetically sealed room.

Since this laminated sheet is easily molded, it can be formed into a three-dimensional curved surface without impairing its aesthetic appearance (that is, without causing wrinkles and reducing transparency). This is because the upper layer amorphous PET sheet is easily formed into a curved shape integrally with the lower layer PVC sheet. Amorphous PET has a glass transition temperature higher than that of a) ordinary PET. It is low and close to the molding temperature of the joined PVC sheets, and b) has a wide temperature range with flexibility required for heat molding, and therefore exhibits sufficient elongation during molding. Therefore, this laminated sheet can be easily attached to the surface of an object including a curved surface such as a table top or a rack cabinet.

In addition, since the upper layer amorphous PET sheet and the lower layer PVC sheet are joined by sandwiching an ultraviolet curable adhesive and irradiating with ultraviolet rays instead of heating and pressure bonding, the hardness between both sheets is high. There is also an advantage that the embossing is not broken regardless of the above relationship, or that both sheets have no hardness restriction.

The molded product according to claim 2 is one in which the laminated sheet according to claim 1 is attached to the surface of a base material so as to be commercialized as a table top, a rack cabinet or the like. This molded body is manufactured by, for example, applying an adhesive to the surface of a base material that has been shaped in advance, placing the laminated sheet on it, and subjecting the laminated sheet to vacuum forming or pressure forming to form the laminated sheet and the base material. Adhesion (bonding) to the substrate may be performed at the same time. Despite the fact that the surface of the base material includes the curved portion, the laminated sheet is easy to mold as described above,
The base material and the laminated sheet are exactly overlapped with each other, and no wrinkles are formed on the outer surface.

Since the laminated sheet has the excellent aesthetics and its durability as described above, the molded body is naturally excellent in appearance.

[0016]

FIG. 1 shows an embodiment of the present invention.
(a) is a cross-sectional view of the molded body 1 having the laminated sheet 10 stuck on the surface, and (b) is an enlarged view of the b portion. This molded product 1 which is a semi-finished product before being commercialized as a table top is M
As shown in the figure, a base material 20 made of a DF (mutual density fiber; high-grade particle board product) with a curved surface (three-dimensional curved surface) around the base material and a separately manufactured laminated sheet 10 are attached as shown in the figure. It is a combination. Hereinafter, the structure of the adhesive sheet 10 will be shown first, and then the method for manufacturing the sheet 10 and the base material 2 will be described.
A method of forming and adhering on the surface of 0 will be described.

The laminated sheet 10 has a flat plate shape that can be applied to a high-grade floor material before it is attached to the base material 20, and has an embossed pattern inside the transparent layer to give it a unique aesthetic appearance, It is a product that is designed to be maintained for a long period of time. As shown in FIG. 1B, this laminated sheet 10 is composed of the following three layers.

Sheet 11: Transparent amorphous PET
Sheet (A-PET (trademark) manufactured by Denki Kagaku Kogyo Co., Ltd.)
And, the thickness is 25 μm. Sheet 12: Pearl-colored PVC sheet sheet, the plasticizer is 10 PHR, and the thickness is 0.15 mm. An embossed surface 12a formed at the time of calendar forming of the sheet 12 is provided on an upper surface which is a joint surface with the sheet 11.

Adhesive 13: Transparent UV-curable urethane-acrylate resin.

With this structure, the laminated sheet 10 is
When observed from the front side (on the sheet 11), the embossed surface 12a is visible under the transparent sheet 11 and is beautiful. Since the sheets 11 and 12 are joined by the adhesive 13 as described above, continuous production (described later) is easy, and the embossed surface 12a formed in advance has a concavo-convex pattern. Even after that, it is clear without breaking. Especially,
Since the upper layer sheet 11 is made of amorphous PET, it has excellent aesthetics based on its transparency and gloss, and is also resistant to stains and resistant to oil, alcohol, acid and alkali.

2 (a) and 2 (b) are drawings schematically showing a method for manufacturing the laminated sheet 10 and the molded body 1, respectively. First, the laminated sheet 10 is manufactured by the same process (a) as described below.

1) A strip-shaped sheet 1 wound around the reel 11R
1 and the similar sheet 12 wound on the reel 12R are arranged as shown in the drawing, and the leading end is wound on the take-up reel 10R so that both are continuously conveyed to the right in the drawing. Both of the sheets 11 and 12 are passed between a pair of pinch rolls 17, and they are superposed on each other at that time.
The orientation of the reel 12R is set such that the embossed surface 12a of the reel is on the inner side (that is, the side in contact with the sheet 11).

2) The sheet 11 and the sheet 12 that move continuously as described above are joined by sequentially performing the following steps. First, the ultraviolet curable adhesive 13 is applied to the sheet 12 passing on the support roll 16 on the upstream side of the pinch roll 17 on the embossed surface 12a by the applicator 15. As described above, the sheet 11 and the sheet 12 are overlapped between the pinch rolls 17 and lightly pressed.
Sheets 11 and 12 with adhesive 13 in between
Through the ultraviolet irradiation device 18. By irradiating the transparent sheet 11 with ultraviolet rays at an intensity of about 80 W / cm, the adhesive 13 is cured and the joining is completed, and the laminated sheet 10 is obtained.

After the strip-shaped laminated sheet 10 obtained on the reel 10A is cut according to the size of the molded body 1, it is further molded on the base material 20 by the vacuum pressing process of FIG. 2 (b). And glue. The process is performed as follows.

3) The base material 20 produced in advance by MDF is mounted on the mounting table 31 at the center of the base plate 31.
It is set on a and the adhesive 25 is applied on the surface thereof.
As the adhesive 25, a two-component water-based adhesive (CVC45L (trademark) manufactured by Konishi Co., Ltd.) containing urethane acrylic as a main component is used with an air spray gun (5 g / square angle). The base plate 31 has a mounting table 31a that is raised one step higher as shown in the figure, is provided with a plurality of exhaust ports 31b around the mounting table 31a, and is provided with a frame plate 31c around it.

4) The above laminated sheet 10 is spread and overlapped on the base material 20 to which the adhesive 25 is applied. In order to turn the transparent sheet 11 outward, the side of the PVC sheet 12 is set to the base material 20 side (downward).

5) Airbag 32a made of rubber under the iron plate
The upper plate 32 with the attached
The sheet 10 is formed and adhered onto the base material 20 at the same time by a vacuum pressing method in which the base plate 31 is pressed down from above and air is exhausted from the exhaust port 31b. The conditions of this vacuum press are as follows: Temperature of the air bag 32a: 60 ° C. (333 K) Time under pressure: 150 seconds Pressure under pressure: 35 kg / cm ² (3.4M
Pa) Pressure after exhausting: -730 mmH in gauge pressure
g (-97 kPa) The laminated sheet 10 includes the sheets 11 and 12 and the adhesive 13.
Are flexible and rich in moldability, and therefore can be easily press-molded into a three-dimensional curved surface as a whole. The molded body 1 is completed by being integrated.

Although one embodiment has been introduced above, the present invention can also be carried out as follows.

A) PVC sheet 12 in the introduced embodiment
There was an embossed surface 12a on the upper surface of the
The lower surface of the ET sheet 11 may be embossed. Even in that case, light is diffusely reflected on the surface, and the pattern or the like of the lower sheet 12 is unevenly refracted, so that the appearance is also excellent.

B) It goes without saying that the detailed specifications such as the specific material, the composition, and the color tone of the amorphous PET sheet, the PVC sheet, etc. are not limited to those of the embodiment.

C) The laminated sheet of the present invention (claim 1) comprises
It can also be commercialized as a tile floor material. At that time, another sheet, a plate-shaped filling layer, or the like may be laminated on the lower layer of the PVC sheet.

D) The material and the like of the base material forming the molded body (claim 2) are not limited to those of the embodiment.

[0033]

The laminated sheet according to the first aspect of the present invention has the following effects. That is, 1) Since the two-layer sheets for aesthetic appearance are joined without heating and pressure bonding, there is a risk of embossing breakage during manufacturing while imparting high hardness and abrasion resistance to each sheet. Absent. That is, it is easily manufactured and the embossing is clear.

2) Since the upper layer is amorphous PET, its aesthetic appearance is particularly remarkable due to its transparency and the like.
Its aesthetic appearance is maintained for a long time due to stain resistance, chemical resistance, and impact resistance.

3) Since the molding is easy, wrinkles are not generated and the transparency is not deteriorated, and the aesthetic appearance is maintained.
Can be curved.

Further, since the molded product according to claim 2 has the above-mentioned laminated sheet adhered to the surface thereof, it has excellent aesthetics and maintainability and is easy to manufacture. Is extremely suitable for use as a product.

[Brief description of drawings]

1 shows an embodiment of the present invention, FIG. 1 (a) is a cross-sectional view of a molded body 1 having a laminated sheet 10 stuck on the surface thereof, FIG.
FIG. 7 is an enlarged view of a portion b of FIG.

2 (a) is a schematic diagram showing a method for producing the laminated sheet 10 of FIG. 1, and FIG. 2 (b) is a schematic diagram showing a method for producing a molded body 1 using the sheet 10. is there.

[Explanation of symbols]

1 Molded Product 10 Laminated Sheet 11 Amorphous PET (Amorphous Polyethylene Terephthalate) Sheet 12 PVC (Vinyl Chloride) Sheet 12a Embossed Surface 13 Ultraviolet Curing Adhesive 20 Base Material

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Office reference number FI technical display location B32B 27/16 B32B 27/16 27/36 27/36 31/12 7148-4F 31/12 31 / 28 7148-4F 31/28 33/00 33/00

Claims (2)

(57) [Claims] 1. An amorphous polyethylene terephthalate sheet is used as an upper layer, a vinyl chloride sheet is used as a lower layer, and at least one of inner side surfaces, which is a bonding surface, is embossed and both sheets are bonded by an ultraviolet curable adhesive. Laminated sheet characterized by. 2. The laminated sheet according to claim 1, the amorphous polyethylene terephthalate sheet facing outward, molded along the surface of a base material including a curved surface portion, and attached onto the surface. A molded body having laminated sheets, which are characterized by being combined.