JP3175482B2 - Decorative sheet and method for producing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative sheet which has been subjected to arbitrary printing and embossing, and a method of manufacturing the same. In particular, the present invention has the same properties as vinyl chloride resin without using vinyl chloride resin and has a problem in incineration. And a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, a vinyl chloride resin sheet has been most commonly used as a decorative sheet to be used as a decorative sheet by attaching it to the surface of a wooden boat, an inorganic board, a metal plate or the like. However, vinyl chloride resin is also said to cause hydrogen chloride gas generation, acid rain, and dioxin generation during incineration. In recent years, from the viewpoint of environmental issues, decorative sheets that do not use resin sheets other than vinyl chloride resin have been required. Have been.

[0003] Accordingly, as disclosed in JP-A-6-16832, a decorative sheet comprising a polyolefin-based thermoplastic elastomer has been disclosed. However, in these, the moderate flexibility of vinyl chloride, friction resistance, chemical resistance, stain resistance,
It did not satisfy well-balanced properties such as weather resistance.

In addition, according to the manufacturing methods shown in these publications, embossing is performed mechanically by the same heat and pressure as a conventional vinyl chloride resin sheet, so that the embossing can be reproduced only about 70% of the embossing plate. In addition, there is a disadvantage that the emboss disappears when left in an atmosphere of about 100 ° C. for a long time.

[0005]

SUMMARY OF THE INVENTION The present invention has been made to solve such a problem, and an object of the present invention is to use a material other than the vinyl chloride resin to attain the characteristics of the vinyl chloride resin. The present invention is to provide a decorative sheet having properties superior to those of the present invention and a method for producing the same, and in particular, to provide a decorative sheet having appropriate flexibility suitable for post-processing and excellent in emboss reproducibility and a method for producing the same. It is in.

[0006]

Since the present invention SUMMARY OF] is to solve this problem, the substrate sheet formed of a resin containing a random polymer of polypropylene and 5 to 30% by weight of the polyolefin based soft component, a random polymer polypropylene 5-
Provided is a decorative sheet characterized by being bonded with an embossed sheet made of a resin containing 30% by weight of a polyolefin-based soft component.

Further, the polyolefin-based soft component low-density polyethylene, alpha-olefin, ethylene - either one of propylene copolymer rubber is characterized by a mixture thereof, also the random polymerization polypropylene <br/> A decorative sheet characterized by being a simple mixture of non-crosslinked polyolefin-based soft components and non-crosslinked polyolefin-based components.

Further, the base sheet contains an inorganic coloring pigment, the base sheet is provided with an arbitrary pattern printing on the surface thereof, the embossed sheet has transparency, and a nucleating agent is added. The present invention provides a decorative sheet characterized in that:

Further, a resin containing a molten random-polymerized polypropylene and 5 to 30% by weight of a polyolefin-based soft component is extruded onto an embossed cooling roll to form an embossed sheet. And Landa
At least one of the surfaces of a base sheet made of a resin containing a polymerized polypropylene and a resin containing 5 to 30% by weight of a polyolefin-based soft component is subjected to corona treatment, an adhesive is applied to at least one of the surfaces, and a hot-press roll is dried. Characterized in that the polyolefin-based soft component is
Low-density polyethylene, α-olefin, ethylene-propylene
Any one of the ren copolymer rubbers or their mixture
A method for producing a decorative sheet is provided.

Hereinafter, the present invention will be described in detail. FIG. 1 shows an example of a cross-sectional configuration of the decorative sheet of the present invention. An arbitrary pattern printing layer 2 is provided on the surface of the base sheet 1, and an embossed sheet 4 is provided via an adhesive 3. There is an embossed pattern 5 on the embossed sheet surface. On these, a wiping ink 6, a top coat layer 7, and the like can be arbitrarily provided.

The base sheet 1 according to the present invention is made of a resin containing polypropylene and a polyolefin-based soft component.

[0012] The polypropylene is required to have homopolypropylene when heat resistance and hardness are required for the obtained sheet, block polymerized polypropylene when impact resistance is required, and to have impact resistance, low temperature processability and transparency. In this case, random polymerization polypropylene may be appropriately selected. In particular, since the low-temperature processability, which is a feature of the vinyl chloride resin sheet, is emphasized, random polymerization polypropylene can be said to be optimal.

The polyolefin-based soft component includes:
Use is made of any one of low-density polyethylene, α-olefin, ethylene-propylene copolymer rubber or a mixture thereof. These are added in an amount of 5 to 30% by weight. 5
If it is less than 30% by weight, there is no effect on low-temperature processability, and if it is more than 30% by weight, the elasticity of the obtained sheet is too large.

The polypropylene and the olefin-based soft component are simply mixed without crosslinking. this is,
Not only is the process simplified, but also to prevent cross-linking between the two, thereby impairing the transparency particularly required for embossed sheets. This is to eliminate the possibility that the interface of the film will cause a whitening phenomenon.

Further, in order to obtain concealing properties when used as a decorative sheet, it is desirable that the base sheet is arbitrarily colored with an inorganic pigment.

[0016] In addition, a phenolic antioxidant for preventing thermal oxidation when extruding the sheet, and a hindered amine light stabilizer for preventing deterioration of the obtained product due to ultraviolet rays are added to the base sheet. May be added as appropriate.

As the arbitrary pattern 2 provided on the surface of the base sheet, a pattern 2 having good adhesion to the base sheet is used. In particular, urethane-based ink is most suitable in view of the cohesiveness and versatility of the ink itself.

The adhesive 3 used for bonding the base sheet and the embossed sheet is not particularly limited as long as it is an adhesive for a polyolefin resin, but a urethane adhesive is used for the same reason as the ink. Optimal. The amount of the adhesive applied is preferably 2 to 15 μm. 2 μm
Below, sufficient adhesive strength cannot be obtained, and when it is 15 μm or more, whitening occurs at the time of folding of the sheet.

As the embossed sheet 4 in the present invention, the same resin as the base sheet can be used. In particular, since the sheet to be embossed is required to have transparency, in some cases, a nucleating agent may be added to polypropylene to improve the transparency.

In addition to the antioxidant and the light stabilizer, an ultraviolet absorber represented by a benzotriazole type may be appropriately added to the embossed sheet in order to prevent ultraviolet rays from the base sheet.

Hereinafter, the method for producing a decorative sheet of the present invention will be described in detail step by step. FIG. 2 shows an example of a production process of the decorative sheet of the present invention. The molten resin 9 is extruded onto the embossed cooling roll 10, a corona treatment is performed by a corona treatment device 13 on a back surface of the obtained embossed sheet 12 having the embossed pattern 5, and an adhesive is applied to the corona treated surface. An adhesive is applied by the processing apparatus 14 and the base sheet 1 on which an arbitrary pattern 2 is applied is bonded by a hot-press roll 16. Thus, an embossed decorative sheet is obtained. In some cases, it is also possible to improve the design by embedding the wiping ink 6 in the emboss of the obtained embossed decorative sheet and thereafter providing the top coat layer 7 on the outermost surface.

Here, the molten resin 9 is cooled and solidified and embossed simultaneously by the embossed cooling roll 10. This is a state in which molten resin is put in a mold instead of being mechanically embossed as in the case of heating doubling embossing performed with a conventional vinyl chloride decorative sheet, so for example, holograms A very fine emboss as used can be included without any problem, and the emboss after embossing has good heat resistance.

In a conventional casting method such as an air knife or air chamber method which is performed by molding polypropylene, etc., the force for pressing the resin against the emboss is weak.
Embossing becomes sweet. Therefore, in the present invention, in order to emboss, the molten resin is pressed against the embossed cooling roll 10 by the pressure roll 8.

The degree of corona treatment in the present invention varies depending on the surface condition of the embossed sheet to be extruded, but it is preferable that the sheet surface tension is in the range of 40 to 55 dyn / cm.

[0025]

As described above, by using an olefin-based resin as the base sheet and the resin to be melt-extruded as in the present invention, printability, heat resistance, weather resistance, and flexibility over vinyl chloride sheets are improved. It became possible to grant.
In particular, by appropriately selecting the polypropylene and the soft component, a sheet excellent in post-processing suitability at a low temperature can be obtained.

Further, the resin is melt-extruded and simultaneously held on the embossed cooling roll, so that there is no fear of the emboss returning due to heat during the post-processing, and fine embossing such as used for holograms can be provided. It has become possible.

[0027]

EXAMPLES As a base sheet, 78.3% by weight of randomly polymerized polypropylene, 15% by weight of low density polyethylene, 6% by weight of an inorganic coloring material, 0.2% by weight of a phenolic antioxidant, hindered amine 0-based light stabilizer.
Using a sheet obtained by melt-extruding a resin to which 3% by weight and 0.2% by weight of an antiblocking agent are added, a corona treatment is performed on the surface of the sheet, and then a gravure printing method is used for a pattern ink (manufactured by Toyo Ink Mfg. Co., Ltd .: "Lamister").

As an embossed sheet, 77.8% by weight of random polymerized polypropylene and 15% of low density polyethylene were used.
Wt%, phenolic antioxidant 0.2 wt%, hindered amine light stabilizer 0.3 wt%, benzotriazole UV absorber 0.5 wt%, antiblocking agent 0.2 wt% %, A sheet obtained by extruding a resin onto a cooling roll having a conduit embossed by an extruder using a sheet is subjected to a corona treatment on its back surface, and then an adhesive (Adcoat 806, manufactured by Toyo Morton Co., Ltd.) Was applied to a thickness of 3 μm by a gravure method.

The embossed sheet thus obtained and the substrate sheet were rolled at a roll temperature of 80 ° C. and a linear pressure of 5 kg / c.
m to form a decorative sheet.

Comparative Example 1 A decorative sheet was obtained in the same manner as in Example except that a soft component, that is, low-density polyethylene was not added to the resin to be melt-extruded.

<Comparative Example 2> A sheet in which ink (manufactured by Toyo Ink Mfg. Co., Ltd .: "VCGT-K") was printed on a colored vinyl chloride resin sheet by a gravure printing method, and a transparent vinyl chloride sheet were doubled. A decorative sheet was obtained by laminating with heat simultaneously with embossing by embossing.

The decorative sheet thus obtained was bonded to a plywood with an adhesive to prepare a decorative sheet, subjected to V-cut processing, left in an atmosphere of 0 ° C. for 24 hours, and then subjected to V-cut. The surfaces were bonded together, and the degree of whitening at the edges was observed. In addition, the depth of the applied emboss was measured by a surface roughness meter to evaluate what percentage of the depth of the embossing plate could be reproduced. Further, after the obtained embossed decorative sheet was left in an atmosphere at 100 ° C. for 5 hours, the shape of the emboss was measured by a surface roughness meter to evaluate what percentage of the embossed plate could be reproduced with respect to the depth. . The results are shown below.

[0033]

[Table 1]

As is clear from Table 1, the sheet obtained according to the present invention is a decorative sheet which does not use vinyl chloride, the embossing applied faithfully reproduces the embossing plate, and No change in emboss depth at
Further, the suitability for processing at low temperatures was superior to that of the vinyl chloride resin sheet.

[0035]

As described in detail above, according to the decorative sheet of the present invention and the method for producing the same, there is no concern about environmental pollution because no vinyl chloride is used, and the decorative sheet has physical properties equal to or higher than that of vinyl chloride. A sheet is obtained. In particular, a resin sheet is extruded and embossed, so that a decorative sheet excellent in emboss reproducibility and heat resistance can be obtained. Further, due to the influence of the soft component to be added, a material having a workability at a low temperature that is higher than that of a vinyl chloride resin sheet can be obtained.

[0036]

[Brief description of the drawings]

FIG. 1 is an explanatory diagram showing an example of a cross-sectional structure of a decorative sheet according to the present invention.

FIG. 2 is an explanatory view showing an example of steps of a method for producing a decorative sheet according to the present invention.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Base sheet 2 ... Picture ink 3 ... Adhesive 4 ... Embossed sheet 5 ... Embossed pattern 6 ... Wiping ink 7 ... Top coat layer 8 ... Pressure roll 9 ... Molten resin 10 ... Embossed cooling roll 11 ... Peeling roll 12 ... Embossed sheet 13 ... Corona treatment device 14 ... Adhesive coating device 15 ... Dryer 16 ... Hot pressure roll 17 ... Substrate sheet with picture 18

────────────────────────────────────────────────── ─── Continued on the front page (51) Int.Cl. ⁷ identification code FI // B29K 23:00 B29L 9:00 (58) Field surveyed (Int.Cl. ⁷ , DB name) B32B 1/00-35 / 00

Claims (10)

(57) [Claims] 1. A randomly polymerized polypropylene with a substrate sheet consisting of 5 to 30 wt% of resin containing a polyolefin-based soft component, random polymerization of polypropylene and 5
A decorative sheet provided with an embossed sheet made of a resin containing up to 30% by weight of a polyolefin-based soft component. 2. The method according to claim 1, wherein the polyolefin-based soft component has a low density.
Ethylene, α-olefin, ethylene-propylene copolymer
Any one of the synthetic rubbers or their mixture
The decorative sheet according to claim 1, wherein: 3. A method according to claim 1, wherein said randomly polymerized polypropylene and 5 to 3
Resin containing 0% by weight of polyolefin-based soft component
But random polymerized polypropylene and polyolefin soft
Characterized by simple mixing without cross-linking
The decorative sheet according to claim 1. 4. The method according to claim 1, wherein the base sheet contains an inorganic color pigment.
The method according to any one of claims 1 to 3, wherein
Decorative sheet. 5. An arbitrary pattern print is provided on the surface of the base sheet.
The method according to any one of claims 1 to 4, wherein
On the decorative sheet. 6. A nucleating agent, wherein said embossed sheet has transparency.
The composition according to claim 1, wherein
6. The decorative sheet according to any one of items 5 to 5. 7. An embossed pattern on the embossed sheet
A ping ink is provided.
The decorative sheet according to any one of claims 6 to 10. 8. An embossing machine provided with the wiping ink.
And wherein the Rukoto such by providing a top coat layer on the over door
The decorative sheet according to claim 7. 9. A cosmetic sheet according to any one of claims 1 to 8,
A method for producing a molten polymer
Pyrene and 5 to 30% by weight of a polyolefin-based soft component
Is pressed on the embossed cooling roll.
To make an embossed sheet.
Randomized polypropylene and 5-30% by weight of polyole
Base sheet made of resin containing fin-based soft component
And at least one is corona treated to at least
Apply adhesive on one side, dry and glue with hot-press roll
A method for producing a decorative sheet, comprising: 10. The polyolefin-based soft component has a low density.
Polyethylene, α-olefin, ethylene-propylene
Be any one of the polymerized rubbers or a mixture thereof.
5. The makeup system according to claim 1, wherein
To