JP3265255B2 - Decorative panel and manufacturing method thereof - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a decorative panel and a method for manufacturing the same. More specifically, the present invention relates to a panel having a laminated structure using a base sheet made of a polypropylene-based resin, which has an excellent appearance that gives a sense of quality, and does not generate chlorine gas or the like during incineration. And a method for efficiently producing the same.

[0002]

2. Description of the Related Art Conventionally, as a decorative panel for a cabinet of furniture or kitchen products, a decorative sheet in which, for example, a wood-grain pattern is printed on a metal-based material such as a wood-based material, an inorganic-based material, or a steel plate is generally used. The thing of the structure bonded by the adhesive is used. A decorative sheet used for such a surface decorative plate has been generally made of a vinyl chloride resin because it has moderate flexibility and has good workability such as V-cut workability and lapping workability. Sheets have been used. However, the vinyl chloride resin sheet has poor durability (resistance to abrasion, scratching, dents, etc.) and cleaning properties (easy cleaning properties, wax coating properties, antifouling properties, and antibacterial properties), and is inefficient when incinerated. Since it generates harmful chlorine and dioxin, it has a problem in terms of environmental pollution and also has a problem that a plasticizer contained therein easily bleeds and causes poor appearance. Therefore, there has been a demand for a decorative sheet that does not use a vinyl chloride resin, has good workability such as V-cut workability, and is excellent in durability and cleanability. On the other hand, in recent years, with the trend toward high-end products of consumers, high-grade feeling is required for furniture and kitchen product cabinets and the like, and therefore, the decorative sheet used for them also has a high-grade appearance. Things are desired.

[0003]

Under these circumstances, the present invention provides good cutting workability such as V-cutting workability, excellent durability and cleanability, and gives a sense of quality. An object of the present invention is to provide a decorative panel that has an excellent appearance and does not generate chlorine gas or the like at the time of incineration, has no disposal problem, and is preferably used for cabinets of furniture and kitchen products.

[0004]

The present inventors have conducted intensive studies to develop a decorative panel having the above-mentioned excellent properties, and as a result, have found that a polypropylene containing an inorganic filler, preferably calcium carbonate, in a specific ratio. A laminate having a smooth surface in which a pattern layer, a transparent plastic film layer, and a clear coat layer are sequentially laminated on one surface of a base resin-based base sheet, and a depth reaching at least the base sheet from the lower surface of the clear coat layer. The present inventors have found that a decorative panel in which concave grooves of a geometric pattern are formed can be suitable for the purpose, and based on this finding, have completed the present invention. That is, the present invention provides: (1) a transparent plastic film layer via a picture layer on one side of a polypropylene resin base sheet containing 30 to 80% by weight of an inorganic filler, and a surface of the transparent plastic film layer; A groove having a geometric pattern is formed by cutting at least to a depth reaching the substrate sheet, and has a smooth surface provided with a clear coat layer on the transparent plastic film layer and the groove. A decorative panel having a laminated structure; (2) a transparent plastic film having a pattern layer printed on the back side on one side of a base sheet obtained by molding a polypropylene resin composition containing 30 to 80% by weight of an inorganic filler; After adhering the pattern layer and the base sheet facing each other, from the surface of this transparent plastic film layer,
Forming a concave groove of a geometric pattern by cutting at least to a depth reaching the base sheet, then providing a clear coat layer on the transparent plastic film layer and the concave groove,
(3) a pattern layer on one surface of a base sheet obtained by molding a polypropylene-based resin composition containing 30 to 80% by weight of an inorganic filler; After printing, a transparent plastic film is laminated on this pattern layer, and a concave groove of a geometric pattern is formed by cutting from the surface of the transparent plastic film layer at least to a depth reaching the base sheet. Then, a clear coat layer is provided on the transparent plastic film layer and the concave groove to form a smooth surface, and a method for manufacturing a decorative panel is provided. In a preferred embodiment of the present invention, (4) the decorative panel according to (1), wherein the inorganic filler is calcium carbonate; (5) a decorative panel provided with a concealing layer between the base sheet and the picture layer. (1) The decorative panel according to (4), (6) the second (2), wherein the inorganic filler is calcium carbonate.
(3) The method for producing a decorative panel according to (3), (7) a concealing layer is further provided on one surface of the base sheet, and a transparent plastic film having a pattern layer printed on the back surface is provided thereon. Face to face and glue
(2) The method for producing a decorative panel according to (6), and (8) a third method wherein a concealing layer is further provided on one surface of the base sheet, and a picture layer is provided thereon by printing. The method for producing a decorative panel according to the above item.

[0005]

BEST MODE FOR CARRYING OUT THE INVENTION The decorative panel of the present invention is a laminated panel having a smooth surface in which a picture layer, a transparent plastic film layer and a clear coat layer are sequentially laminated on one side of a substrate sheet, As the sheet, a sheet made of a polypropylene-based resin containing 30 to 80% by weight of an inorganic filler is used. There is no particular limitation on the polypropylene resin used for the base sheet, for example, isotactic propylene homopolymer having crystallinity,
Ethylene-propylene random copolymer having a low ethylene unit content, composed of a homo part composed of a propylene homopolymer and a copolymer part composed of a relatively large ethylene-propylene random copolymer having an ethylene unit content. Propylene block copolymer, further each homo part or copolymer part in the propylene block copolymer,
Further, there may be mentioned a crystalline propylene-ethylene-α-olefin copolymer composed of a copolymer of α-olefin such as butene-1. The melt index of these polypropylene resins (measured at 230 ° C. and 2.16 kgf) is not particularly limited, but is preferably from 0.3 to
13.0 g / 10 min, more preferably 0.5 to 8.5.
The range is 0 g / 10 minutes. The polypropylene resin may be used singly or in combination of two or more. Further, a soft polypropylene resin may be blended with the above-mentioned crystalline polypropylene resin in an appropriate ratio. On the other hand, as the inorganic filler used in the base sheet, for example, calcium carbonate, magnesium carbonate, aluminum hydroxide, magnesium hydroxide, kaolin, silica, perlite, calcium sulfate, barium sulfate, calcined alumina, calcium silicate, talc, Mica and the like may be used, and these may be used alone or in combination of two or more. Among these inorganic fillers, calcium carbonate is particularly preferable from the viewpoint of machinability and the like. The calcium carbonate is not particularly limited, and any of precipitated calcium carbonate, heavy calcium carbonate, light calcium carbonate and the like can be used. The average particle size of the calcium carbonate is usually in the range of 0.05 to 20 μm, preferably 0.1 to 10 μm. If the content of the inorganic filler is less than 30% by weight, the machinability is insufficient,
It is not possible to form a recess groove described later in a satisfactory manner, and it is inferior in cutting workability such as V-cut workability. 80% by weight
If it exceeds 300, sheet formability and impact resistance will decrease, and the weight will increase. In consideration of machinability, sheet formability, impact resistance, light weight, and the like, the preferred content of the inorganic filler is in the range of 40 to 70% by weight, particularly 50 to 60% by weight.
A range of weight percent is preferred. In the base sheet, various additive components such as an antioxidant, a heat stabilizer, an ultraviolet absorber, a light stabilizer, a chlorine scavenger, a flame retardant, a flame retardant, and the like may be used as long as the object of the present invention is not impaired. A combustion aid, a lubricant, a process oil, a release agent, a colorant, and other thermoplastic resins and thermoplastic elastomers can be appropriately contained.

In the present invention, in order to enhance the design, the base sheet may be appropriately colored according to the pattern and color tone of the pattern layer provided thereon, A foamed product may be used, or a product obtained by applying both of them may be used. The thickness of the base sheet is appropriately selected according to the use of the decorative panel.
For example, when the decorative panel is used as it is as a decorative surface of furniture or a cabinet of a kitchen product, it is generally selected in the range of 1.0 to 6.00 mm, preferably 1.50 to 4.00 mm. When a decorative sheet is prepared and used as a so-called decorative sheet on a surface of a wood-based board, an inorganic board, a metal plate, or the like to be used, generally 0.08 to 2.00 mm, preferably 0.10 mm. It is selected in the range of ~ 1.00 mm. In the decorative panel of the present invention, the pattern layer provided on one side of the base sheet includes, for example, wood grain,
Prints expressing stone patterns, surface patterns of natural leather, cloth patterns, abstract patterns, etc. are attached, and there is no particular limitation on the binder of the ink for providing these pattern patterns. For example, polyurethane resins, vinyl chloride resins , Vinyl chloride-vinyl acetate copolymer resin, vinyl chloride-vinyl acetate copolymer resin / acrylic resin, chlorinated polypropylene resin, acrylic resin, polyester resin, polyamide resin, butyral resin, polystyrene Arbitrary ones from among a series resin, a nitrocellulose resin, and an acetylcellulose resin are used. In addition, the ink includes:
Colorants such as pigments and dyes, extenders, solvents and the like are appropriately mixed. The thickness of the picture layer is usually about 1 to 5 μm. In the decorative panel of the present invention, a concealing layer can be provided between the base sheet and the picture layer, if desired, for the purpose of enhancing the design. As the ink used for forming the concealing layer, an ink obtained by appropriately mixing a binder with a coloring agent such as a pigment and a dye, an extender pigment, a solvent, a stabilizer, a plasticizer, a catalyst, a curing agent, and the like is used. Examples of the binder include the same binders as those exemplified as the binder for the ink used to form the picture layer. As the concealing layer, a solid printing layer having a thickness of about 1 to 20 μm is suitable. In the decorative panel of the present invention, the transparent plastic film layer provided on the pattern layer is not particularly limited, for example, a polyolefin resin film such as a polypropylene resin or a polyethylene resin, an ethylene-vinyl alcohol copolymer resin film, Polyester-based resin film, acrylate-based resin film, ethylene-vinyl acetate copolymer-based resin film, etc., among these, among them, easily laminated by heat fusion to the substrate sheet provided with the picture layer A polyolefin-based resin film is preferred from the standpoint of yield.
This transparent plastic film may contain an antioxidant, an ultraviolet absorber, a light stabilizer and the like, if desired, in order to improve the weather resistance. The thickness of the transparent plastic film is generally 0.03.
It is preferably about 0.50 mm.

[0007] In the decorative panel of the present invention, from the surface of the transparent plastic film layer laminated on the picture layer,
The concave groove of the geometric pattern is formed at least at a depth reaching the base sheet. The depth of the concave groove is preferably such that it penetrates a part of the base sheet, and although it depends on the thickness of the transparent plastic film layer, it is generally 0.05 to 0.50.
mm is preferable. The width of the groove is generally 1.
A range of 0 to 15.0 mm is preferred. There is no particular limitation on the cross-sectional shape of the concave groove, and any shape such as a V-shape, a U-shape, or a rectangular shape with a missing upper side can be formed. There is no particular limitation on the number and shape of the concave grooves, but when the decorative panel is, for example, a square plate, one or more concave panels may be formed in parallel with the longitudinal side surface. Then, one or more pieces may be formed in parallel with the side face in the width direction, or one or more pieces may be formed in each of the side face in the longitudinal direction and the side face in the width direction. In the decorative panel of the present invention,
A clear coat layer is provided on the transparent plastic film layer and the concave groove of the laminate having the concave groove thus formed. This clear coat layer is provided to fill the above-mentioned concave groove to form a smooth surface and to provide the decorative panel with abrasion resistance, weather resistance, scratch resistance, stain resistance and the like. As the clear coat layer, for example, an acrylic resin, a polyurethane resin, an ultraviolet curable resin, and the like, a resin having a thickness of 10 to 10
It is a layer of about 200 μm. This clear coat layer may be colored pink or blue if desired,
In addition, various known antibacterial agents can be contained. By containing an antibacterial agent, contamination by microorganisms such as mold can be prevented. In the decorative panel of the present invention having such a configuration, a thick base sheet can be used as a surface decorative plate as it is, and a thin base sheet is
For example, wood, plywood, laminated wood, wood-based base materials such as particle boats and hardboards, metal-based base materials such as steel plates, stainless steel plates and aluminum plates, inorganic base materials such as gypsum boats, etc. The material sheet side is adhered and can be used as a surface decorative board. In the decorative panel of the present invention, the concave groove looks like a joint at first sight, gives an impression as if assembled using a plurality of panels, and has an appearance such as a woodgrain, thereby giving a sense of quality. FIG. 1A is a cross-sectional view of one example of the decorative panel of the present invention, and FIG. 1B is a plan view of the decorative panel. A transparent plastic film layer 3 is provided on one side of a rectangular plate-shaped substrate sheet 1 with a picture layer 2 interposed therebetween. The transparent plastic film layer 3 has a depth at which it penetrates a part of the substrate sheet 1 from the surface thereof. The V-shaped concave grooves 4 and 4 ′ are formed in two rows parallel to the longitudinal side surface of the base sheet. Further, a clear coat layer 5 is provided on the transparent plastic film layer 3 to fill the concave grooves 4 and 4 'and form a smooth surface.

Next, a method for manufacturing a decorative panel according to the present invention will be described. The method for producing the decorative panel is not particularly limited as long as the decorative panel having the above configuration can be obtained, and any method may be used. Well, decorative panels can be manufactured. According to the method of the present invention, (1)
On one surface of the substrate sheet, a transparent plastic film having a pattern layer printed on the back surface is adhered with the pattern layer and the substrate sheet facing each other, and then, from the surface of this transparent plastic film layer, at least to the substrate sheet. A method of manufacturing a decorative panel by forming a concave groove of a geometric pattern at a reaching depth by cutting, and then providing a clear coat layer on the transparent plastic film layer and the concave groove to form a smooth surface. (1st method), and (2) after providing a pattern layer by printing on one side of the base sheet, laminating a transparent plastic film on the pattern layer,
From the surface of the transparent plastic film layer, at least a depth of the geometric pattern is formed by cutting at a depth reaching the base sheet, and then a clear coat layer is provided on the transparent plastic film layer and the concave groove, By forming a smooth surface, a decorative panel can be obtained by a method of manufacturing a decorative panel (second method). In the first and second methods, first, a base sheet is formed using a polypropylene-based resin composition. The polypropylene-based resin composition used as the material of the base sheet,
The aforementioned polypropylene-based resin, 30 to 80% by weight based on the total amount of the composition, an inorganic filler such as calcium carbonate, and various additives used as desired are blended and mixed with a tumbler blender, a Henschel mixer, or After mixing, it is prepared by melt-kneading and granulating using a single-screw extruder or a multi-screw extruder, or by melt-kneading and granulating with a kneader, a Banbury mixer or the like. Next, this composition is molded by various methods such as cast molding and calender molding, and has a thickness of 1.0 to 6.0.
A base sheet of about 0 mm or about 0.08 to 2.00 mm is prepared. Next, in the first method, a thickness of 0.03 printed with a pattern layer on the back surface on one side of the base sheet.
A transparent plastic film having a thickness of about 0.15 mm is adhered with the picture layer and the base sheet facing each other, and a laminate having a transparent plastic film layer on the base sheet via the picture layer is produced. As the transparent plastic film, those exemplified above are used, and in order to improve weather resistance, an antioxidant, an ultraviolet absorber,
Those containing a light stabilizer or the like are preferred. This film is subjected to a surface treatment such as a corona treatment, an ozone treatment, and a plasma treatment on both surfaces in order to improve the adhesion between the pattern layer provided on the back surface and the clear coat layer provided on the surface. Can be. The picture layer can be provided by performing general printing such as gravure printing, screen printing, offset printing, or flexographic printing on one surface of the transparent plastic film.

As a method for bonding the transparent plastic film having the picture layer and the base sheet, there are a method using an adhesive and a method using heat fusion, and the method can be appropriately selected according to the material of the film to be used. I just need. For example, if the film is a polyolefin-based resin film, it is advantageous to use a heat fusion method. Further, if desired, when a concealing layer is provided, a concealing layer is provided on one surface of the base sheet by the same printing method as described above, and a transparent plastic film having a pattern layer on the back surface is formed thereon. And the concealing layer may be faced and bonded. On the other hand, in the second method, on one side of the base material sheet, if necessary, a concealing layer is provided by printing, and further, a picture layer is provided thereon by printing, and then a transparent plastic film is provided on the picture layer. Laminate. The printing method, the method of laminating the transparent plastic film, and the transparent plastic film are as described in the first method. Next, in the first and second methods, at least a depth reaching the base sheet from the surface of the transparent plastic film layer of the thus obtained laminated body, preferably a part of the base sheet, is cut. At depth, a concave groove of a geometric pattern is formed using a cutting tool. The shape, size, number, shape, etc. of the concave groove are as described above. As a cutting tool used for forming the concave groove, for example, a counterbore, a Sanehagi router bit and the like can be mentioned. In the present invention, by using a polypropylene-based resin sheet containing an inorganic filler such as calcium carbonate in a specific ratio as a base material sheet, the cutability is good, and the concave groove is formed cleanly and easily. be able to. Lastly, on the transparent plastic film layer and the groove, a clear coat layer forming material is applied to fill the groove, and a clear coat layer is provided with a thickness of 10 to 200 μm,
By forming a smooth surface, a desired decorative panel is obtained. As described above, an acrylic resin, a polyurethane resin, an ultraviolet curable resin, or the like is used as the clear coat layer forming material.

[0010]

Next, the present invention will be described in more detail with reference to examples, but the present invention is not limited to these examples. Example 1 (1) Preparation of Polypropylene Film Having Picture Layer An unstretched transparent polypropylene film having a thickness of 80 μm [trade name: RXC-3, manufactured by Tocelo Co., Ltd.] was subjected to corona treatment on both sides, and one side thereof was covered with oak. A pattern layer similar to the wood pattern of the wood was printed using a three-color ink with a gravure rotary press to produce a polypropylene film having a pattern layer. (2) Preparation of base sheet Homopolypropylene [manufactured by Idemitsu Petrochemical Co., Ltd., trade name: E
-100G] 45 parts by weight, 55 parts by weight of calcium carbonate powder having an average particle size of 1.0 μm, and 0.2 parts by weight of a phenolic antioxidant are dry-blended and then melt-kneaded with a twin-screw kneader to obtain pellets. Was. Next, a base sheet having a thickness of 3.0 mm was prepared by calendering using the pellets. (3) Preparation of decorative panel One side of the base sheet obtained in the above (2) is provided with the above (1)
A polypropylene film having a pattern layer obtained in
The pattern layer and the base material sheet were overlapped so as to face each other, were thermally fused at 170 ° C., and were bonded. Next, from the surface of the polypropylene film layer of this laminate, the width was 5.0 mm and the depth was 0.5 mm.
A 15 mm V-shaped concave groove was formed using a Sanehagi router bit [attached to a CNC machine tool manufactured by Shoda Tekko Co., Ltd.].
This V-shaped concave groove could be formed very cleanly and easily. Next, an acrylic resin [manufactured by China Paint Co., Ltd., trade name: Aurex 278] is applied on the polypropylene film layer and the concave groove to fill the concave groove and have a smooth surface with a thickness of 50 μm. A clear coat layer was formed. In the decorative panel obtained in this manner, the V-shaped concave groove looks like a joint at first sight, gives the impression of being assembled using two panels, and has a high-quality woodgrain. Was. Example 2 Example 1
A substrate sheet having a thickness of 3.5 mm was prepared in the same manner as in (2), and a pattern layer similar to a wood grain pattern of oak was formed on one surface of the substrate sheet using a three-color ink. Printed at the turning point. Next, both sides of an acrylonitrile-based film [manufactured by Tamapoly Corporation, product name: Hytron BX] having a thickness of 40 μm were subjected to corona treatment, and then superposed on the pattern layer of the above-mentioned base sheet, heat-sealed at 170 ° C., and laminated. . Thereafter, in the same manner as in Example 1 (3), a V-shaped concave groove was formed, and a clear coat layer having a smooth surface was formed. At this time, the V-shaped concave groove could be formed very cleanly and easily. In the decorative panel obtained in this way, the V-shaped concave groove looks like a joint at a glance,
It gave the impression of assembling using two panels, and had a high-quality woodgrain.

[0011]

Industrial Applicability The decorative panel of the present invention has good cutting workability such as V-cut workability, excellent durability and cleanability, has an excellent appearance giving a sense of quality, and has a chlorine appearance when incinerated. Because there is no gas generated, there is no disposal problem,
It is preferably used for cabinets for furniture and kitchen products. Further, according to the method of the present invention, this decorative panel can be manufactured extremely efficiently.

[Brief description of the drawings]

FIG. 1 is a sectional view (a) and a plan view (b) of one example of a decorative panel of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Base sheet 2 Picture layer 3 Transparent plastic film layer 4 Concave groove 4 'Concave groove 5 Clear coat layer

────────────────────────────────────────────────── ─── Continuation of the front page (56) References JP-A-10-24529 (JP, A) JP-A-9-314756 (JP, A) JP-A-9-300559 (JP, A) JP-A 8- 267682 (JP, A) (58) Field surveyed (Int. Cl. ⁷ , DB name) B32B 1/00-35/00

Claims (4)

(57) [Claims] 1. A on one side of the polypropylene resin base sheet containing an inorganic filler 30-80 wt%, a transparent plastic film layer through the pattern layer, the transparent plastics
At least the depth from the surface of the stick film layer to the base sheet, the concave groove of the geometric pattern is cut.
While being Katachi設I, decorative panels laminated structure having a smooth surface formed by clear coat layer is provided on the transparent plastic film layer and the concave on the groove. 2. The decorative panel according to claim 1, wherein the inorganic filler is calcium carbonate. 3. A transparent plastic film having a pattern layer printed on one side of a substrate sheet obtained by molding a polypropylene-based resin composition containing 30 to 80% by weight of an inorganic filler, After the base sheet is adhered with the base sheet, the concave groove of the geometric pattern is formed by cutting from the surface of the transparent plastic film layer at least to a depth reaching the base sheet, and then the transparent plastic film is formed. A method for producing a decorative panel, comprising: providing a clear coat layer on a film layer and a concave groove to form a smooth surface. 4. A pattern layer is printed on one side of a base sheet obtained by molding a polypropylene resin composition containing 30 to 80% by weight of an inorganic filler, and then a transparent plastic film is laminated on the pattern layer. At the same time, from the surface of the transparent plastic film layer, a concave groove of a geometric pattern is formed by cutting at least at a depth reaching the base sheet, and then a clear coat layer is formed on the transparent plastic film layer and the concave groove. And forming a smooth surface.