JP3705482B2 - Printed resin film for decorative board lamination and decorative board laminated with the resin film - Google Patents

Printed resin film for decorative board lamination and decorative board laminated with the resin film Download PDF

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JP3705482B2
JP3705482B2 JP2000600839A JP2000600839A JP3705482B2 JP 3705482 B2 JP3705482 B2 JP 3705482B2 JP 2000600839 A JP2000600839 A JP 2000600839A JP 2000600839 A JP2000600839 A JP 2000600839A JP 3705482 B2 JP3705482 B2 JP 3705482B2
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resin
layer
decorative
printing
resin film
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寛之 岩下
幸治 田熊
義之 杉本
芳樹 武居
行治 藤井
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Toyo Kohan Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/08—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/14—Printing or colouring
    • B32B38/145—Printing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/402—Coloured
    • B32B2307/4023—Coloured on the layer surface, e.g. ink
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/714—Inert, i.e. inert to chemical degradation, corrosion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2367/00—Polyesters, e.g. PET, i.e. polyethylene terephthalate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2451/00—Decorative or ornamental articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/06—Embossing

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  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Wood Science & Technology (AREA)
  • Laminated Bodies (AREA)

Description

技術分野
本発明は、化粧板積層用印刷樹脂フィルムおよびその樹脂フィルムを積層した化粧板に関し、より詳しくは電気冷蔵庫のドア、エアコンカバー等の家庭電化製品の外装や鋼製家具、エレベータ、建築物等の内装のように、特に意匠性を要求される用途に適した化粧板積層用印刷樹脂フィルムおよびその樹脂フィルムを積層した化粧板に関する。
背景技術
従来、各種家具類や建築内装材等に使用される化粧板としては、
（１）基材となる樹脂層に通常の方法を用いて印刷を施し、印刷層の表面保護のために、アミノアルキッド樹脂、ウレタン樹脂等のコート層を設けた化粧フィルム、
（２）基材となる樹脂層に印刷を施した後、透明な二軸延伸ポリエステルフィルムを接着剤層を介して積層した化粧フィルム、
（３）ポリ塩化ビニルフィルムの上に通常の方法を用いて印刷を施した後、透明なポリ塩化ビニルフィルムや二軸延伸ポリエステルフィルムを積層した化粧フィルム、
などの化粧フィルムを、接着剤を介して亜鉛めっき鋼板、合板、またはＭＤＦなどの基板に積層したものが知られている。
しかしながら、上記（１）の化粧フィルムを積層した化粧板は、化粧フィルムの強度が不十分であるため、Ｖカット加工などを施す場合、加工時に化粧フィルムが割れたり、コーナー部のインキが剥離し易いという問題があり、Ｖカット加工などを施す用途には適していない。（２）の化粧フィルムを積層した化粧板は、耐汚染性、耐溶剤性などの表面物性には優れているが、表面フィルムの柔軟性に乏しく、軟化温度が高いためエンボス加工を施す場合、エンボスが入り難い。
（３）の化粧フィルムを積層した化粧板は、ポリ塩化ビニルフィルムが用いられているため、耐汚染性、耐溶剤性などの表面物性が劣り、また焼却して廃棄処理する際に、塩化水素ガスのような有毒ガスおよびそれに起因する有害物質が発生して環境を汚染したり、焼却する際に焼却炉を傷めたりするおそれがあるなどの問題を抱えている。
本発明は上記の問題を解決することを目的として、従来のポリ塩化ビニル樹脂フィルムを用いた化粧シートと同等以上の意匠性に優れた、ワイピング印刷を施してなる絵柄模様を有し、耐汚染性、耐溶剤性などの表面物性に優れた化粧板積層用印刷樹脂フィルムおよびその樹脂フィルムを積層した化粧板を提供することを課題とする。
発明の開示
本発明の化粧板積層用印刷樹脂フィルムは、基材樹脂層、印刷層、着色樹脂層、ワイピング印刷層、表面保護層、艶調整層が下から順次積層されたことを特徴とする。
本発明の化粧板積層用印刷樹脂フィルムは、着色樹脂層、ワイピング印刷層、表面保護層、艶調整層が下から順次積層されたことを特徴とする。
本発明の化粧板積層用印刷樹脂フィルムは、着色樹脂層、ワイピング印刷層、表面保護層が下から順次積層されたことを特徴とする。
上記印刷樹脂フィルムは、前記ワイピング印刷層が、前記着色樹脂層の全面に設けられてなることが望ましい。
上記印刷樹脂フィルムは、前記着色樹脂層がエンボス加工が施され、該エンボス加工により形成されたエンボス凹部にインキが充填されてなるワイピング印刷層を有することが望ましい。
上記印刷樹脂フィルムは、前記基材樹脂層および着色樹脂層がポリブチレンテレフタレート樹脂からなることが望ましい。
上記印刷樹脂フィルムは、前記着色樹脂層がポリブチレンテレフタレート樹脂からなることが望ましい。
本発明の化粧板は、樹脂フィルムを積層する基板の少なくとも片面に、上記のいずれかの化粧板積層用印刷樹脂フィルムを積層したものであることを特徴とする。
上記化粧板は、前記基板と前記化粧板積層用印刷樹脂フィルムの間に接着剤層を介して積層してなることが望ましい。
上記化粧板は、前記基板が金属板であることが望ましい。
上記化粧板は、前記基板が木質板、またはボードであることが望ましい。
【図面の簡単な説明】
図１は、本発明の化粧板積層用印刷樹脂フィルムの一例を示す断面図である。図２は、本発明の化粧板積層用印刷樹脂フィルムの他の一例を示す断面図である。図３は、本発明の化粧板積層用印刷樹脂フィルムの他の一例を示す断面図である。図４は、本発明の化粧板の一例を示す断面図である。図５は、本発明の化粧板の他の一例を示す断面図である。
発明を実施するための最良の形態
本発明の発明者等は、焼却時に有毒ガスおよびそれに起因する有害物質が発生して環境を汚染するおそれがあるポリ塩化ビニル樹脂フィルムに替わる、意匠性に優れた絵柄模様を有し、かつ耐汚染性、耐溶剤性などの表面物性に優れた化粧板に積層する印刷可能な樹脂フィルムについて鋭意検討した結果、印刷下地となる基材樹脂層ならびに着色樹脂層としてポリブチレンテレフタレートフィルムを用い、それに絵柄印刷層を形成し、さらに、着色樹脂層にエンボス加工を施してエンボス凹部を形成した後、ワイピング法を用いてエンボス凹部にインキを充填してなるワイピング印刷層を設け、その上に選択的にエンボス加工が施される表面保護層、またはさらにその上に選択的に施される艶調整層を下から順次積層することにより、上記の要求特性を満足する化粧板に積層する樹脂フィルムが得られることを見出した。
さらに、上記の樹脂フィルムを金属板、合板、ボードなどに積層した化粧板は、樹脂フィルムの上記の優れたフィルム物性に加えて、意匠性にも優れていることを見出した。
以下に本発明についてその内容を説明する。
図１は本発明の化粧板積層用印刷樹脂フィルムの一例を示す断面図、図２および図３は本発明の化粧板積層用印刷樹脂フィルムの他の例を示す断面図、図４および図５は本発明の化粧板の例を示す断面図である。１は化粧板積層用印刷樹脂フィルム、２は基板、３は接着剤層、４は基材樹脂層、５は絵柄印刷層、６は着色樹脂層、７はワイピング印刷用エンボス凹部、８はワイピング印刷層、９は表面保護層、１０はエンボス凹部、１１は艶調整層、１２は化粧板をそれぞれ表している。
本発明の化粧板積層用印刷樹脂フィルム１は、図１に示すように着色樹脂層６の上面に、エンボス加工を施してエンボス凹部７を形成した後、ワイピング法を用いてエンボス凹部７にインキを充填してなるワイピング印刷層８が形成され、さらにその上面に、表面保護層９が積層される。
また、本発明の化粧板積層用印刷樹脂フィルム１は、図２に示すように図１の化粧板積層用印刷樹脂フィルムの表面保護層９として、表面にエンボス加工を施した表面保護層９を用いてもよい。
さらに、本発明の化粧板積層用印刷樹脂フィルム１は、図３に示すように、図２の化粧板積層用印刷樹脂フィルムの着色樹脂層６の下面に、絵柄印刷層５を施した基材樹脂層４を積層し、さらに図２の化粧板積層用印刷樹脂フィルムの表面保護層９の上層にエンボス凹部１０を消失させない程度に艶調整層１１を設けてもよい。
図４は、図２に示した化粧板積層用印刷樹脂フィルム１を、接着剤層３を介して基板２に積層した化粧板１２を示す。
図５は、図３に示した化粧板積層用印刷樹脂フィルム１を、接着剤層３を介して基板２に積層した化粧板１２を示す。
本発明に用いられる基材樹脂層４および着色樹脂層６としては、１.０〜２.０の固有粘度（ＩＶ値）を有するポリブチレンテレフタレートフィルムを用いることが好ましいが、固有粘度は製膜性の面から１.５以下、耐水経時性（耐水劣化性）の面から１.２以上であることがより好ましい。また、基材樹脂層４も押出機を用いて製膜する際に、着色顔料を混練して着色樹脂層としてもよい。
絵柄印刷層５は、例えば、木目、石目、天然皮革の表面柄、布目、抽象柄などの模様を表現した層であり、絵柄印刷層５を形成するインキのビヒクルとしては、例えばニトロセルロース、酢酸セルロースなどのセルロース誘導体、ポリエステルウレタン樹脂などの公知のものが使用できるが、なかでも密着及び熱接着性の両観点からニトロセルロース−アルキド樹脂系インキが好ましい。
また、着色樹脂層６にエンボス加工を施してエンボス凹部７を形成した後、ワイピング法を用いてエンボス凹部７にインキを充填してなるワイピング印刷層８を設ける際に、ワイピング印刷用のエンボス凹部７に充填されるワイピングインキとしては、塗料もしくはインキが用いられる。
例えば、天然樹脂またはその変成樹脂類、セルロース誘導体類、ポリエステル系樹脂、アクリル系樹脂、ポリウレタン系樹脂等の合成樹脂類をビヒクルの構成材料とし、ビヒクル中に着色顔料、体質顔料等を添加して成る塗料もしくはインキが用いられる。使用されるビヒクルとしてはウレタン２液硬化型のものが好適に用いられる。ワイピング法としては、ドクターブレード法、ロールコート法など、従来から使用されているワイピング法のいずれによってもよい。
表面保護層９としてはポリエステル樹脂フィルムを用いることが好ましく、なかでも１.０〜２.０の固有粘度を有するポリブチレンテレフタレート樹脂フィルムを用いることがより好ましい。このポリエステル樹脂フィルムは、可塑剤及びハロゲン属元素を含まないポリエステル樹脂からなることを特徴とする。
このポリエステル樹脂を構成する材料の一例としては、以下の組成を有する共重合ポリエステル樹脂などが好適に用いられる。すなわち、樹脂を形成するソフトセグメントとして、ポリエチレングリコール、ポリテトラメチレングリコールなどのポリオキシアルキレングリコール、あるいはポリε−カプロラクトン、アゼライン酸、セバシン酸、ドデカンジオン酸、ダイマー酸などのＨＯＯＣ−［ＣＨ2］ｎ−ＣＯＯＨの分子構造を有する脂肪族ジカルボン酸と、脂肪族および／または脂環族ジオールからなる脂肪族ポリエステルなどが好適に用いられる。
また、樹脂を構成するハードセグメントとしては、エチレンテレフタレート、ブチレンテレフタレート、シクロヘキサンジメチレンテレフタレート、シクロヘキサンジメチレンシクロヘキサンジカルボキシレート、ブチレン２，６ナフタレンジカルボキシレートなどの芳香族および／または脂環族エステルユニットから選ばれた少なくとも一つから構成されていることが好ましい。
さらに、アルコール成分として、１，４ブタンジオール残基を含有していることが耐溶剤性の点で好ましく、共重合ポリエステルを形成する全アルコール成分に占める１，４ブタンジオール残基が４０モル％以上、６５モル％以下であることが好ましい。
基板とのより強力な密着性が要求される場合には、基材樹脂層４の樹脂成分の一部にアイオノマー樹脂成分を含有させると良好な密着性が得られる。この場合、アイオノマー樹脂成分を樹脂成分の全体の１〜５０重量％とすることが好ましい。
そして図１に示す本発明の化粧板積層用印刷樹脂フィルムは、次のようにして作成することができる。すなわち、押出機により加熱溶融し着色顔料を混練した樹脂をＴダイからエンボス加工を施したキャスティングロール上に押出して片面にエンボス凹部７を有する着色樹脂層６を製膜する。前記着色樹脂層６のエンボス凹部７を形成された面にワイピングによりエンボス凹部７にインキを充填してなるワイピング印刷層８を設け、その上面に表面保護層９を重ね合せたまま１対の熱ロール間に通して挟み付けて圧着するとともに熱融着して積層し、一枚の積層フィルムを製造する。加熱しながら加圧することにより、着色樹脂層６のワイピング印刷層面を表面保護層９に融着して一枚の化粧板積層用印刷樹脂フィルム１を作るものである。
また、着色樹脂層６と表面保護層９を積層する際に、上記の熱ロールとしてエンボスロールを使用することにより、積層とエンボス加工を同時に実施することができ、表面保護層９の表面にエンボス凹部１０が形成された図２に示す化粧板積層用印刷樹脂フィルム１を得ることができる。そして、着色樹脂層６がエンボス加工性に優れるために鮮明なワイピング印刷が可能となる上に、寸法安定性に優れるため、張力や熱に起因する伸縮変動を抑えることが可能となり、印刷柄とエンボス柄が同調した、高意匠性を有するエンボス化粧フィルムとすることができる。上記の積層作業やエンボス加工などの工程は、従来のポリ塩化ビニル樹脂フィルムにおけるのと同じ条件で作業することが可能である。
さらに、図２の化粧板積層用印刷樹脂フィルムの着色樹脂層６と表面保護層９をエンボス加工しながら積層する際に、着色樹脂層６の下面に絵柄印刷層５を施した基材樹脂層４の印刷面を対向させて積層し、次いで、図３に示すように、表面保護層９の表面に艶調整層１１を施して、意匠性をより一層向上させた化粧板積層用印刷樹脂フィルム１とすることもできる。
艶調整層１１は、無色透明であってもまたは着色透明であっても、さらに艶消しの透明であってもよく、化粧板積層用印刷樹脂フィルム１の表面の光沢度を調整するために設けるものであるが、表面保護層としての役割も兼ねる。艶調整層１１は適宜のビヒクルを用いた塗料を塗布することにより形成することができる。ビヒクルとしてはフェノール樹脂、不飽和ポリエステル樹脂、エポキシ樹脂、ポリウレタン系樹脂などの熱硬化性樹脂の１種または２種以上の混合樹脂を用いることが出来る。艶調整層１１を形成する塗料には通常適量の艶消剤を分散させて所望の光沢度を付与しているが、艶消剤としてはマイカ、シリカ、アルミナ、炭酸カルシウム、ケイソウ土、ケイ砂、シラスバルーンなどが用いられる。上記塗料の塗布方法としては、グラビアコート、ロールコート、エアナイフコートなど、公知の塗布方式を用いることができる。
また、上記の方法によって得られた化粧板積層用印刷樹脂フィルム１を、接着剤層３を介在させて基板２と貼合わせることにより、図４または図５に示すような化粧板１２が得られる。基板２としては、例えば、木材単板、木材合板、パーチクルボード、ＭＤＦ等の木質板、鋼板、アルミニウム合金板、亜鉛や亜鉛合金をめっきした亜鉛めっき鋼板などの金属板、または石膏ボード、珪酸カルシウムボード、石綿スレートボードなどの無機質からなるボードが用いられる。
化粧板積層用印刷樹脂フィルム１と基板２の貼合わせに用いられる接着剤層３の接着剤としては、一般的な接着剤、例えば、酢酸ビニル樹脂系、エチレン−ビニルアセテート樹脂系、尿素樹脂系、ウレタン樹脂系などのエマルジョン型接着剤が、火気に対して安全で、臭気もなく、価格的にも安価なため好ましく用いられる。
実施例
次に実施例により本発明をさらに詳細に説明する。
（実施例１）
市販のポリブチレンテレフタレート樹脂にクリーム色顔料２０重量％を混練したものを押出製膜機により加熱溶融し、Ｔダイからエンボス加工を施したキャスティングロール上に押出して片面にエンボス凹部を有する厚さ６０μｍの着色樹脂層を製膜した。次いで、前記エンボス凹部を有する面に２液硬化型ウレタン系着色インキ（昭和インク製、ＰＷ−００１）をロールコート法によって塗工した後、ドクターブレードでエンボス凹部以外の部分に付着している着色インキをワイピングで除去した後、積層フィルムの表面に形成されているエンボス凹部内に充填された着色インキを固化させて、印刷樹脂フィルムを作成した。さらに、この印刷樹脂フィルムのエンボス加工面に、市販のポリブチレンテレフタレート樹脂を用いて押出製膜機により作成した厚さ６０μｍの未延伸フィルムを重ねて、圧着用ロールの加熱温度：２１０℃、樹脂フィルムの送り速度：２０ｍ／ｍｉｎ、圧着用ロールのニップ圧：１５ｋｇｆ／ｃｍ2の条件で両フィルムを加熱圧着して積層し、化粧板積層用印刷樹脂フィルムを作成した。次に、厚さ０.５ｍｍの電気亜鉛めっき鋼板にポリエステル系接着剤を１０ｇ／ｍ2の塗布量で塗布し、前記の化粧板積層用印刷樹脂フィルムを加熱温度：２２０℃、接着圧力：１５ｋｇｆ／ｃｍ2、圧着時間：５秒の条件で加熱圧着し、化粧板を得た。
（実施例２）
実施例１と同一のポリブチレンテレフタレート樹脂の未延伸フィルムに、実施例１と同様にして印刷が施されたワイピング印刷層面と、実施例１と同一の透明ポリブチレンテレフタレート樹脂からなるフィルムとを対向させ、実施例１の加熱圧着による積層条件と同条件にて、透明ポリブチレンテレフタレートフィルム面をエンボスロール側として、エンボスロールとシリコンゴムロールからなる圧着用ロールの間に通して圧着することにより、透明ポリブチレンテレフタレートフィルム表面にエンボス凹部を有する化粧板積層用印刷樹脂フィルムを作成した。次に、厚さ６ｍｍの木材合板にポリウレタン系接着剤を５０ｇ／ｍ2の塗布量で塗布し、前記化粧板積層用印刷樹脂フィルムを加熱温度：１６０℃、接着圧力：１５ｋｇｆ／ｃｍ2、圧着時間：１５秒の条件で加熱圧着し、化粧板を得た。
（実施例３）
市販のポリブチレンテレフタレート樹脂を用いて押出製膜機により作成した厚さ４０μｍの未延伸フィルムの片面に、ニトロセルロース−アルキド系インキ（昭和インク製、ＳＡＭ）を用い、絵柄印刷層をグラビア輪転機によりインラインにて印刷した。次いで、前記未延伸フィルムの印刷面に、実施例１と同様にして印刷された実施例１と同一のポリブチレンテレフタレート樹脂の未延伸フィルムのワイピング印刷層面と実施例１と同一の透明ポリブチレンテレフタレートフィルムとを対向させたものを重ねて、実施例１の加熱圧着による積層条件と同条件にて、透明ポリブチレンテレフタレートフィルム面をエンボスロール側として、エンボスロールとシリコンゴムロールからなる圧着用ロールの間に通して圧着することにより、透明ポリブチレンテレフタレートフィルム表面にエンボス凹部を有する化粧板積層用印刷樹脂フィルムを作成した。さらに、この化粧板積層用印刷樹脂フィルムのエンボス加工面に、２液硬化型ウレタン系艶調整用塗料（昭和インク製、ＯＰ−Ｎｏ.８１）を版深３０μｍのグラビアロールにてコートし、意匠性に優れた化粧フィルムを作成した。次に、厚さ８ｍｍの石膏ボードにポリウレタン系接着剤を８０ｇ／ｍ2の塗布量で塗布し、前記化粧板積層用印刷樹脂フィルムを加熱温度：１８０℃、接着圧力：１５ｋｇｆ／ｃｍ2、圧着時間：２０秒の条件で加熱圧着し、化粧板を得た。
（樹脂フィルムの特性評価）
実施例１、２、および３で作成した化粧板を、下記の特性について評価した。
（エンボス加工性）
本発明の化粧板積層用印刷樹脂フィルムのワイピング印刷用エンボス加工性の良否は、エンボス加工を施した樹脂フィルムの基材樹脂層の表面の粗さの程度によって判断される。本発明においては、平均表面粗さ（Ｒａ）：１１μｍの凹凸が付与された砂目の彫刻ロールを用いてエンボス加工を施した樹脂フィルムの着色樹脂層の表面を肉眼観察し、エンボス加工性の良否を下記の３段階の基準で評価した。
○：良好、△：やや不良、×：不良
なお、上記の評価基準は、ポリ塩化ビニル樹脂フィルムの表面粗さ（Ｒａ：μｍ）を東京精密社製ＳＵＲＦＣＯＭ表面粗さ計を用いてＪＩＳ Ｂ０６０１に準拠して測定し、平均表面粗さが４μｍである場合をエンボス加工性の合格基準とし、平均表面粗さが４μｍのポリ塩化ビニル樹脂フィルムの表面と同等以上の外観を有するものを良好（○）とし、ポリ塩化ビニル樹脂フィルムの表面と比べてやや劣るが実用上問題ない外観を有するものをやや不良（△）とし、エンボス加工が入らないものを不良（×）として、判定した。
（耐汚染性）
実施例１、２、および３で作成した化粧板の最表層の樹脂フィルム面に、黒色の油性マジックインキで描画し２４時間放置した後、エタノールを含浸させた布で清拭し、樹脂フィルム面に残存するマジックインキの程度を肉眼観察し、下記の基準で評価した。
◎：マジックインキは全く認められない。
○：実用上問題ない程度の極くわずかなマジックインキの残存が認められる。
△：実用上問題となる程度のわずかなマジックインキの残存が認められる。
×：かなりの程度にマジックインキの残存が認められる。
（耐溶剤性）
実施例１、２、および３で作成した化粧板の最表層の樹脂フィルム面に、メチルエチルケトンを含浸させたスポンジを載せ、２４時間放置した後、フィルム表面の変色および膨れの発生の程度を肉眼観察し、下記の基準で評価した。
◎：変色および膨れの発生は全く認められない。
○：実用上問題ない程度の極くわずかな変色または膨れの発生が認められる。
△：実用上問題となる程度のわずかな変色または膨れの発生が認められる。
×：かなりの程度に変色および膨れが認められる。
（耐水劣化性）
本発明の化粧板を高温多湿の状態で長時間経時させた場合（例えばユニットバスの内装材として用いた場合など）を想定し、長時間水と接した場合の樹脂フィルムの耐水劣化性をデュポン衝撃試験法で評価した。
実施例１、２および３で作成した化粧板積層用印刷樹脂フィルムを、厚さ０.５ｍｍの亜鉛めっき鋼板に積層し試験片とした。この試験片を６０ｍｍ×６０ｍｍの大きさに切り出し、３８±２℃の温度に保持された脱塩水中に１カ月間浸漬した後室温で乾燥し、デュポン衝撃試験機を用い、ＪＩＳ Ｋ ５４００に準拠した条件（衝撃部の大きさ１／２inchφ、重さ１ｋｇ、落下高さ５０ｃｍ）で衝撃を負荷した。衝撃を負荷した後の樹脂フィルムの状態を肉眼観察し、下記の５段階で評価した。
◎：樹脂フィルムに割れが認められない。
○：樹脂フィルムの一部に細かい割れが認められる。
△：樹脂フィルムのエンボス加工部全体に細かい割れが認められる。
×：樹脂フィルムのエンボス加工部全体に大きな割れが認められる。
××：樹脂フィルム全体に割れが著しい。
上記の評点において、◎および○は使用上の問題はない。なお、この試験は１０枚の試験片について実施した。これらの化粧板の特性評価を下記に示す。

Figure 0003705482
表１に示すように、本発明の化粧板は、エンボス性、耐汚染性、耐溶剤性、耐水劣化性のいずれにおいても優れた特性を示す。
産業上の利用可能性
本発明の化粧板積層用印刷樹脂フィルムは上記のように構成されており、ポリブチレンテレフタレートフィルムからなる基材樹脂層および着色樹脂層が熱や張力に対する伸縮変動が少なく、優れた寸法安定性を有しているため、印刷見当精度のよい印刷物を得ることが出来る。さらに、エンボス加工性に優れるため、鮮明なワイピング印刷が可能である。
また、従来のポリ塩化ビニル樹脂フィルムと同様の製造方法および製造条件で化粧フィルムが得られるために、新規設備の増設や設備の改造などの設備投資を必要とせず、従来のポリ塩化ビニル樹脂フィルムと同様の、印刷柄とエンボス柄が同調した意匠性に優れた絵柄模様を表現することができる。
さらに、基材樹脂層や表面保護層を構成する樹脂中に可塑剤を含有していないために、可塑剤のブリードによる表面汚染などの問題が生じることなく、耐汚染性、耐溶剤性、耐水性などの表面物性に優れている。
またさらに、焼却廃棄する際に、塩化水素ガスのような有毒ガスの発生がないため、環境を汚染する心配もなく環境保全性においても優れている。TECHNICAL FIELD The present invention relates to a printing resin film for laminating decorative plates and a decorative plate laminated with the resin films, and more specifically, exteriors of home appliances such as electric refrigerator doors and air conditioner covers, steel furniture, elevators, and buildings. In particular, the present invention relates to a printed resin film for laminating a decorative plate suitable for applications requiring design properties, and a decorative plate laminated with the resin film.
BACKGROUND ART Conventionally, as a decorative board used for various furniture and building interior materials,
(1) A decorative film on which a resin layer serving as a base material is printed using a normal method, and a coating layer such as an aminoalkyd resin or a urethane resin is provided to protect the surface of the printed layer;
(2) A decorative film in which a transparent biaxially stretched polyester film is laminated via an adhesive layer after printing on a resin layer serving as a substrate;
(3) A decorative film in which a transparent polyvinyl chloride film or a biaxially stretched polyester film is laminated after printing on a polyvinyl chloride film using a normal method,
A laminate of a decorative film such as galvanized steel sheet, plywood or MDF with an adhesive is known.
However, since the decorative film laminated with the decorative film of (1) has insufficient strength of the decorative film, when performing V-cut processing or the like, the decorative film is cracked during processing or the ink at the corners is peeled off. There is a problem that it is easy to use, and it is not suitable for applications in which V-cut processing or the like is performed. The decorative board laminated with the decorative film of (2) is excellent in surface physical properties such as stain resistance and solvent resistance, but the surface film is poor in flexibility and has a high softening temperature. Embossing is difficult to enter.
The decorative board laminated with the decorative film of (3) uses a polyvinyl chloride film, so the surface properties such as contamination resistance and solvent resistance are inferior, and when incineration and disposal, hydrogen chloride There are problems such as the generation of toxic gas such as gas and harmful substances resulting from it, polluting the environment, and damaging the incinerator during incineration.
In order to solve the above problems, the present invention has a design pattern that has been subjected to wiping printing and has a design pattern that is superior to or better than a decorative sheet using a conventional polyvinyl chloride resin film, and is resistant to contamination. An object of the present invention is to provide a printed resin film for laminating a decorative plate excellent in surface properties such as property and solvent resistance, and a decorative plate laminated with the resin film.
DISCLOSURE OF THE INVENTION A printing resin film for laminating decorative sheets according to the present invention is characterized in that a base resin layer, a printing layer, a colored resin layer, a wiping printing layer, a surface protective layer, and a gloss adjusting layer are laminated in order from the bottom. .
The decorative resin laminated printing resin film of the present invention is characterized in that a colored resin layer, a wiping printing layer, a surface protective layer, and a gloss adjusting layer are sequentially laminated from the bottom.
The decorative resin laminate printing resin film of the present invention is characterized in that a colored resin layer, a wiping printing layer, and a surface protective layer are sequentially laminated from the bottom.
As for the said printing resin film, it is desirable for the said wiping printing layer to be provided in the whole surface of the said colored resin layer.
The printing resin film preferably has a wiping printing layer in which the colored resin layer is embossed and an embossed recess formed by the embossing is filled with ink.
In the printing resin film, the base resin layer and the colored resin layer are preferably made of a polybutylene terephthalate resin.
As for the said printing resin film, it is desirable for the said colored resin layer to consist of polybutylene terephthalate resin.
The decorative board of the present invention is characterized in that any of the above-mentioned decorative resin laminate printing resin films is laminated on at least one surface of a substrate on which a resin film is laminated.
The decorative plate is preferably formed by laminating an adhesive layer between the substrate and the printed resin film for laminating a decorative plate.
As for the said decorative board, it is desirable for the said board | substrate to be a metal plate.
As for the said decorative board, it is desirable for the said board | substrate to be a wooden board or a board.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing an example of a printing resin film for laminating decorative sheets according to the present invention. FIG. 2 is a cross-sectional view showing another example of the decorative resin laminated printing resin film of the present invention. FIG. 3 is a cross-sectional view showing another example of the decorative resin laminated printing resin film of the present invention. FIG. 4 is a cross-sectional view showing an example of the decorative board of the present invention. FIG. 5 is a cross-sectional view showing another example of the decorative board of the present invention.
BEST MODE FOR CARRYING OUT THE INVENTION The inventors of the present invention are excellent in design, replacing a polyvinyl chloride resin film that may generate toxic gases and harmful substances resulting from the incineration, and may contaminate the environment. As a result of intensive studies on a printable resin film to be laminated on a decorative board having a good pattern and having excellent surface properties such as stain resistance and solvent resistance, a base resin layer and a colored resin layer serving as a printing base Wiping printing that uses a polybutylene terephthalate film as a film, forms a pattern printing layer on it, further embosses the colored resin layer to form embossed recesses, and then fills the embossed recesses with ink using the wiping method. A surface protective layer that is selectively embossed on the surface, or a gloss adjusting layer that is selectively applied on the surface. By following lamination, it found that resin film to be laminated to the decorative plate satisfying the above required characteristics can be obtained.
Furthermore, the decorative board which laminated | stacked said resin film on the metal plate, the plywood, the board, etc. discovered that it was excellent also in the design property in addition to the said outstanding film physical property of a resin film.
The contents of the present invention will be described below.
FIG. 1 is a cross-sectional view showing an example of a printed resin film for laminating decorative plates according to the present invention. FIGS. 2 and 3 are cross-sectional views showing another example of the printed resin film for laminating decorative plates of the present invention. These are sectional drawings which show the example of the decorative board of this invention. DESCRIPTION OF SYMBOLS 1 is printing resin film for laminated decorative boards, 2 is a board | substrate, 3 is an adhesive layer, 4 is a base resin layer, 5 is a pattern printing layer, 6 is a colored resin layer, 7 is an embossing recessed part for wiping printing, 8 is wiping A printed layer, 9 is a surface protective layer, 10 is an embossed recess, 11 is a gloss adjusting layer, and 12 is a decorative board.
As shown in FIG. 1, the decorative resin laminate printing resin film 1 of the present invention is embossed on the upper surface of the colored resin layer 6 to form an embossed recess 7, and then an ink is applied to the embossed recess 7 using a wiping method. Is formed, and a surface protective layer 9 is laminated on the upper surface thereof.
In addition, the decorative resin laminate printing resin film 1 of the present invention has a surface protective layer 9 having an embossed surface as the protective surface layer 9 of the decorative resin laminate printing resin film of FIG. 1 as shown in FIG. It may be used.
Further, as shown in FIG. 3, the decorative resin laminate printing resin film 1 of the present invention is a base material provided with a pattern printing layer 5 on the lower surface of the colored resin layer 6 of the decorative resin laminate printing resin film of FIG. 2. The resin layer 4 may be laminated, and the gloss adjustment layer 11 may be provided on the upper surface protective layer 9 of the printing resin film for laminating decorative plates in FIG.
FIG. 4 shows a decorative board 12 in which the decorative resin laminate printing resin film 1 shown in FIG. 2 is laminated on the substrate 2 via the adhesive layer 3.
FIG. 5 shows a decorative board 12 in which the decorative resin laminate printing resin film 1 shown in FIG. 3 is laminated on the substrate 2 via the adhesive layer 3.
As the base resin layer 4 and the colored resin layer 6 used in the present invention, it is preferable to use a polybutylene terephthalate film having an intrinsic viscosity (IV value) of 1.0 to 2.0. It is more preferable that it is 1.5 or less from the viewpoint of water resistance and 1.2 or more from the viewpoint of water aging resistance (water deterioration resistance). The base resin layer 4 may also be kneaded with a color pigment to form a colored resin layer when forming the film using an extruder.
The pattern print layer 5 is a layer expressing a pattern such as a grain pattern, a stone pattern, a surface pattern of natural leather, a texture pattern, an abstract pattern, and the like. Examples of the ink vehicle forming the pattern print layer 5 include nitrocellulose, Cellulose derivatives such as cellulose acetate and known ones such as polyester urethane resin can be used, and among these, nitrocellulose-alkyd resin-based inks are preferred from the viewpoints of adhesion and thermal adhesiveness.
Further, after embossing the colored resin layer 6 to form the embossed recess 7, the embossed recess for wiping printing is provided when the wiping printing layer 8 is formed by filling the embossed recess 7 with ink using a wiping method. As the wiping ink filled in 7, paint or ink is used.
For example, natural resins or their modified resins, cellulose derivatives, polyester resins, acrylic resins, polyurethane resins and other synthetic resins are used as vehicle constituent materials, and coloring pigments, extender pigments, etc. are added to the vehicle. A paint or ink is used. As the vehicle to be used, a urethane two-component curing type is preferably used. As the wiping method, any of conventionally used wiping methods such as a doctor blade method and a roll coating method may be used.
As the surface protective layer 9, it is preferable to use a polyester resin film, and it is more preferable to use a polybutylene terephthalate resin film having an intrinsic viscosity of 1.0 to 2.0. This polyester resin film is characterized by comprising a polyester resin containing no plasticizer and no halogen element.
As an example of the material constituting the polyester resin, a copolymerized polyester resin having the following composition is preferably used. That is, as a soft segment for forming a resin, polyoxyalkylene glycol such as polyethylene glycol and polytetramethylene glycol, or HOOC- [CH 2 ] such as polyε-caprolactone, azelaic acid, sebacic acid, dodecanedioic acid, and dimer acid An aliphatic dicarboxylic acid having an n-COOH molecular structure and an aliphatic polyester composed of an aliphatic and / or alicyclic diol are preferably used.
In addition, as the hard segment constituting the resin, aromatic and / or alicyclic ester units such as ethylene terephthalate, butylene terephthalate, cyclohexane dimethylene terephthalate, cyclohexane dimethylene cyclohexane dicarboxylate, butylene 2,6 naphthalene dicarboxylate, etc. It is preferably composed of at least one selected from.
Further, it is preferable that the alcohol component contains 1,4 butanediol residue from the viewpoint of solvent resistance, and 40 mol% of 1,4 butanediol residue occupies in all the alcohol components forming the copolymer polyester. As mentioned above, it is preferable that it is 65 mol% or less.
In the case where stronger adhesion to the substrate is required, good adhesion can be obtained by including an ionomer resin component in a part of the resin component of the base resin layer 4. In this case, the ionomer resin component is preferably 1 to 50% by weight of the total resin component.
And the printing resin film for lamination | stacking of the decorative board of this invention shown in FIG. 1 can be produced as follows. That is, a resin obtained by heating and melting with an extruder and kneading the color pigment is extruded from a T die onto an embossed casting roll to form a colored resin layer 6 having an embossed recess 7 on one side. A wiping print layer 8 formed by filling the embossed recess 7 with ink by wiping is provided on the surface of the colored resin layer 6 where the embossed recess 7 is formed, and a pair of heat is applied while the surface protective layer 9 is superimposed on the upper surface. The film is sandwiched between rolls and pressure-bonded and heat-sealed and laminated to produce a single laminated film. By applying pressure while heating, the surface of the colored resin layer 6 is fused to the surface protective layer 9 to produce one decorative resin laminated printing resin film 1.
Further, when the colored resin layer 6 and the surface protective layer 9 are laminated, by using an embossing roll as the above-mentioned heat roll, lamination and embossing can be performed simultaneously, and the surface of the surface protective layer 9 is embossed. The decorative resin laminated printed resin film 1 shown in FIG. 2 in which the recesses 10 are formed can be obtained. And since the colored resin layer 6 is excellent in embossability, it is possible to perform clear wiping printing, and in addition, because it is excellent in dimensional stability, it is possible to suppress expansion and contraction variation caused by tension and heat. It can be set as the embossing decorative film which has the high design property which the embossed pattern synchronized. Steps such as the above laminating operation and embossing can be performed under the same conditions as in conventional polyvinyl chloride resin films.
Furthermore, when the colored resin layer 6 and the surface protective layer 9 of the printed resin film for laminating decorative plates in FIG. 2 are laminated while being embossed, the base resin layer provided with the pattern printing layer 5 on the lower surface of the colored resin layer 6 4 are laminated with the printing surfaces facing each other, and then, as shown in FIG. 3, a gloss adjusting layer 11 is applied to the surface of the surface protective layer 9 to further improve the design properties. It can also be 1.
The gloss adjusting layer 11 may be colorless and transparent, or colored and transparent, and may be matte and transparent, and is provided for adjusting the glossiness of the surface of the decorative resin laminated printing resin film 1. However, it also serves as a surface protective layer. The gloss adjusting layer 11 can be formed by applying a paint using an appropriate vehicle. As the vehicle, one or a mixture of two or more thermosetting resins such as phenol resin, unsaturated polyester resin, epoxy resin, and polyurethane resin can be used. The paint forming the gloss adjusting layer 11 is usually provided with a desired gloss by dispersing an appropriate amount of a matting agent. Examples of the matting agent include mica, silica, alumina, calcium carbonate, diatomaceous earth, and quartz sand. A shirasu balloon or the like is used. As the coating method of the coating material, a known coating method such as gravure coating, roll coating, air knife coating or the like can be used.
Moreover, the decorative board 12 as shown in FIG. 4 or FIG. 5 is obtained by bonding the printed resin film 1 for decorative board lamination obtained by said method with the board | substrate 2 with the adhesive bond layer 3 interposed. . As the substrate 2, for example, a wood plate, a wood plywood, a particle board, a wood plate such as an MDF, a steel plate, an aluminum alloy plate, a metal plate such as a galvanized steel plate plated with zinc or a zinc alloy, a gypsum board, a calcium silicate board A board made of an inorganic material such as an asbestos slate board is used.
As an adhesive for the adhesive layer 3 used for laminating the printed resin film 1 for laminating a decorative plate and the substrate 2, a general adhesive such as a vinyl acetate resin, an ethylene-vinyl acetate resin, or a urea resin is used. An emulsion type adhesive such as urethane resin is preferably used because it is safe against fire, has no odor, and is inexpensive.
EXAMPLES Next, the present invention will be described in further detail with reference to examples.
(Example 1)
A commercially available polybutylene terephthalate resin kneaded with 20% by weight of a cream pigment is heated and melted by an extrusion film forming machine, extruded from a T-die onto an embossed casting roll, and has a thickness of 60 μm having an embossed recess on one side. A colored resin layer was formed. Next, a two-component curable urethane-based colored ink (Showa Ink, PW-001) is applied to the surface having the embossed recesses by a roll coating method, and then is attached to a portion other than the embossed recesses with a doctor blade. After the ink was removed by wiping, the colored ink filled in the embossed depressions formed on the surface of the laminated film was solidified to produce a printed resin film. Further, an unstretched film having a thickness of 60 μm prepared by an extrusion film forming machine using a commercially available polybutylene terephthalate resin was stacked on the embossed surface of the printing resin film, and the heating temperature of the pressure bonding roll: 210 ° C., resin Both films were heat-pressed and laminated under the conditions of a film feed speed of 20 m / min and a nip pressure of a pressure bonding roll of 15 kgf / cm 2 to prepare a printed resin film for decorative plate lamination. Next, a polyester-based adhesive is applied to an electrogalvanized steel sheet having a thickness of 0.5 mm at a coating amount of 10 g / m 2 , and the decorative resin laminate printing resin film is heated at a temperature of 220 ° C. and an adhesive pressure of 15 kgf. / Cm 2 , pressure bonding time: heat-bonded under conditions of 5 seconds to obtain a decorative board.
(Example 2)
A wiping print layer surface printed in the same manner as in Example 1 on an unstretched film of the same polybutylene terephthalate resin as in Example 1 is opposed to a film made of the same transparent polybutylene terephthalate resin as in Example 1. The transparent polybutylene terephthalate film surface is the embossing roll side under the same conditions as the laminating conditions by thermocompression bonding in Example 1, and it is made transparent by pressing between the embossing roll and the silicon rubber roll. A printed resin film for laminating decorative plates having an embossed recess on the surface of the polybutylene terephthalate film was prepared. Next, a polyurethane adhesive is applied to a 6-mm-thick wood plywood at a coating amount of 50 g / m 2 , and the decorative resin laminate printing resin film is heated at 160 ° C., adhesive pressure: 15 kgf / cm 2 , and pressed. Time: Heat-bonded under conditions of 15 seconds to obtain a decorative board.
(Example 3)
Using a commercially available polybutylene terephthalate resin with an extrusion film forming machine on one side of a 40 μm thick unstretched film, nitrocellulose-alkyd ink (manufactured by Showa Ink, SAM) is used to print a pattern printing layer on a gravure rotary press. Printed inline. Next, the same non-stretched film wiping print layer surface of the same polybutylene terephthalate resin as in Example 1 printed on the printing surface of the unstretched film and the same transparent polybutylene terephthalate as in Example 1 were printed. Between the rolls for pressure bonding composed of an embossing roll and a silicon rubber roll with the transparent polybutylene terephthalate film surface as the embossing roll side under the same conditions as the lamination conditions by thermocompression bonding of the films facing each other A decorative resin laminated printing resin film having an embossed depression on the surface of the transparent polybutylene terephthalate film was prepared by pressure-bonding through the sheet. Further, the embossed surface of the decorative resin laminate printing resin film was coated with a two-component curable urethane-based gloss adjustment coating (manufactured by Showa Ink, OP-No. 81) with a gravure roll having a plate depth of 30 μm. An excellent decorative film was created. Next, a polyurethane adhesive is applied to a gypsum board having a thickness of 8 mm at an application amount of 80 g / m 2 , and the printing resin film for laminating a decorative board is heated at a temperature of 180 ° C., an adhesive pressure is 15 kgf / cm 2 , and pressed. Time: Heat-bonded under conditions of 20 seconds to obtain a decorative board.
(Characteristic evaluation of resin film)
The decorative plates prepared in Examples 1, 2, and 3 were evaluated for the following characteristics.
(Embossability)
The embossability for wiping printing of the decorative resin laminate printing resin film of the present invention is determined by the degree of roughness of the surface of the base resin layer of the embossed resin film. In the present invention, the surface of the colored resin layer of the resin film embossed using a gravel engraving roll having an average surface roughness (Ra) of 11 μm asperities is visually observed, The quality was evaluated according to the following three criteria.
○: Good, Δ: Slightly poor, X: Poor The above evaluation criteria are the surface roughness (Ra: μm) of the polyvinyl chloride resin film in JIS B0601 using a SURFCOM surface roughness meter manufactured by Tokyo Seimitsu Co., Ltd. When the average surface roughness is 4 μm, the embossability is accepted as the acceptance standard, and the average surface roughness is good with an appearance equal to or better than the surface of the polyvinyl chloride resin film having the average surface roughness of 4 μm. ), Those having an appearance that is slightly inferior to the surface of the polyvinyl chloride resin film but having no practical problems were determined as slightly defective (Δ), and those not embossed were determined as defective (×).
(Contamination resistance)
The resin film surface of the outermost layer of the decorative board prepared in Examples 1, 2, and 3 was drawn with black oil-based magic ink and allowed to stand for 24 hours, and then wiped with a cloth impregnated with ethanol to obtain a resin film surface. The degree of magic ink remaining in the film was visually observed and evaluated according to the following criteria.
(Double-circle): Magic ink is not recognized at all.
○: A very slight amount of magic ink remained to the extent that there is no practical problem.
(Triangle | delta): Remaining slight magic ink which is a problem in practical use is recognized.
X: Remaining magic ink is recognized to a considerable extent.
(Solvent resistance)
A sponge impregnated with methyl ethyl ketone was placed on the outermost resin film surface of the decorative board prepared in Examples 1, 2, and 3, and allowed to stand for 24 hours, and then the degree of occurrence of discoloration and swelling of the film surface was visually observed. And evaluated according to the following criteria.
A: No discoloration or swelling is observed.
◯: Generation of slight discoloration or swelling that is not problematic for practical use is recognized.
(Triangle | delta): Generation | occurrence | production of slight discoloration or swelling of the grade which is a problem practically is recognized.
X: Discoloration and swelling are recognized to a considerable extent.
(Water degradation resistance)
Assuming that the decorative board of the present invention is aged for a long time in a hot and humid state (for example, when used as an interior material for a unit bath), the water resistance deterioration resistance of the resin film when in contact with water for a long time is determined by DuPont. The impact test method evaluated.
The printed resin films for laminating decorative plates prepared in Examples 1, 2, and 3 were laminated on a galvanized steel sheet having a thickness of 0.5 mm to obtain test pieces. This test piece was cut into a size of 60 mm × 60 mm, immersed in demineralized water maintained at a temperature of 38 ± 2 ° C. for 1 month, dried at room temperature, and in compliance with JIS K 5400 using a DuPont impact tester. The impact was applied under the conditions (impact part size 1/2 inchφ, weight 1 kg, drop height 50 cm). The state of the resin film after applying the impact was observed with the naked eye and evaluated in the following five stages.
(Double-circle): A crack is not recognized by the resin film.
○: Fine cracks are observed in a part of the resin film.
(Triangle | delta): A fine crack is recognized in the whole embossing part of a resin film.
X: A big crack is recognized by the whole embossing part of a resin film.
XX: The crack is remarkable in the whole resin film.
In the above ratings, ◎ and ○ are not problematic in use. In addition, this test was implemented about ten test pieces. The characteristic evaluation of these decorative boards is shown below.
Figure 0003705482
As shown in Table 1, the decorative board of the present invention exhibits excellent characteristics in any of embossability, stain resistance, solvent resistance, and water resistance.
Industrial Applicability The decorative resin laminate printing resin film of the present invention is configured as described above, and the base resin layer and the colored resin layer made of a polybutylene terephthalate film have little expansion and contraction variation due to heat and tension. Since it has excellent dimensional stability, it is possible to obtain a printed matter with good printing registration accuracy. Furthermore, since the embossability is excellent, clear wiping printing is possible.
In addition, since a decorative film can be obtained with the same manufacturing method and manufacturing conditions as conventional polyvinyl chloride resin films, there is no need for capital investment such as expansion of new facilities or modification of existing facilities. Similar to the above, it is possible to express a pattern having excellent design properties in which the printed pattern and the embossed pattern are synchronized.
In addition, since the resin constituting the base resin layer and the surface protective layer does not contain a plasticizer, there are no problems such as surface contamination due to bleed of the plasticizer, and there is no contamination resistance, solvent resistance, water resistance. Excellent surface properties such as properties.
Furthermore, since no toxic gas such as hydrogen chloride gas is generated during incineration, there is no fear of polluting the environment and the environment is excellent.

Claims (12)

基材樹脂層、印刷層、着色樹脂層、ワイピング印刷層、表面保護層、艶調整層が下から順次積層された化粧板積層用印刷樹脂フィルム。A decorative resin laminated printing resin film in which a base resin layer, a printing layer, a colored resin layer, a wiping printing layer, a surface protective layer, and a gloss adjustment layer are sequentially laminated from the bottom. 着色樹脂層、ワイピング印刷層、表面保護層、艶調整層が下から順次積層された化粧板積層用印刷樹脂フィルム。A printing resin film for laminating decorative sheets, in which a colored resin layer, a wiping printing layer, a surface protective layer, and a gloss adjustment layer are laminated sequentially from the bottom. 着色樹脂層、ワイピング印刷層、表面保護層が下から順次積層された化粧板積層用印刷樹脂フィルム。A decorative resin laminated printing resin film in which a colored resin layer, a wiping printing layer, and a surface protective layer are laminated in order from the bottom. 前記ワイピング印刷層が、前記着色樹脂層の全面に設けられてなる、請求項１〜３のいずれかに記載の化粧板積層用印刷樹脂フィルム。The decorative resin laminated printing resin film according to any one of claims 1 to 3, wherein the wiping printing layer is provided on the entire surface of the colored resin layer. 前記着色樹脂層がエンボス加工が施され、該エンボス加工により形成されたエンボス凹部にインキが充填されてなるワイピング印刷層を有する、請求項１〜４のいずれかに記載の化粧板積層用印刷樹脂フィルム。The decorative resin laminate printing resin according to any one of claims 1 to 4, wherein the colored resin layer is embossed and has a wiping print layer in which an embossed recess formed by the embossing is filled with ink. the film. 前記基材樹脂層および着色樹脂層がポリブチレンテレフタレート樹脂からなる、請求項１に記載の化粧板積層用印刷樹脂フィルム。The decorative resin laminated printing resin film according to claim 1, wherein the base resin layer and the colored resin layer are made of polybutylene terephthalate resin. 前記着色樹脂層がポリブチレンテレフタレート樹脂からなる、請求項２〜５のいずれかに記載の化粧板積層用印刷樹脂フィルム。The printed resin film for decorative board lamination according to any one of claims 2 to 5, wherein the colored resin layer is made of polybutylene terephthalate resin. 樹脂フィルムを積層する基板の少なくとも片面に、請求項１〜７のいずれかに記載の化粧板積層用印刷樹脂フィルムを積層した化粧板。The decorative board which laminated | stacked the printing resin film for decorative board lamination in any one of Claims 1-7 on the at least single side | surface of the board | substrate which laminates | stacks a resin film. 前記基板と前記化粧板積層用印刷樹脂フィルムの間に接着剤層を介して積層した、請求項８に記載の化粧板。The decorative board according to claim 8, which is laminated via an adhesive layer between the substrate and the printed resin film for laminating a decorative board. 前記基板が金属板である、請求項８または９に記載の化粧板。The decorative board according to claim 8 or 9, wherein the substrate is a metal plate. 前記基板が木質板である、請求項８または９に記載の化粧板。The decorative board according to claim 8 or 9, wherein the substrate is a wooden board. 前記基板がボードである、請求項８または９に記載の化粧板。The decorative board according to claim 8 or 9, wherein the substrate is a board.
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AU2693800A (en) 2000-09-14
TW458887B (en) 2001-10-11

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