JP3825000B2 - Decorative multi-layer molded product - Google Patents
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Description
【０００１】
【発明の属する技術分野】
本発明は、住宅用等に使用できる、深みのある色彩を有し、且つ耐久性および耐候性を備えた加飾性多層共押出成形体に関する。
【０００２】
【従来の技術】
住宅等の内外装材や室内のユニットバスやキッチンのカウンター部材として模様を有する加飾性成形体が多種使用されている。これらの製品を大別すると、模様を有する表面材を基材上に積層したものおよび模様を有する基材に保護層として透明樹脂からなる表面層を被覆したものである。前者の例として透明または不透明の合成樹脂中にマイカのような無機質粉体を分散させたり、染料や顔料を不均一に分散させたりして石目模様や木目模様を形成したものを表面層とし、これを例えば低発泡または無発泡合成樹脂からなる基材層に積層したもの（例：特公平７−１１９０４７号公報）、また後者の例としては、基材としての発泡樹脂に発泡ムラによる模様や立体模様を形成し、その上に透明樹脂層を積層したもの（例：特開平７−３２９２２９号公報）等が例示できる。さらに、透明合成樹脂からなる表面層、透明または半透明である模様付き合成樹脂層を含む中間層、低発泡熱可塑性合成樹脂からなる基材層、の少なくとも３層からなる深みのある模様を有する加飾性多層共押出成形体も出現している（特開平１０−３２９２５３号公報）。
【０００３】
上記種々の技術から、石目模様・木粉模様等の模様付与商品については深みのある模様が得られてきており、商品化も行なわれている。しかし、色彩のみにおける深み感を有する成形体については、上記記載の技術を使用しても、未だ得られていない。通常考えれば、表面側の透明樹脂層を通常より分厚く、例えば７〜１０ｍｍ形成すれば、色彩の深み感は発現するのであるが、低発泡共押出成形において、表面側の樹脂を７〜１０ｍｍのように厚く均一に積層する方法は、未だ確立されていない。特に、いわゆる平板状以外、例えばＬ字型、コ字型等の異形断面品については、表面側の層を厚く均一に積層することは極めて困難であり、そのため深み感のある色彩を持った成形体を得ることができない。さらに、基材層に表面層を、通常厚みの０．２ｍｍ〜３ｍｍ程度積層した２層構成では、基材層である低発泡層と表面層との界面に凹凸が発生し、当該凹凸による色ムラが生じ、結果的に深み感のある色彩を持った成形体を得ることはできない。
【０００４】
【特許文献１】
特開平７−３２９２２９号公報
【特許文献２】
特開平１０−３２９２５３号公報
【０００５】
【発明が解決しようとする課題】
本発明は、住宅などの内外装材や内装化粧部位に使用するに好適な深みのある色彩を有し、且つ耐候性と耐久性の優れた加飾性多層共押出成形体を提供することを目的とする。
【０００６】
【課題を解決するための手段】
本発明は、ひとつの態様として、（ａ）低発泡熱可塑性合成樹脂からなる基材層、（ｂ）透明または半透明である合成樹脂層を含む中間層、および（ｃ）透明または半透明である合成樹脂からなる表面層の少なくとも３層からなる加飾性多層成形体であって、中間層（ｂ）は着色透明または着色半透明合成樹脂層を含み、表面層（ａ）は中間層と同一または類似色相に着色された透明または半透明合成樹脂層であって、中間層よりも明度が高く且つ彩度が低い樹脂層である加飾性多層共押出成形体に関する。
また、本発明は、もうひとつの態様として、（ａ）低発泡熱可塑性合成樹脂からなる基材層、（ｂ）不透明合成樹脂層からなる中間層、および（ｃ）透明または半透明である合成樹脂からなる表面層の少なくとも３層からなる加飾性多層成形体であって、中間層（ｂ）は少なくとも表面層と接する部分が着色不透明合成樹脂層であり、表面層（ａ）は中間層と同一または類似色相に着色された透明または半透明合成樹脂層であって、中間層よりも明度および彩度が低い樹脂層である加飾性多層共押出成形体に関する。
【０００７】
上記本発明の第１の態様の加飾性多層共押出成形体においては、基材層は、少なくともその中間層側に中間層と同一または類似色相である樹脂層を有することが好ましい。
本発明のもうひとつの好ましい態様では、加飾性多層共押出成形体は、異形断面形状を有する。
【０００８】
本発明の加飾性多層共押出成形体は、単一色相の中で特有の深み感と特有の透明感とを備えた独特の意匠性を有することを特徴とする。
【０００９】
【発明の実施の形態】
本発明の加飾性多層共押出成形体は、少なくとも基材層（ａ）、中間層（ｂ）および表面層からなる多層成形体であり、中間層と表面層とが同一または類似色相からなる。また表面層は透明または半透明である。中間層は、第１の態様では透明または半透明であり、且つ表面層の明度は中間層よりも高く、彩度は中間層よりも低い。第２の態様では、中間層は不透明であり、表面層の明度および彩度はいずれも中間層よりも低い。このような構成が、本発明の加飾性多層共押出成形体が特有の深み感と透明感という特徴を発現するための必須の要件である。
基材層は、無着色等であってもよいが、白色若しくは中間層と同一または類似色相であることが好ましく、特に好ましくは第１の態様では、中間層と同一または類似色相である。
【００１０】
本発明において、色相、明度および彩度とは、いずれも色彩をその３属性で表した場合の表現法であり、感覚的に表現すれば、それぞれ色の色合い、色の明るさおよび色の鮮やかさに近い概念を表すものである。これらの３つの属性は、例えばＬ＊ａ＊ｂ＊表色系やＬ＊Ｃ＊ｈ＊表色系あるいはマンセル表色系等によって一定条件では定量的に表すこともできる。
【００１１】
本発明においては、同一または類似色相とは、次のように定義される。
同一色相とは、例えば同一着色剤を使用し、単に着色剤の添加量の差において、明度および色彩を変更する場合等に示現し、反射率グラフにおける最大吸収波長がほぼ同じになる場合などである。
類似色相とは、例えば、Ｌ＊Ｃ＊ｈ＊表色系で表した場合の色相角度ｈが基準角度から±３５度の範囲、またはマンセル表色系で表した場合に色相環で表して基準点から２種程度の差の範囲として定量的に表すこともできる。例えば、基準点を５Ｇとすると、５ＧＹ〜５ＢＧ程度までを類似色相という。
【００１２】
また、本発明において、高明度とは、Ｌ＊ａ＊ｂ＊表色系で表せば、例えば０〜１００で定量表示される明度値（Ｌ）がより高い数値となる方向をいう。またマンセル表色系でいえば例えば１／〜９／で定量表示される明度値（Ｖ）がより高い数値となる方向をいう。
また、本発明において、低彩度とは、Ｌ＊Ｃ＊ｈ＊表色系で表せば、例えば０〜６０で定量表示される彩度値（Ｃ）がより低い数値となる方向をいう。またマンセル表色系でいえば例えば／２〜／１６で定量表示される彩度値（Ｃ）がより低い数値となる方向をいう。
【００１３】
本発明の表面層は、透明または半透明であることが必要である。また中間層は少なくとも表面層と接する部分は透明または半透明であってもよいし、また表面層と接する部分が不透明であってもよい。
【００１４】
基材層は発泡剤を含む熱可塑性樹脂から低発泡成形した低発泡熱可塑性合成樹脂である。低発泡熱可塑性合成樹脂とすることにより相当の厚さを持たせた場合でも加工性と軽量性を保持することができるとともに、成形時の冷却工程での反りや変形を防止することができるという利点がある。基材層を形成する熱可塑性合成樹脂は、特に限定するものではないが、ポリ塩化ビニル樹脂（以後、ＰＶＣ樹脂という）、アクリロニトリル-ブタジエン-スチレン共重合樹脂（以後、ＡＢＳ樹脂という）、ポリスチレン樹脂（以後、ＰＳ樹脂という）、ハイインパクトポリスチレン樹脂（以後、ＨＩＰＳ樹脂という）、アクリロニトリル-スチレン共重合樹脂（以後、ＡＳ樹脂という）、変性ポリフェニレンエーテル樹脂、ポリエチレン樹脂、ポリプロピレン樹脂、ポリメチルメタクリレート樹脂（以降、ＰＭＭＡ樹脂という）、メチルメタクリレート−ブチルアクリレート共重合樹脂、メチルメタクリレート−スチレン共重合樹脂、などのアクリル系樹脂またはこれらの混合樹脂等から選ぶことができる。成形性、強靭性、経済性の面から特に好ましいのはＰＶＣ樹脂、ＡＢＳ樹脂、ＨＩＰＳ樹脂である。
【００１５】
これらの熱可塑性合成樹脂には、炭酸カルシウム、タルク、マイカ、シラスバルーン等の充填材や軽量化材、ガラス繊維やセルロース繊維等の補強材、難燃剤、その他熱安定剤、滑剤等合成樹脂成形体に添加される各種添加剤を含むことができる。またリサイクル性を考慮し、木粉等を混合してもよい。
【００１６】
低発泡である基材層の発泡倍率は１.５〜３.５倍、好ましくは２.０〜３.０倍である。１.５以下では軽量化と加工性の特徴を発現することが困難であり、３.５以上では強度が不十分となる。
【００１７】
中間層（ｂ）は、第１の態様では、透明または半透明であって、着色透明または着色半透明の合成樹脂層を含む。中間層（ｂ）は着色透明または着色半透明の単一の層からなるものであってもよいし、２層以上からなるものであってもよい。２層以上からなる場合、図２に例示するように表面層側に位置する層（ｂ−１）は着色透明または着色半透明であり、基材層側に位置する更なる層（ｂ−２）は層（ｂ−１）と同一または類似色相であり、必ずしも透明または半透明であることを要しない。層（ｂ−２）は単層でもよいし２層以上から構成されていてもよい。
【００１８】
中間層を形成する熱可塑性樹脂は、特に限定されるものではないが、ＰＶＣ樹脂、ＡＢＳ樹脂、ＰＳ樹脂、ＨＩＰＳ樹脂、ＡＳ樹脂、ポリエチレン樹脂、ポリプロピレン樹脂、ＰＥＴ樹脂、アクリル系樹脂、ニトリル樹脂またはこれらの混合樹脂等を使用することができる。中間層を通して、中間層の色彩と中間層の裏面側（中間層の一部または基材層）の色彩とを重ね合わせて深みのある色彩を発現するという本発明の特徴の一面を実現するためには、中間層の一部を透明または半透明とすることが好ましく、そのような合成樹脂としては、上記中間層を形成する樹脂の中で、透明性に優れるもの、例えばＰＶＣ樹脂、アクリル系樹脂、ＰＳ樹脂、透明ＡＢＳ樹脂、ＡＳ樹脂、ＰＥＴ樹脂、ニトリル樹脂またはこれらの混合樹脂が例示される。特に好ましい樹脂はアクリル系樹脂、中でもＰＭＭＡ樹脂である。
中間層樹脂には、種々の物理的または化学的特性を付与するために、通常合成樹脂に用いられる種々の添加剤を添加してもよい。
【００１９】
中間層は、第２の態様では不透明であって、少なくとも表面層と接する部分は着色不透明合成樹脂層からなる。中間層は少なくとも顔料を含有することによって着色され、表面層よりも明度および彩度を高く設定される。
中間層は顔料によって不透明とすることができるため、中間層を形成する熱可塑性合成樹脂自体は透明であっても不透明であってもよく、第１の態様で使用できる樹脂をいずれも使用することができる。
【００２０】
中間層の厚さは全体として０.２〜３.０ｍｍ、好ましくは０.５〜１.５ｍｍである。０.２ｍｍ以下では深みのある色彩が得難く、一方、３.０ｍｍ以上になると多層成形体としての加工性を損なうようになり、また均一に積層することが困難になる。
【００２１】
表面層（ｃ）には透明または半透明熱可塑性合成樹脂が用いられる。このような熱可塑性合成樹脂としては、中間層のところで記載したと同じ透明樹脂が使用可能であるが、好ましくはアクリル系樹脂、ＰＳ樹脂、透明ＡＢＳ、ＡＳ、ＡＡＳ、ＰＶＣである。
表面層樹脂には種々の物理的または化学的特性を付与するために、必要な透明性または半透明性を損なわない範囲で、通常合成樹脂に用いられる種々の添加剤を添加してもよい。
表面層の厚さは０.２〜３.０ｍｍ、好ましくは０.３〜１.０ｍｍである。０.２ｍｍ以下では深みを出すことが難しく、３.０ｍｍ以上では効果が変わらない割りには経済的に不利となり、また均一に積層することが困難となる。
なお、図１及び図２は成形体の片側のみに中間層及び表面層を形成したものであるが、当然成形体全面に深みのある色彩が必要な場合は、全面に中間層及び表面層を形成すればよく、当該場合は、厚み０.２〜３.０ｍｍ中間層及び表面層を、それぞれの面に設けるのが好ましい。
【００２２】
本発明の加飾性多層共押出成形体は、生産性、長尺物成形、製品特性の一定性という面から、図３に示すような多層押出成形法により、１個のダイス内で各樹脂を積層する等の共押出成形法で製造される。
共押出成形を行うには、従来から合成樹脂の共押出成形体の製造に使用されているもの、例えばセルカ法等を適宜利用して、通常の共押出成形方法により行うことができる。基材層を低発泡押出するために、上記の基材層の熱可塑性合成樹脂には発泡剤を配合する必要がある。発泡剤は押出温度で分解して気体を発生する固体状の発泡剤が好ましく、このような発泡剤として重炭酸ナトリウム、炭酸アンモニウム、アゾジカルボン酸アミド、ベンゼンスルホニルヒドラジド等を用いることができる。
【００２３】
着色樹脂層を形成するには、ベース樹脂に染料、顔料等の合成樹脂着色用の通常の着色剤をいずれも使用できるが、表面層および中間層の着色には、樹脂の透明または半透明性を損なわないように着色剤の種類および添加量を選択する必要がある。その点では染料・透明顔料が好ましい。中間層を不透明とする第２の態様の場合は、中間層に顔料を使用することもできる。
【００２４】
本発明の加飾性多層共押出成形体の断面構造をＬ型異形押出成形体を例にとって図１に示した。図中、ａは基材層、ｂは中間層、ｃは表面層である。また、中間層が２層以上からなるもうひとつの態様に相当する例を図２に示した。図中、ｂ−１は表面層側中間層、ｂ−２は基材層側中間層である。
【００２５】
【実施例】
以下、実施例により本発明をより詳細に且つ具体的に説明する。
実施例 １
基材層、中間層および表面層のコンパウンドまたは合成樹脂を、それぞれ基材層用押出機、中間層用押出機、表面層用押出機から同時に押出し、ダイス内で積層して３層の押出成形体を成形した。押出条件は次の通りである：
基材用押出機： ４５φ、二軸押出機
中間層用押出機：４０φ、一軸押出機
表面層用押出機：４０φ、一軸押出機
ダイス： Ｌ型異形（３５ｍｍ×１２０ｍｍ）
基材層、中間層および表面層にはその配合を表１に記載したコンパウンドを用いた。この配合では中間層が透明または半透明な多層成形体が得られる。
【００２６】
上記のようにして３層共押出成形を行なうことにより、表２に示す各層厚さおよび発泡倍率（基材層）を有する深みのある色彩を持った加飾性多層共押出成形体を得た。
【００２７】
実施例 ２〜５
表面層および中間層のコンパウンドとして表１に記載したものを用いた以外は実施例１と同様にして３層の押出成形体を得た。この多層成形体はいずれも中間層が透明または半透明である。
【００２８】
実施例 ６
表面層および中間層のコンパウンドとして表１に記載したものを用いた以外は実施例１と同様にして３層の押出成形体を得た。この多層成形体はいずれも中間層が不透明である。
【００２９】
【表１】
実施例１〜６で成形した加飾性多層共押出成形体について、表面層、中間層および基材層の色相、明度および彩度を測定した。この色彩３属性の測定結果を表２に記載した。これらの色彩３属性の測定は、成形体を断面と垂直な方向の厚さが２ｍｍ程度となるように薄片状に切り出し、断面部を粗さ＃８００および＃２０００のサンドペーパーで研磨したのち、該断面部に現れた表面層、中間層および基材層部分を画像分光測色機「ｋｕｒａｂｏ ＣＯＬＯＲ−７Ｓ」（倉敷紡績社製）にて各層の分光反射率を測定し、当該値をもとに明度（Ｌ）、彩度（Ｃ）、色相（Ｈ°）を計算した。
【００３１】
【表２】
また、得られた加飾性多層共押出成形体はいずれも従来得られなかった特有の深みのある色彩を有していた。
【００３３】
比較例 １
表１に記載した配合の基材層および表面層のコンパウンドおよび合成樹脂を、それぞれ実施例１で用いた基材層用押出機および表面層用押出機から実施例１と同じ押出条件で同時に押出し、ダイス内で積層して２層の共押出成形体を成形した。基材層および表面層の厚みはそれぞれ１２ｍｍおよび０.８ｍｍであった。得られた共押出成形体は、表面層が着色されているものの、基材層と表面層との界面の凹凸により色ムラが発生し、実施例の成形体のような深みのある色彩を有するものではなかった。
【００３４】
【発明の効果】
本発明の加飾性多層共押出成形体は、従来の加飾性成形体性や積層化粧板とちがって、深みのある色彩を有し、しかも耐候性、耐久性に優れ、住宅等の室内の加飾性を要する部位をはじめ、外壁等にも使用でき、建築物の価値を高めることができる。
【図面の簡単な説明】
【図１】 本発明の加飾性多層成形体の断面構造を示す模式図。
【図２】 本発明の加飾性多層成形体のもうひとつの態様の断面構造を示す模式図。
【図３】 本発明の加飾性多層成形体の成形方法の１例を示す共押出成形の模式図。
【符号の説明】
ａ：基材層、
ｂ：中間層、
ｂ−１：表面層側中間層、
ｂ−２：基材層側中間層、
ｃ：表面層、
Ａ：表面層用押出機、
Ｂ：中間層用押出機、
Ｃ：基材層用メイン押出機。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a decorative multi-layer coextrusion molded body having a deep color and having durability and weather resistance, which can be used for housing and the like.
[0002]
[Prior art]
Various decorative molded bodies having patterns are used as interior and exterior materials for houses, indoor unit baths, and counter members for kitchens. When these products are roughly classified, a surface material having a pattern is laminated on a substrate, and a substrate having a pattern is coated with a surface layer made of a transparent resin as a protective layer. As an example of the former, the surface layer is formed by dispersing a mineral powder such as mica in a transparent or opaque synthetic resin or by unevenly dispersing dyes or pigments to form a stone pattern or wood grain pattern. For example, a laminate of a low-foamed or non-foamed synthetic resin (eg, Japanese Examined Patent Publication No. 7-119047). And a three-dimensional pattern formed thereon and a transparent resin layer laminated thereon (example: JP-A-7-329229). Furthermore, it has a deep pattern consisting of at least three layers: a surface layer made of a transparent synthetic resin, an intermediate layer including a patterned synthetic resin layer that is transparent or translucent, and a base material layer made of a low-foamed thermoplastic synthetic resin. A decorative multilayer coextruded product has also appeared (Japanese Patent Laid-Open No. 10-329253).
[0003]
From the above-mentioned various technologies, deep patterns have been obtained for products with patterns such as stone patterns and wood powder patterns, and commercialization has also been carried out. However, a molded product having a sense of depth only in color has not been obtained even if the above-described technique is used. If considered normally, if the transparent resin layer on the surface side is thicker than usual, for example, 7 to 10 mm is formed, a deep feeling of color will be manifested, but in low foam coextrusion molding, the resin on the surface side is 7 to 10 mm. A method for uniformly and thickly layering has not yet been established. In particular, for irregular shaped products such as L-shaped and U-shaped, other than the so-called flat plate shape, it is extremely difficult to laminate the surface layer thickly and uniformly, and therefore, forming with a deep color. I can't get a body. Furthermore, in the two-layer configuration in which the surface layer is laminated on the base material layer with a thickness of about 0.2 mm to 3 mm, unevenness occurs at the interface between the low foam layer, which is the base material layer, and the surface layer. Unevenness occurs, and as a result, it is impossible to obtain a molded product having a deep color.
[0004]
[Patent Document 1]
JP 7-329229 A [Patent Document 2]
Japanese Patent Laid-Open No. 10-329253
[Problems to be solved by the invention]
The present invention provides a decorative multilayer coextrusion molded article having a deep color suitable for use in interior and exterior materials such as houses and interior decorative parts, and having excellent weather resistance and durability. Objective.
[0006]
[Means for Solving the Problems]
The present invention includes, as one aspect, (a) a base material layer made of a low foam thermoplastic synthetic resin, (b) an intermediate layer including a synthetic resin layer that is transparent or translucent, and (c) transparent or translucent. A decorative multilayer molded article comprising at least three surface layers made of a synthetic resin, wherein the intermediate layer (b) includes a colored transparent or colored translucent synthetic resin layer, and the surface layer (a) includes an intermediate layer and The present invention relates to a decorative multi-layer coextrusion molded body which is a transparent or translucent synthetic resin layer colored in the same or similar hue, which is a resin layer having higher brightness and lower chroma than an intermediate layer.
In another aspect, the present invention provides (a) a base material layer made of a low-foaming thermoplastic synthetic resin, (b) an intermediate layer made of an opaque synthetic resin layer, and (c) a transparent or translucent synthetic material. A decorative multilayer molded body comprising at least three surface layers made of a resin, wherein the intermediate layer (b) is a colored opaque synthetic resin layer at least in contact with the surface layer, and the surface layer (a) is an intermediate layer It is related with the decorative multilayer coextrusion molded object which is the transparent or semi-transparent synthetic resin layer colored by the same or similar hue, and is a resin layer whose brightness and chroma are lower than an intermediate | middle layer.
[0007]
In the decorative multilayer coextrusion molded product of the first aspect of the present invention, the base material layer preferably has a resin layer having the same or similar hue as the intermediate layer on at least the intermediate layer side.
In another preferred embodiment of the present invention, the decorative multi-layer co-extruded product has an irregular cross-sectional shape.
[0008]
The decorative multilayer coextrusion molded product of the present invention is characterized by having a unique design with a unique depth feeling and a unique transparency in a single hue.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
The decorative multilayer coextrusion molded article of the present invention is a multilayer molded article comprising at least a base material layer (a), an intermediate layer (b), and a surface layer, and the intermediate layer and the surface layer have the same or similar hue. . The surface layer is transparent or translucent. The intermediate layer is transparent or translucent in the first embodiment, and the brightness of the surface layer is higher than that of the intermediate layer, and the saturation is lower than that of the intermediate layer. In the second aspect, the intermediate layer is opaque, and the brightness and saturation of the surface layer are both lower than the intermediate layer. Such a configuration is an indispensable requirement for the decorative multi-layer coextrusion molded product of the present invention to express the characteristics of a unique sense of depth and transparency.
The substrate layer may be uncolored or the like, but is preferably white or has the same or similar hue as that of the intermediate layer, and particularly preferably in the first aspect, has the same or similar hue as that of the intermediate layer.
[0010]
In the present invention, hue, lightness, and saturation are all expression methods when colors are represented by their three attributes. If expressed sensuously, the hue of the color, the brightness of the color, and the vividness of the color, respectively. It represents a close concept. These three attributes can also be expressed quantitatively under certain conditions by, for example, L * a * b * color system, L * C * h * color system or Munsell color system.
[0011]
In the present invention, the same or similar hue is defined as follows.
The same hue is expressed when, for example, the same colorant is used and the brightness and color are changed simply by the difference in the amount of the colorant added, and the maximum absorption wavelength in the reflectance graph is almost the same. is there.
A similar hue is, for example, a hue angle h in the range of ± 35 degrees from the reference angle when represented in the L * C * h * color system, or a hue circle when represented in the Munsell color system. It can also be expressed quantitatively as a range of about two kinds of differences from the point. For example, when the reference point is 5G, a range from about 5GY to about 5BG is called a similar hue.
[0012]
Further, in the present invention, high brightness means a direction in which the brightness value (L) quantitatively displayed, for example, from 0 to 100 becomes a higher value when expressed in the L * a * b * color system. In the Munsell color system, for example, the lightness value (V) quantitatively displayed at 1 to 9 / is a direction in which the value becomes higher.
In the present invention, the low saturation means a direction in which the saturation value (C) quantitatively displayed at 0 to 60, for example, becomes a lower value when expressed in the L * C * h * color system. In the Munsell color system, for example, the saturation value (C) quantitatively displayed at / 2 to / 16 is a direction in which the value becomes lower.
[0013]
The surface layer of the present invention needs to be transparent or translucent. In addition, the intermediate layer may be transparent or translucent at least at the portion in contact with the surface layer, or may be opaque at the portion in contact with the surface layer.
[0014]
The base material layer is a low foam thermoplastic synthetic resin obtained by low foam molding from a thermoplastic resin containing a foaming agent. By using a low-foam thermoplastic synthetic resin, workability and lightness can be maintained even when a considerable thickness is provided, and warpage and deformation in the cooling process during molding can be prevented. There are advantages. The thermoplastic synthetic resin for forming the base material layer is not particularly limited, but polyvinyl chloride resin (hereinafter referred to as PVC resin), acrylonitrile-butadiene-styrene copolymer resin (hereinafter referred to as ABS resin), polystyrene resin. (Hereinafter referred to as PS resin), high impact polystyrene resin (hereinafter referred to as HIPS resin), acrylonitrile-styrene copolymer resin (hereinafter referred to as AS resin), modified polyphenylene ether resin, polyethylene resin, polypropylene resin, polymethyl methacrylate resin ( Hereinafter, it can be selected from acrylic resins such as methyl methacrylate-butyl acrylate copolymer resin, methyl methacrylate-styrene copolymer resin, or mixed resins thereof. Particularly preferred from the viewpoints of moldability, toughness and economy are PVC resin, ABS resin and HIPS resin.
[0015]
These thermoplastic synthetic resins include fillers such as calcium carbonate, talc, mica, and shirasu balloons, lightweight materials, reinforcing materials such as glass fibers and cellulose fibers, flame retardants, other heat stabilizers, lubricants, and other synthetic resin moldings. Various additives added to the body can be included. In consideration of recyclability, wood powder or the like may be mixed.
[0016]
The expansion ratio of the low-foam base layer is 1.5 to 3.5 times, preferably 2.0 to 3.0 times. If it is 1.5 or less, it is difficult to express characteristics of weight reduction and workability, and if it is 3.5 or more, the strength is insufficient.
[0017]
In the first embodiment, the intermediate layer (b) is transparent or translucent and includes a colored transparent or colored translucent synthetic resin layer. The intermediate layer (b) may be composed of a single colored transparent or semi-transparent layer, or may be composed of two or more layers. When it consists of two or more layers, as illustrated in FIG. 2, the layer (b-1) located on the surface layer side is colored transparent or colored translucent, and the further layer (b-2) located on the substrate layer side ) Has the same or similar hue as the layer (b-1) and does not necessarily need to be transparent or translucent. The layer (b-2) may be a single layer or may be composed of two or more layers.
[0018]
The thermoplastic resin forming the intermediate layer is not particularly limited, but PVC resin, ABS resin, PS resin, HIPS resin, AS resin, polyethylene resin, polypropylene resin, PET resin, acrylic resin, nitrile resin or These mixed resins can be used. In order to realize one aspect of the feature of the present invention, through the intermediate layer, the color of the intermediate layer and the color of the back side of the intermediate layer (a part of the intermediate layer or the base material layer) are superimposed to express a deep color. It is preferable that a part of the intermediate layer is transparent or semi-transparent, and as such a synthetic resin, among the resins forming the intermediate layer, those having excellent transparency, for example, PVC resin, acrylic type Examples thereof include resin, PS resin, transparent ABS resin, AS resin, PET resin, nitrile resin, or a mixed resin thereof. Particularly preferred resins are acrylic resins, especially PMMA resins.
In order to impart various physical or chemical properties to the intermediate layer resin, various additives usually used for synthetic resins may be added.
[0019]
The intermediate layer is opaque in the second embodiment, and at least a portion in contact with the surface layer is formed of a colored opaque synthetic resin layer. The intermediate layer is colored by containing at least a pigment, and has higher brightness and saturation than the surface layer.
Since the intermediate layer can be made opaque by a pigment, the thermoplastic synthetic resin itself forming the intermediate layer may be transparent or opaque, and any resin that can be used in the first embodiment should be used. Can do.
[0020]
The thickness of the intermediate layer as a whole is 0.2 to 3.0 mm, preferably 0.5 to 1.5 mm. If the thickness is 0.2 mm or less, it is difficult to obtain a deep color. On the other hand, if the thickness is 3.0 mm or more, the processability as a multilayer molded article is impaired, and uniform lamination becomes difficult.
[0021]
A transparent or translucent thermoplastic synthetic resin is used for the surface layer (c). As such a thermoplastic synthetic resin, the same transparent resin as described in the intermediate layer can be used, but acrylic resin, PS resin, transparent ABS, AS, AAS, and PVC are preferable.
In order to impart various physical or chemical properties to the surface layer resin, various additives that are usually used in synthetic resins may be added within a range that does not impair the required transparency or translucency.
The thickness of the surface layer is 0.2 to 3.0 mm, preferably 0.3 to 1.0 mm. If the thickness is 0.2 mm or less, it is difficult to obtain a depth. If the thickness is 3.0 mm or more, it is economically disadvantageous for the effect to be unchanged, and uniform lamination is difficult.
1 and 2 show an intermediate layer and a surface layer formed on only one side of the molded body. Naturally, when a deep color is required on the entire surface of the molded body, the intermediate layer and the surface layer are formed on the entire surface. In this case, it is preferable to provide an intermediate layer and a surface layer having a thickness of 0.2 to 3.0 mm on each surface.
[0022]
The decorative multi-layer coextrusion molded product of the present invention is made of each resin in one die by a multi-layer extrusion method as shown in FIG. 3 in terms of productivity, long product molding, and constant product characteristics. Are manufactured by a coextrusion molding method such as laminating.
Co-extrusion molding can be carried out by a conventional co-extrusion molding method by appropriately using a conventional resin co-extrusion molding, for example, the Celca method. In order to extrude the base material layer with low foaming, it is necessary to add a foaming agent to the thermoplastic synthetic resin of the base material layer. The foaming agent is preferably a solid foaming agent that decomposes at the extrusion temperature to generate gas, and sodium bicarbonate, ammonium carbonate, azodicarboxylic amide, benzenesulfonyl hydrazide, or the like can be used as such a foaming agent.
[0023]
In order to form the colored resin layer, any of the usual colorants for coloring synthetic resins such as dyes and pigments can be used as the base resin. However, the surface layer and the intermediate layer can be colored transparently or translucently. Therefore, it is necessary to select the type and amount of the colorant so as not to damage the color. In this respect, dyes and transparent pigments are preferable. In the case of the second embodiment in which the intermediate layer is opaque, a pigment can also be used for the intermediate layer.
[0024]
The cross-sectional structure of the decorative multilayer coextrusion molded product of the present invention is shown in FIG. 1 taking an L-shaped profile extrusion molded product as an example. In the figure, a is a base material layer, b is an intermediate layer, and c is a surface layer. An example corresponding to another embodiment in which the intermediate layer is composed of two or more layers is shown in FIG. In the figure, b-1 is a surface layer side intermediate layer, and b-2 is a base material layer side intermediate layer.
[0025]
【Example】
Hereinafter, the present invention will be described in more detail and specifically by way of examples.
Example 1
The base layer, intermediate layer and surface layer compound or synthetic resin are extruded simultaneously from the base layer extruder, intermediate layer extruder, and surface layer extruder, respectively, and laminated in a die to form three layers. The body was molded. Extrusion conditions are as follows:
Extruder for base material: 45φ, Extruder for twin screw extruder intermediate layer: 40φ, Extruder for surface layer of single screw extruder: 40φ, Single screw extruder die: L-shaped profile (35mm × 120mm)
For the base material layer, the intermediate layer, and the surface layer, the compounds described in Table 1 were used. With this formulation, a multilayer molded body having a transparent or translucent intermediate layer can be obtained.
[0026]
By performing the three-layer coextrusion molding as described above, a decorative multilayer coextrusion molded body having a deep color having each layer thickness and foaming ratio (base material layer) shown in Table 2 was obtained. .
[0027]
Example 2-5
A three-layer extruded product was obtained in the same manner as in Example 1 except that the compounds described in Table 1 were used as the surface layer and intermediate layer compounds. In any of the multilayer molded products, the intermediate layer is transparent or translucent.
[0028]
Example 6
A three-layer extruded product was obtained in the same manner as in Example 1 except that the compounds described in Table 1 were used as the surface layer and intermediate layer compounds. In any of the multilayer molded products, the intermediate layer is opaque.
[0029]
[Table 1]
About the decorative multilayer co-extrusion molded body molded in Examples 1 to 6, the hue, brightness, and saturation of the surface layer, the intermediate layer, and the base material layer were measured. The measurement results of the three color attributes are shown in Table 2. The measurement of these three color attributes is performed by cutting the molded body into a thin piece so that the thickness in the direction perpendicular to the cross section is about 2 mm, and polishing the cross section with sandpaper having a roughness of # 800 and # 2000. The spectral reflectance of each layer was measured for the surface layer, the intermediate layer and the base material layer portion appearing in the cross section with an image spectrocolorimeter “Kurabo COLOR-7S” (manufactured by Kurashiki Boseki Co., Ltd.). The brightness (L), saturation (C), and hue (H °) were calculated.
[0031]
[Table 2]
In addition, all of the obtained decorative multilayer coextrusion molded products had a unique deep color that could not be obtained conventionally.
[0033]
Comparative example 1
The base layer and surface layer compounds and synthetic resins having the formulations shown in Table 1 were simultaneously extruded from the base layer extruder and the surface layer extruder used in Example 1 under the same extrusion conditions as in Example 1. Then, it was laminated in a die to form a two-layer coextrusion molded body. The thicknesses of the base material layer and the surface layer were 12 mm and 0.8 mm, respectively. Although the obtained co-extruded molded product has a colored surface layer, unevenness of color occurs due to unevenness at the interface between the base material layer and the surface layer, and has a deep color like the molded product of the example. It was not a thing.
[0034]
【The invention's effect】
The decorative multi-layer coextrusion molded product of the present invention has a deep color unlike conventional decorative molded product properties and laminated decorative boards, and is excellent in weather resistance and durability. It can be used not only for parts that require decorativeness, but also for outer walls, etc., and can increase the value of buildings.
[Brief description of the drawings]
FIG. 1 is a schematic view showing a cross-sectional structure of a decorative multilayer molded body of the present invention.
FIG. 2 is a schematic view showing a cross-sectional structure of another embodiment of the decorative multilayer molded body of the present invention.
FIG. 3 is a schematic diagram of coextrusion molding showing an example of a molding method for a decorative multilayer molded body of the present invention.
[Explanation of symbols]
a: base material layer,
b: middle layer,
b-1: surface layer side intermediate layer,
b-2: base material layer side intermediate layer,
c: surface layer,
A: Extruder for surface layer,
B: Extruder for intermediate layer,
C: Main extruder for base material layer.
Claims (3)
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| JP2003014973A JP3825000B2 (en) | 2002-03-15 | 2003-01-23 | Decorative multi-layer molded product |
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| JP2002-71814 | 2002-03-15 | ||
| JP2002071814 | 2002-03-15 | ||
| JP2003014973A JP3825000B2 (en) | 2002-03-15 | 2003-01-23 | Decorative multi-layer molded product |
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| JP3825000B2 true JP3825000B2 (en) | 2006-09-20 |
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| JP4897260B2 (en) * | 2004-09-09 | 2012-03-14 | 倉敷紡績株式会社 | Decorative multi-layer coextrusion molding |
| JP4758088B2 (en) * | 2004-09-28 | 2011-08-24 | 倉敷紡績株式会社 | Decorative multi-layer coextrusion molding |
| JP5892885B2 (en) * | 2012-07-11 | 2016-03-23 | 三菱電機株式会社 | Decorative molded body and method for producing decorative molded body |
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