JP4538936B2 - Cosmetic material - Google Patents

Description

【００７３】
上記表１の評価結果より、熱可塑性樹脂と木質系充填剤とを含有し、且つ発泡している木質樹脂発泡成形体の表面に、前記木質樹脂発泡成形体に含有される熱可塑性樹脂と同系の熱可塑性樹脂を主体とする化粧シートが積層されてなる本発明の化粧材は、木質感があり、切削性や釘打ち性、汎用接着剤による接着性等の加工性が良く、且つ、優れた意匠性とリサイクル性とを併せ持つ化粧材であることが確認された。
【００７４】
【発明の効果】
以上詳細に説明した様に、本発明の化粧材は、熱可塑性樹脂と木質系充填剤を含有し、且つ発泡している木質樹脂発泡成形体の表面に、前記木質樹脂発泡成形体に含有される熱可塑性樹脂と同系の熱可塑性樹脂を主体とする化粧シートが積層されてなるので、切削や釘打ち等の加工性に優れており、化粧シートによる高意匠と木質樹脂発泡成形体による視覚的及び触覚的な木質感とを有し、木質樹脂発泡成形体と化粧シートとの分離の必要なく容易にリサイクル可能であり、しかも木質樹脂発泡成形体は発泡していることから、揮発成分を含む水性エマルジョン型や溶剤型等の木材用の汎用の接着剤により容易且つ強固に化粧シートの接着が可能であるほか、発泡構造に由来する弾性や断熱性により、天然木材に似た暖かく柔軟な触感や衝撃に対する緩衝性を有している。
【００７５】
この様にして、本発明の化粧材は、化粧シートによる高意匠性を活かして、これまでの意匠性に劣る木質樹脂成形体では使用しにくかった建築内装材、建具、家電品の表面材などの用途にも十分に使用できるものとなった。しかも、従来より木質系の化粧材について行われて来た各種の後加工の応用が可能であり、特に本発明によって接着作業において汎用の木材用接着剤の使用が可能となり、従来の合板や中密度繊維板（ＭＤＦ）等の汎用の木質材料と同等の使い易さが実現したので、従来の木質材料に代わる腐蝕しにくくリサイクル容易な材料として、産業の発展及び地球環境の保護に貢献するところ頗る大きいものである。
【図面の簡単な説明】
【図１】本発明の化粧材の実施の形態を模式的に示す断面図である。
【符号の説明】
１ 化粧シート
２ 木質樹脂発泡成形体
３ 熱可塑性樹脂
４ 木質系充填剤
５ 気泡[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a decorative material used for building interior materials such as floor materials, wall materials, and ceiling materials, joinery, and surface materials of home appliances.
[0002]
[Prior art]
Conventionally, as a decorative material for the above-mentioned various uses, a natural veneer, a decorative paper or a decorative sheet that has been designed by printing on a paper or a synthetic resin sheet, and the like are bonded to a wooden substrate such as plywood or fiberboard Many things are used. However, these cosmetic materials have problems such as warpage due to moisture absorption and release of wood base materials, worm-eatenness and corrosion, and are difficult to recycle. Are disposed of by landfill or incineration.
[0003]
In addition, as a decorative material using a base material other than wood, one in which a decorative sheet is bonded to the surface of a synthetic resin base material by profile extrusion or the like is used. The above-mentioned disadvantages caused by the use of the wood are not found, and the appearance looks like wood by applying the decorative sheet of wood grain design. However, there are problems such that there is no wood texture in terms of specific gravity, rigidity, etc., and various processes such as cutting and nailing are difficult, and it can be used only in limited parts.
[0004]
In recent years, many attempts have been made to provide a wood resin molded article containing a thermoplastic resin and a wood filler for applications such as building interior materials, floor materials, joinery, and surface materials of household electrical appliances. However, these wooden resin molded products are excellent in recyclability, workability such as cutting and nailing, and wood texture, etc., and the surface is a monotonous color colored with a wooden filler. Therefore, there is a disadvantage that it is inferior in design.
[0005]
Therefore, it is also conceivable to impart desired excellent design properties by bonding a surface material such as a natural veneer, decorative paper, or decorative sheet to the surface of the above-described woody resin molded body. However, cosmetic materials with various surface materials bonded to the surface of a wooden resin molded body in this way are technically capable of separating the surface material from the discarded end material and the wooden resin molded body that is the main body of the waste material. In addition, there is a concern that a problem that the recyclability of the bent wood resin molding cannot be fully utilized due to the difficulty in terms of economy.
[0006]
On the other hand, the present inventors mainly have the same thermoplastic resin as the thermoplastic resin contained in the wood resin molding on the surface of the wood resin molding containing the thermoplastic resin and the wood filler. Has already proposed a decorative material on which decorative sheets are laminated (Japanese Patent Application No. 2000-178362). This decorative material has excellent workability such as wood texture, workability such as cutting and nailing, and excellent design and recyclability.
[0007]
However, the above-mentioned decorative material is inferior in adhesiveness compared to a normal wooden base material such as plywood or fiberboard, and the wood resin molded body as the base material is particularly widely used for normal wood. When a decorative sheet is attached using an adhesive containing a volatile component that is not 100% solid content, such as a water-based emulsion type adhesive or a solvent-type adhesive, the volatile component in the adhesive is not air-permeable. Because it does not come off easily between the resin molded body and the decorative sheet, it stays in the adhesive for a long time, so a long curing period is required after bonding, and wrinkles, misalignment, and swelling occur during curing. There is a problem that adhesion failure such as the above is likely to occur, and it is difficult to bond the woody resin molded body and the decorative sheet.
[0008]
[Problems to be solved by the invention]
The present invention has been made in order to solve the above-described problems in the prior art, and the object of the present invention is a woody resin molded article having good workability such as wood texture, cutting and nailing. And a decorative material having a laminate structure with a decorative sheet excellent in design, which can be easily recycled without the need to separate the wooden resin molded body from the decorative sheet, and the wooden resin molded body and the decorative sheet It is to provide a cosmetic material having excellent adhesiveness.
[0009]
[Means for Solving the Problems]
The decorative material of the present invention is Long chain branching introduced by electron beam crosslinking On the surface of a foamed wood resin foamed article that contains a thermoplastic resin and a wood filler. ,heat A decorative sheet mainly made of plastic resin is not laminated. The thermoplastic resin contained in the wood resin foam molded article and the thermoplastic resin contained in the decorative sheet are polyolefin resins. This is a cosmetic material characterized by that.
[0010]
In particular, in the decorative material, the wooden resin foam molded article is a decorative material characterized in that it has at least part of a part containing a wooden filler or contains a wooden filler in its entirety. .
[0011]
In particular, in the above-mentioned decorative material, the wood-based filler has a mean particle size of 1 to 200 μm.
[0012]
In particular, in the decorative material, a mixing ratio of the wood filler in a portion containing the wood filler is 10 to 500 parts by weight with respect to 100 parts by weight of the thermoplastic resin. It is a cosmetic material.
[0013]
In particular, in the above-mentioned decorative material, the woody resin foam molded article is a decorative material characterized in that it has a part that is foamed or is entirely foamed.
[0014]
In particular, in the above-mentioned decorative material, the wood resin foam molded article has a foaming ratio of 1.1 to 10.0 times.
[0015]
In particular, in the cosmetic material, Polyolefin Resin polypropylene A cosmetic material characterized by being a resin.
[0016]
Further, in particular, in the above-mentioned decorative material, the decorative sheet is a decorative material characterized by having a wood grain design.
[0017]
In particular, the decorative material is a decorative material in which the decorative sheet has transparency.
[0018]
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1, the decorative material of the present invention contains a thermoplastic resin 3 and a wood filler 4 on the surface of a wood resin foam molded body 2 which is foamed (there are bubbles 5 inside). A decorative material comprising a decorative sheet 1 mainly composed of a thermoplastic resin similar to the thermoplastic resin 3 contained in the woody resin foam molded body 2.
[0019]
As described above, in the decorative material of the present invention, the decorative sheet 1 and the wood resin foam molded body 2 are mainly composed of the same type of thermoplastic resin. Without being separated from the body 2, it can be used again as a material for the wood resin foam molded body 2, and there is no molding defect at the time of molding at the time of recycling. There is no decline in strength.
[0020]
Moreover, since the wood resin foam molded body 2 is porous including bubbles 5 inside due to foaming, the adhesive between the decorative sheet 1 and the wood resin foam molded body 2 is a water-based emulsion type adhesive or solvent type adhesive. Even when an adhesive containing a general-purpose volatile component for wood, such as an agent, is used, the volatile component in the adhesive diffuses through the bubbles 5 inside the wood resin foam molded body 2 so that the adhesive is quickly Since it can be dried and solidified, it can be efficiently and stably manufactured without requiring a long period of time for curing after bonding, or causing wrinkles, misalignment, swelling, etc. during curing. In addition, there is an advantage that the adhesive force is improved by the anchoring effect because the adhesive enters the inside of the bubbles near the bonding surface of the wood resin foam molded body 2 after the bonding.
[0021]
In addition to the above, foaming of the woody resin foam molded body 2 can prevent a cold touch or dew condensation due to increased heat insulation, and can be provided with appropriate elasticity (cushioning property) to provide a good impact. There are also advantages such as improved safety and a feeling of walking as a flooring material, and improved workability and economy due to weight reduction.
[0022]
In particular, if the decorative sheet 1 has a wood grain design, the wood resin foam molded body 2 contains the wood filler 4, so that the mouth that can be seen by cutting or grooving also has a wood texture. Therefore, in addition to the sense of incongruity with the wood grain design on the surface, the printing ink for giving the wood grain design to the decorative sheet 1 has the same color as the wood material. Even if it mixes in the foaming molding 1, there is an advantage that there is no sense of incongruity in color.
[0023]
The material of the wood filler 4 used in the present invention is not particularly limited as long as it is basically a powdery, granular or short fiber filler manufactured using natural wood as a main raw material. It can be arbitrarily selected from conventionally known ones. Generally, wood is broken by a cutter mill or the like, and is pulverized by a ball mill or impeller mill to give a fine powder (wood flour). Can be suitably used.
[0024]
In addition, in the case where the blending amount of the wood filler 4 is a high blending amount exceeding 100 parts by weight with respect to 100 parts by weight of the thermoplastic resin, dispersibility in the resin is particularly important. Therefore, it is preferable to use a granular wood filler 4 having relatively little cilia. Specifically, as the wood filler 4 having less cilia, a polishing powder obtained by mainly polishing a particle board or the like is preferably used.
[0025]
Although the average particle diameter of the wood filler 4 is not particularly limited, it is generally 1 to 200 μm, more preferably 5 to 100 μm. When the average particle size is less than 1 μm, it is difficult to handle, and particularly when the amount of the wood filler 4 is large, if the dispersion state in the resin is poor, the mechanical strength may be reduced. There is. On the other hand, if it is larger than 200 μm, it tends to cause a decrease in the homogeneity, flatness and mechanical strength of the molded product.
[0026]
The blending amount of the wood filler 4 is not particularly limited in the present invention, but is generally within a range of about 10 parts by weight to 500 parts by weight with respect to 100 parts by weight of the thermoplastic resin 3. Although the selection can be made as appropriate, the optimum blending amount varies depending on the use of the cosmetic material. Therefore, it is desirable to design appropriately according to the use.
[0027]
Specifically, for example, when a polyolefin resin is used as the thermoplastic resin 3, for a purpose of performing a cutting process or a V-cut process after being formed into a flat plate by a compression molding method or the like, a post-processing such as a cutting property is performed. In order to obtain an excellent material, the amount of the wood filler 4 is preferably 50 to 500 parts by weight, more preferably 100 to 500 parts by weight, based on 100 parts by weight of the thermoplastic resin 3. . On the other hand, for use molded by, for example, a profile extrusion method or an injection molding method, the wood filler 4 is 10 to 10 parts by weight with respect to 100 parts by weight of the thermoplastic resin 3 in order to improve moldability and homogeneity. It is desirable that the amount be 200 parts by weight, more preferably 15 to 150 parts by weight.
[0028]
Examples of the thermoplastic resin 3 used for the wood resin foam molded body 2 in the present invention include polyolefin resins, polystyrene resins, polycarbonate resins, polyester resins, polyamide resins, polyvinyl alcohol resins, acrylic resins, polychlorinated resins. It is possible to select from various conventionally known thermoplastic resins such as vinyl resins and fiber derivatives, but generation of harmful substances such as hydrogen chloride gas and dioxin during incineration, outflow of environmental hormones during landfill, etc. In view of the above problems, it is desirable to use a non-halogen resin, and in particular, in order to satisfy performance such as weather resistance and heat resistance as a member, resistance to chemicals and solvents, it is preferable to use a polyolefin resin. Most desirable.
[0029]
Examples of the polyolefin resin used here include polyethylene, polypropylene, polybutene, polyisoprene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, ethylene-α olefin copolymer, propylene-α olefin copolymer, Ethylene-ethyl acrylate copolymers and their acid-modified products (grafted with unsaturated carboxylic acids or anhydrides for the purpose of improving adhesion), ionomers (metal hydration of olefin-unsaturated carboxylic acid copolymers) Etc.) can be selected as appropriate, and may be a single type or a mixture of plural types.
[0030]
However, in the case of mixing multiple types, in order to obtain a wood resin foam molded body 2 that can maintain sufficient physical properties as a base material for decorative materials after recycling, select those that are compatible with each other as much as possible. It is desirable to combine them. Alternatively, in the case of mixing resins having poor compatibility, it is also effective to add a compatibilizing agent. For example, when incompatible resins are mixed, such as mixing or lamination of polyethylene and polypropylene, these are compatible, for example. It is more desirable to blend ethylene-propylene copolymer. In particular, in order to increase the adhesiveness between the resins and increase the internal strength, the blending ratio of the acid-modified resin is increased (about 20 to 50% by weight of the entire resin), the resin itself has polarity, and the woody system It is desirable to improve the adhesiveness with the filler 4.
[0031]
Further, in order to improve foamability in foam molding of the woody resin foam molded article 2, it is desirable that the thermoplastic resin 3 contained therein has a high melt tension. When using low-grade resins, it is necessary to use known methods such as the use of resins with long-chain branches introduced by electron beam crosslinking, adjustment of molecular weight distribution, or addition of additives that increase melt tension. Accordingly, it is desirable to use a resin adjusted to have a high melt tension.
[0032]
In the present invention, the foaming method of the woody resin foam molded body 2 is not particularly limited, and any of various conventionally known resin foaming methods can be arbitrarily used. Specifically, for example, there is a mechanical foaming method in which the bubbles 5 are mechanically introduced by vigorously stirring the molten thermoplastic resin 3 in the air. In many cases, a foaming technique using a foaming agent as an additive to the thermoplastic resin 3 is used. Generally, the foaming method using such a foaming agent has a low-boiling point as a foaming agent introduced into a resin, and a chemical foaming method using a chemical foaming agent having a property of generating gas by thermal decomposition or chemical reaction. It is classified as a physical foaming method in which liquid is vaporized by applying heat.
[0033]
Examples of the chemical foaming agent include inorganic foaming agents such as sodium bicarbonate, ammonium carbonate, ammonium bicarbonate, ammonium nitrite, sodium borohydride, light metals, and azide compounds, and organic compounds such as azo, nitroso, and hydrazide. There are foaming agents and the like, and these can be used in any combination. In particular, physical foaming is mainly used for foaming at a high foaming ratio exceeding 2 times, and carbon dioxide gas and aliphatic hydrocarbons are mainly used as foaming agents. In addition, a chemical foaming agent is often used in combination in order to adjust the cell shape of the foam during physical foaming.
[0034]
If the expansion ratio of the wood resin foam molded body 2 is too low, various effects due to foaming are poor. On the other hand, if the expansion ratio is too high, the mechanical strength is lowered and the load or stress applied to the decorative material cannot be resisted. Since the adhesive strength with the decorative sheet may decrease as a result of the decrease in strength, the range is generally 1.1 to 10.0 times, more preferably 1.3 to 8.0 times, although it depends on the application. It is desirable to be inside.
[0035]
In addition to the above-mentioned wood-based filler 4 and foaming agent, the woody resin foam molded body 2 includes a heat stabilizer, an acid neutralizer, an ultraviolet absorber, a light stabilizer, a colorant such as a pigment or a dye, if necessary. From various additives such as non-wood based organic or inorganic fillers, antistatic agents, lubricants, nucleating agents, flame retardants, antiblocking agents, light scattering agents for translucency, gloss adjusting agents, etc. One or more selected can also be added.
[0036]
Among these additives, hindered phenols, sulfurs, phosphoruss, etc. as heat stabilizers, stearic acid metal salts, hydrotalcite, etc. as acid neutralizers, benzotriazoles, benzoates as ultraviolet absorbers, etc. -Based, benzophenone-based, triazine-based, light stabilizer as hindered amine-based, flame retardant as halogen-based flame retardant, phosphorus-based flame retardant, chlorine-based flame retardant, etc., filler as calcium carbonate, silica, titanium oxide, Barium sulfate, zinc oxide, alumina, talc, mica, magnesium silicate, potassium titanate, magnesium sulfate, aluminum hydroxide, magnesium hydroxide, iron oxide, carbon black, metal powder, etc., lubricants include hydrocarbon lubricants, fatty acids, Nucleating agents such as higher alcohols, fatty acid amides, metal soaps, esters, etc. Carboxylic acid metal salt-based, sorbitol-based, phosphate ester metal salt-based, etc., and pigments such as condensed azo, insoluble azo, quinacridone, isoindolinone, anthraquinone, imidazolone, phthalocyanine and other organic pigments, carbon black, cobalt There are inorganic pigments such as blue, titanium oxide, zinc oxide, and iron oxide, pearl pigments such as titanium oxide-coated mica, and bismuth oxide chloride. These additives can be used in any combination.
[0037]
In the present invention, the wood resin foam molded body 2 may contain the wood filler 4 as a whole, and is the object of the present invention, such as recyclability, wood texture, cutting ability, nailing ability, adhesiveness, etc. If the wood filler 4 is not impaired, for example, the wood filler 4 such as a skin layer (thin layer on the surface) made of the same thermoplastic resin as the thermoplastic resin 3 contained in the portion containing the wood filler 4 is used. There may be a layer not included.
[0038]
Further, in the present invention, the whole of the wood resin foam molded body 2 may be foamed, and the processability such as recyclability, wood texture, cutting property, nailing property, adhesive property, etc., which is the object of the present invention. For example, a non-foamed layer such as a skin layer (a thin layer on the surface) of a thermoplastic resin similar to the thermoplastic resin 3 contained in the foamed portion may be present. Absent.
[0039]
The presence of a skin layer that does not contain wood foam 4 or is not foamed as described above prevents the wood quasi-spotted 4 or foamed bubbles 5 from being exposed on the surface of the wood resin foam molded body 2. In addition, the surface is finished smoothly, and also has an effect of improving the stain resistance and the water resistance particularly in a portion where the decorative sheet 1 is not bonded. However, in view of the object of the present invention described above, in the present invention, it is desirable that at least the surface portion of the wood resin foam molded body 2 in the portion where the decorative sheet 1 is bonded is a foamed portion.
[0040]
As an aspect of presence of the part which does not contain the wood type filler 4 and the part which does not foam, it is not limited to the above-mentioned skin layer, for example, in the form of sea islands or streaks inside the wood resin foam molded body 2, Arbitrary structures such as a mesh shape and a layer shape can be adopted. Further, even in a portion containing the wood filler 4 or a foamed portion, it is not always necessary that the wood filler 4 is uniformly blended or foamed uniformly throughout the wood filler. A plurality of kinds of portions having different blending ratios and foaming ratios of the filler 4 may be configured in, for example, a sea-island shape, a streak shape, a mesh shape, a layer shape, or the like.
[0041]
The wood resin foam molded body 2 is obtained by molding and foaming a wood resin foamable composition obtained by adding and kneading a wood filler 4 and a foaming agent to a thermoplastic resin 3 into an appropriate shape by an appropriate molding method. Can do. The wood filler 4 and the thermoplastic resin 3 may be kneaded in any method, but generally a kneading method using a Banbury mixer and pelletizing using a pelletizer, or a mixing and pelletizing method using a twin screw kneader. Is. Further, the wood filler 4 may be kneaded with the thermoplastic resin 3 simultaneously with the molding of the thermoplastic resin 3. Although the foaming agent can be kneaded at the time of pelletization, it is desirable to add the foaming agent at the time of molding in order to prevent an unexpected foaming accident before molding.
[0042]
Moreover, when recycling the decorative material of the present invention, the crushed material is added to the wood filler 4, the thermoplastic resin 3, and other various additives as necessary, and pelletized again. In this case, the method is not particularly limited.
[0043]
The production method of the woody resin foam molded body 2 is not particularly limited, for example, from various known molding methods such as compression molding method, extrusion molding method, profile extrusion molding method, injection molding method, injection compression molding method, transfer molding method and the like. What is necessary is just to select suitably according to the shape and dimension of a molded object. The shape can be freely selected, for example, a flat plate shape, a three-dimensional shape, a hollow shape, a rib shape, and the like. In the profile extrusion molding method, the use of the Celca method is particularly effective for improving surface properties. Moreover, in order to improve the uniformity of a foaming state, the method of making it into a plate shape after extrusion with a circular die is especially effective for the flat plate shape formed by gas foaming at a high expansion ratio.
[0044]
The decorative material of the present invention is constituted by laminating a decorative sheet 1 for imparting a desired appropriate design on the surface of the above-described wood resin foam molded article 2, but in the present invention, what is important is that The decorative sheet 1 is mainly composed of a thermoplastic resin similar to the thermoplastic resin 3 contained in the wood resin foam molded body 2, thereby ensuring recyclability of the decorative material of the present invention. It is.
[0045]
In the present invention, it is important that the thermoplastic resin of the same type is recyclable without significant change in physical properties even if mixed with each other, and as long as the thermoplastic resin is composed mainly of the decorative sheet 1. As the resin, a similar resin can be selected from various thermoplastic resins similar to those listed as examples of the thermoplastic resin 3 contained in the wood resin foam molded body 2 described above. .
[0046]
Specifically, for example, for polyolefin resins, polyethylene, polypropylene, polybutene, polyisoprene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, ethylene-α olefin copolymer, propylene-α olefin copolymer. Polymers, ethylene-ethyl acrylate copolymers and acid-modified products thereof (grafted with unsaturated carboxylic acid or its anhydride for the purpose of improving adhesion), ionomer (olefin-unsaturated carboxylic acid copolymer) A metal hydrate) can be appropriately selected, and the same or different resins selected from these can be used for the wood resin foam molded body 2 and the decorative sheet 1.
[0047]
When different types of resins are combined, it is desirable that they are a combination of resins that are compatible with each other or that adhere well to each other. If the physical properties after mixing can be maintained by adding a solubilizing agent and / or an adhesive, it can be used. However, in that case, the compatibilizing agent and / or the adhesive is one or both of the wood resin foam molded body 2 and the decorative sheet 1 so that it is not necessary to add a compatibilizing agent and / or an adhesive separately at the time of recycling. It is desirable to add to the resin composition constituting
[0048]
If necessary, one or more selected from the same various additives as in the case of the thermoplastic resin 3 constituting the wood resin foam molded body 2 described above may be added to the thermoplastic resin constituting the decorative sheet 1 as well. Can do.
[0049]
The specific configuration of the decorative sheet 1 is not particularly limited. For example, a single-layer decorative sheet having a pattern printed on the surface of a transparent or colored sheet, the pattern printed on the surface of the colored sheet, and the printed surface. Depending on the application, for example, multi-layer decorative sheets obtained by laminating clear sheets by dry lamination, extrusion lamination, thermal lamination, etc., back-printed single-layer decorative sheets with a pattern printed on the back of a transparent sheet, etc. Appropriate selection is possible. In the case of a multi-layer decorative sheet, it goes without saying that the same kind or different kinds of thermoplastic resins should be used as the thermoplastic resin constituting each layer.
[0050]
The type of design of the printed pattern applied to the decorative sheet 1 is not particularly limited, and can be arbitrarily selected from, for example, a wood grain pattern, a stone pattern, a cloth pattern, an abstract pattern, and the like. In particular, when a decorative sheet of wood grain design is adopted, there is no sense of incongruity with the wooden resin foam molded body 1 that is exposed by cutting and cutting of the decorative material, and the printing ink is similar in color to the wooden material. Even if it mixes in the woody resin foam molded body 2, it can be said that it is most desirable for the purpose of the present invention because there is no problem of color change.
[0051]
At this time, when the decorative sheet 1 has a sufficient hiding property by adopting a colored sheet and / or forming a hiding solid printing layer, there is an advantage that a stable design reproduction is achieved, but conversely When the decorative sheet 1 has transparency, the surface of the wooden resin foam molded body 2 containing the wooden filler 4 can be seen through the decorative sheet 1, so that the wood texture of the wooden resin foam molded body 2 is improved. There is an advantage that it is possible to make use of design expression.
[0052]
Examples of the printing ink binder used for printing the design pattern on the decorative sheet 1 include, for example, nitrified cotton, cellulose, vinyl chloride-vinyl acetate copolymer, polyvinyl butyral, polyurethane, acrylic, polyester and the like alone or each modified product. What is necessary is just to select suitably from the inside. These may be any of aqueous, solvent-based and emulsion types, and can be arbitrarily selected from a one-component type or a two-component type using a curing agent. Further, it is possible to cure the ink by irradiation with ultraviolet rays or electron beams. Among them, the most common one is a two-component curable urethane resin-based printing ink that is cured with a curing agent composed of an isocyanate compound with a polyol prepolymer as a main component, and is particularly excellent in adhesion to polyolefin resins.
[0053]
In addition to these binders, colorants such as pigments and dyes, extender pigments, solvents, and various additives contained in ordinary inks are added. Particularly frequently used pigments include organic pigments such as condensed azo, insoluble azo, quinacridone, isoindolinone, anthraquinone, imidazolone, and phthalocyanine, and inorganic pigments such as carbon black, cobalt blue, titanium oxide, zinc oxide, and iron oxide. There are pearl pigments such as titanium oxide-coated mica and bismuth oxide chloride.
[0054]
Examples of design pattern printing methods include gravure printing, offset printing, gravure offset printing, dry offset printing, screen printing, flexographic printing, letterpress printing, inkjet printing, electrostatic printing, transfer printing A conventionally known appropriate printing method such as the above can be used. When using a solid printing layer such as a concealed solid printing layer, for example, a gravure coating method, a micro gravure coating method, a roll coating method, a knife coating method, an air knife coating method, a kiss coating method, a rod coating method, A coating method such as a die coating method, a lip coating method, a comma coating method, a flow coating method, or a dip coating method can also be used.
[0055]
In addition, if necessary, the surface to be printed such as corona discharge treatment, plasma treatment, ozone treatment, flame treatment, acid treatment, alkali treatment, primer or anchor treatment may be applied to the printing surface of the printing sheet as necessary before printing the design pattern. It is also possible to improve the adhesion with the printing ink.
[0056]
Moreover, in any decorative sheet 1, a primer coat for bonding to the wood resin foam molded body 2 is applied to the back surface, a top coat for surface protection and gloss adjustment, an embossing method, and a wiping method. The surface may be provided with a conduit expression by the gloss mat method or the like.
[0057]
In the decorative material of the present invention, the method of laminating the decorative sheet 1 on the surface of the wood resin foam molded body 2 is not particularly limited, and an appropriate layering method is selected depending on the size and shape of the wood resin foam molded body 2. can do. For example, in the case of a flat plate, the longitudinal direction of a profile extrusion molding method such as a roll laminating method in which an adhesive is applied to the front surface of the flat wooden resin foam molded body 2 and / or the back surface of the decorative sheet 1 and bonded with a roll. For example, a lapping process may be used if the molded body has the same shape, and a vacuum press laminating method may be used if the molded body has a complicated three-dimensional surface.
[0058]
In addition, simultaneous painting can be performed in which a decorative sheet is pasted simultaneously with molding by a profile extrusion molding simultaneous laminating method, an injection molding simultaneous laminating method, or the like. In addition, when using the wood resin foam molded body 2 or the decorative sheet 1 made of a thermoplastic resin that is difficult to adhere, such as polyolefin resin, corona discharge treatment, ozone treatment, plasma discharge treatment, flame treatment, It is desirable to improve the adhesion by performing surface treatment such as acid treatment or alkali treatment, primer coating, anchor coating, or the like.
[0059]
When the decorative material of the present invention is recycled, it is not necessary to peel and separate the wood resin foam molded body 2 and the decorative sheet 1, but the whole is crushed and pelletized again, or heated and melted as it is, and again By molding, a recycled wood resin foam molded body 2 can be obtained. Here, the method of pelletization and molding is exactly the same as the method described above as the method in the original wood resin foam molded body 2 (virgin product). In the case of recycling, the wood filler 4, the thermoplastic resin 3, the foaming agent, and other various additives are appropriately added to the crushed material of the decorative material of the present invention or the heated melt thereof as necessary. May be.
[0060]
As a recycling method, in addition to the above, there is a method in which the thermoplastic resin 3 and the wood filler 4 are separated and recovered, but even in that case, the decorative sheet 1 is separated from the wood resin foam molding 2. It is not necessary and can be recovered together with the thermoplastic resin 3 contained in the woody resin foam molded body 2.
[0061]
Depending on the mode of use of the decorative material of the present invention, it may not be suitable for recycling due to, for example, compositing with other resin parts. Moreover, as a result of repeating the above recycling use many times, it may become unsuitable for recycling use due to accumulation of mixed foreign substances, natural deterioration of resin, and the like. In such a case, in the decorative material of the present invention, as the thermoplastic resin mainly composed of the thermoplastic resin 3 and the decorative sheet 1 contained in the wood resin foam molded body 2, a non-halogen-based material such as a polyolefin resin is used. If this resin is used, it can be incinerated without worrying about the generation of harmful substances such as hydrogen chloride gas and dioxin during combustion. Needless to say, if the waste heat is subjected to thermal recycling in which the waste heat is reused for power generation, hot water supply, air conditioning or the like during the incineration, it becomes a more environmentally friendly use form.
[0062]
【Example】
Hereinafter, the present invention will be described in more detail with reference to specific examples and comparative examples of the present invention.
[0063]
<Example 1>
70 parts by weight of high melt tension polypropylene resin having long chain branching by electron beam cross-linking, 30 parts by weight of homopolypropylene resin modified with maleic acid, and wood were crushed with a cutter mill, and this was pulverized with a ball mill and averaged A wood resin composition was prepared by mixing and pelletizing 400 parts by weight of a wood filler having a particle size of 20 μm with a twin screw extruder kneader. This wood resin composition is extruded from a circular die while being foamed 4 times by a physical foaming method using butane gas, then cut open, formed into a rectangular parallelepiped shape having a cross section of 5 mm × 300 mm, and further subjected to corona discharge treatment on the surface. Thus, a virgin polyolefin-based wood resin foam molded article was prepared.
[0064]
On the other hand, a colored polypropylene resin sheet having a thickness of 100 μm formed by blending a random polypropylene resin with a pigment such as iron oxide or titanium oxide is subjected to wood printing with urethane ink, and the printed surface is homogenized by an extrusion laminating method. Polypropylene resin was simultaneously embossed with a thickness of 100 μm, a primer coat was applied to the back surface, and a top coat was applied to the surface to prepare a decorative sheet made of polyolefin resin.
[0065]
Thereafter, the polyolefin-based resin decorative sheet was bonded to the surface of the polyolefin-based wood resin foam molded article by a lapping method to prepare a virgin cosmetic material of the present invention.
[0066]
Also, the wood resin foam molded body of the virgin decorative material and the decorative sheet were crushed as they were without being separated, and then re-pelletized by a single screw extruder, and this was circular again by physical foaming with butane gas. Extruded after foaming about 4 times from the die, cut open, molded into a rectangular parallelepiped shape with a cross section of 5 mm x 300 mm, and further subjected to corona discharge treatment on the surface to produce a recycled polyolefin-based wood resin foam molded body Produced.
[0067]
After that, the same polyolefin resin decorative sheet as used for the virgin product is bonded to the surface of the recycled polyolefin wood resin foam molded article by the lapping method, and the recycled product of the present invention is used. A decorative material was produced.
[0068]
<Comparative Example 1>
In Example 1, the wood resin composition was extruded into a rectangular parallelepiped shape having a cross section of 5 mm × 300 mm by a profile extrusion molding method without subjecting the wood resin composition to physical foaming with butane gas, and a non-foamed polyolefin wood A resin molded product was obtained, and the others were exactly the same as in Example 1 (however, the manufacturing conditions of the non-foamed polyolefin-based wood resin molded product of the recycled product conform to the virgin product), the virgin product and the recycled product A decorative material was made.
[0069]
<Comparative example 2>
In Example 1, instead of the polyolefin resin decorative sheet, a 100 μm-thick colored polyvinyl chloride resin sheet formed by blending pigments such as iron oxide and titanium oxide was subjected to wood printing with urethane ink. Using a polyvinyl chloride resin decorative sheet prepared by simultaneously laminating a 100 μm thick polyvinyl chloride resin clear sheet on the printed surface with embossing, applying a primer coat on the back and a top coat on the surface In the other respects, virgin and recycled cosmetics were produced in exactly the same manner as in Example 1.
[0070]
<Comparative Example 3>
In Example 1, 30 parts by weight of talc was used in place of 400 parts by weight of the wood filler, and the rest was made in the same manner as in Example 1 except that virgin and recycled cosmetics were produced.
[0071]
<Performance evaluation>
For the virgin and recycled cosmetics of Example 1 and Comparative Examples 1 to 3, respectively, moldability, saw cutting, nailing, adhesiveness with vinyl acetate aqueous emulsion adhesive for wood, and design properties -The wood texture (by visual and tactile sensation) was evaluated. The evaluation results are shown in Table 1.
[0072]
[Table 1]

[0073]
From the evaluation results of Table 1 above, the thermoplastic resin and the wood filler are contained, and on the surface of the foamed wood resin foam molded body, the same system as the thermoplastic resin contained in the wood resin foam molded body is obtained. The decorative material of the present invention in which a decorative sheet mainly composed of thermoplastic resin is laminated has a wood texture, good workability such as machinability, nailing, and adhesion with a general-purpose adhesive, and is excellent. It was confirmed that it is a decorative material that has both design and recyclability.
[0074]
【The invention's effect】
As described above in detail, the decorative material of the present invention contains a thermoplastic resin and a wood filler, and is contained in the wood resin foam molded body on the surface of the foamed wood resin foam molded body. A decorative sheet mainly made of the same type of thermoplastic resin as the thermoplastic resin is laminated so that it is excellent in workability such as cutting and nailing, and a high design by the decorative sheet and visual by the wood resin foam molding And a tactile wood texture, and can be easily recycled without the need to separate the wood resin foam molding from the decorative sheet, and the wood resin foam molding contains a volatile component because it is foamed. A general-purpose adhesive for wood such as water-based emulsion type and solvent type allows easy and strong adhesion of decorative sheets, as well as a warm and soft touch similar to natural wood due to the elasticity and heat insulation derived from the foam structure. Or shock And a buffering against.
[0075]
In this way, the decorative material of the present invention makes use of the high design property of the decorative sheet, and it has been difficult to use in a wooden resin molded body that is inferior in design properties so far. It can be used enough for the following purposes. In addition, it is possible to apply various post-processings that have been performed on wood-based decorative materials, and in particular, the present invention enables the use of general-purpose wood adhesives in bonding operations. Ease of use equivalent to general-purpose wood materials such as density fiberboard (MDF) has been realized, and it contributes to industrial development and protection of the global environment as a material that is easy to recycle instead of conventional wood materials. It ’s a big thing.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view schematically showing an embodiment of a decorative material of the present invention.
[Explanation of symbols]
1 Makeup sheet
2 Wood resin foam molding
3 Thermoplastic resin
4 Wood-based filler
5 bubbles

Claims (9)

A decorative sheet mainly composed of a thermoplastic resin is laminated on the surface of a foamed wood resin foam molded article containing a thermoplastic resin introduced with long chain branching by electron beam crosslinking and a wood filler. A decorative material, wherein the thermoplastic resin contained in the wood resin foam molded article and the thermoplastic resin contained in the decorative sheet are polyolefin resins . The cosmetic material according to claim 1, wherein the wood resin foam molded article has at least a part containing a wood filler, or contains a wood filler as a whole. The decorative material according to claim 1 or 2, wherein an average particle diameter of the wood filler is 1 to 200 µm. The mixing ratio of the wood filler in the portion containing the wood filler is 10 to 500 parts by weight with respect to 100 parts by weight of the thermoplastic resin. Cosmetic material according to. The decorative material according to any one of claims 1 to 4, wherein the woody resin foam molded article has a part that is foamed or is entirely foamed. The decorative material according to any one of claims 1 to 5, wherein a foaming ratio of the woody resin foam molded article is 1.1 to 10.0 times. The cosmetic material according to any one of claims 1 to 6, wherein the polyolefin resin is a polypropylene resin. The said decorative sheet has a wood grain design, The cosmetic material in any one of Claims 1-7 characterized by the above-mentioned. The decorative material according to claim 1, wherein the decorative sheet has transparency.

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