JP5088246B2 - Floor decorative sheet - Google Patents

Description

  The present invention relates to a floor decorative sheet used by being bonded to the surface of a wooden floor material such as a house, store, office, or gymnasium. In particular, it is used by sticking to a wooden flooring material, and is excellent in scratch resistance, caster resistance, three-dimensional coating thickness, impact resistance, dimensional stability, surface strength, etc. It is related with the decorative sheet for floors excellent in winding-up property.

  Known flooring materials for wood-based flooring are those in which a veneer is attached to plywood, grooves are processed by a woodworking machine, the grooves are colored, and then UV-curable paint is applied and cured. ing. However, because the veneer is a natural wood, the color varies and it is difficult to harmonize the color with the walls, ceiling, and furniture.

  Also, a concave groove is provided on the surface of the wooden flooring material, and a synthetic resin paint for coloring a conduit is applied to the surface. After removing the paint other than the concave groove, a conduit concave portion with a grain pattern is formed, and the woody material other than the concave groove A method of applying a transparent synthetic resin paint to the surface of a floor system is known. However, because of the construction made of a wooden floor material and a synthetic resin paint, it has been difficult to provide scratch resistance by a chair with casters, so-called caster resistance. In addition, there is a problem that once the dent is made, it is difficult to restore.

There is also known a method of using a decorative sheet for floors in which a decorative sheet in which a colored thermoplastic resin, a pattern, and a transparent thermoplastic resin are provided in this order on a wooden flooring is bonded to the colored thermoplastic resin side. .
Conventionally, as the thermoplastic resin, a polyvinyl chloride resin that is flexible, easy to process, and inexpensive is often used. However, since polyvinyl chloride resin generates toxic substances such as hydrogen chloride and dioxin during combustion, problems such as fire and environmental problems caused by incineration after use are pointed out. Therefore, it has been desired to use a resin having a performance equivalent to that of a polyvinyl chloride resin.

  For such problems, polyester-based resins, particularly amorphous polyethylene terephthalate, etc. have already been suitably used. However, in consideration of cushioning properties as a decorative sheet, surface resistance, etc., some thickness is required.

  However, if the decorative sheet is too thick, it is difficult to wind in a wave shape (rolled state), and it becomes difficult to cut the sheet on the line during continuous lamination with the wooden flooring. Therefore, since productivity does not increase, when laminating a thermoplastic resin decorative sheet and a wooden flooring, prepare a decorative sheet that has been cut to the same size as the wooden flooring in advance, I had to take the method of laminating one by one

Although it was considered that the colored thermoplastic resin is a polyester resin and the transparent thermoplastic resin is a harder acrylic resin after suppressing the overall thickness, it is too hard and brittle, and the range of the required thickness However, since it is hard even if it is sufficiently thin, there is a problem that it is difficult to wind up as a decorative sheet.
JP 2002-337291 A JP 2002-059512 A

  The present invention has been made in order to solve such problems, and the problem is that there is a three-dimensional thickness of the coating, it is difficult to have dents, etc., and it is excellent in winding up of the decorative sheet. Another object of the present invention is to provide a decorative sheet for floors that can be easily adjusted in color tone, has scratch resistance, caster resistance, impact resistance, etc., can be easily manufactured, and has excellent processability.

  The present invention solves this problem, that is, the invention described in claim 1 is a decorative sheet in which a pattern layer and a transparent thermoplastic resin layer are provided in this order on a colored thermoplastic resin layer. The thermoplastic resin is mainly composed of polybutylene terephthalate resin, and 5 to 15 parts by weight of copolymer polyester resin and 0.2 to 0.5 part by weight of elastomer resin are added to 100 parts by weight of polybutylene terephthalate resin. It is a decorative sheet for floors characterized by comprising.

  The invention according to claim 2 is the decorative sheet for floor according to claim 1, wherein the colored thermoplastic resin layer has a thickness of 70 to 160 μm.

  According to the invention described in claim 1, the present invention is suitable for printing by adding a copolymer polyester resin to a colored thermoplastic resin mainly composed of polybutylene terephthalate resin (hereinafter referred to as PBT) in a suitable range. In addition, by adding an elastomer resin in a suitable range, there is an effect that the followability when laminating other than a flat shape is improved. In addition, it is possible to easily wind up the decorative sheet when manufacturing the decorative sheet, and it is easy to produce on a roll-to-roll basis.

  Further, according to the invention described in claim 2, by making the thickness of the transparent thermoplastic resin layer limited, it is easy to wind up after printing while suppressing generation of thermal wrinkles. It becomes an effect of becoming.

  Hereinafter, the present invention will be described in detail with reference to the drawings. FIG. 1 shows a cross-sectional structure of an embodiment of the floor decorative sheet of the present invention. It consists of a colored thermoplastic resin layer 1, a picture pattern layer 2, and a transparent thermoplastic resin layer 3, and an adhesive layer 4 and a surface protective layer 5 are provided as appropriate. The decorative sheet thus obtained is used as a decorative sheet for a floor that can be bonded to a wooden floor material 7 or the like via an adhesive layer 6 to obtain a decorative material.

For the colored thermoplastic resin layer 1 in the present invention, a resin mainly composed of PBT is used, and a sheet-like material made of this resin is used. By adding a copolymer polyester resin from 5 parts by weight to 15 parts by weight to the PBT as a main resin, and the PBT, the printing suitability is improved, and the followability when laminating to a shape other than a flat shape is improved. There is an effect to improve. When this copolymerized polyester resin is less than 5 parts by weight, the ink is poorly printed. On the other hand, if the copolyester resin exceeds 15 parts by weight, the class Immersion Test for plywood will fail.
As the copolyester in the present invention, a commonly known PET-G resin which is a 1,4-cyclohexanedimethanol copolymerized polyethylene terephthalate resin is preferably used, but is not particularly limited thereto, and a small amount of polyethylene terephthalate is used. those containing ester units other than ethylene terephthalate can be appropriately used.

Furthermore, by adding an elastomer to the PBT, it can be easily wound up during the production of a decorative sheet, so that it is easy to produce on a roll-to-roll basis. When this elastomer is less than 0.2 parts by weight, peeling of the colored PBT layer of the lower base layer and the transparent thermoplastic resin layer of the upper base is likely to occur. On the other hand, when the amount of the elastomer exceeds 0.5 parts by weight, the sheet tends to be stretched and contracted during printing, and it becomes difficult to register the pattern during multicolor printing.
As the elastomer in the present invention, polycaprolactone is preferably used, but is not particularly limited thereto, and an aliphatic polyester such as polybutylene adipate can also be used as appropriate.

  Furthermore, a colored thermoplastic resin layer is formed by adding a colorant such as a pigment. In addition to the colorant, an inorganic filler, a lubricant, a thermoplastic elastomer, a compatibilizing agent, and the like may be added as appropriate.

  The thickness of the colored thermoplastic resin layer 1 is various resistances of the surface when the decorative sheet for flooring is combined with the transparent thermoplastic resin layer 3 to be described later, and the winding as a decorative sheet before being bonded to the wooden flooring 7 Considering suitability, 50 to 200 μm is desirable. If it is less than 50 μm, heat wrinkles and the like are likely to occur at the time of printing, and if it is thicker than 200 μm, it becomes difficult to wind up at the time of printing.

  The design pattern layer 2 in the present invention is provided for imparting a design of a desired design. The type of the pattern formed by the pattern layer 2 is not particularly limited. For example, a wood grain pattern, a stone pattern, a cloth pattern, a grain pattern, an abstract pattern, a geometric figure, a character or a symbol, or a combination thereof is optional. It is.

  The pattern layer 2 can be provided by printing with printing ink or the like. The kind of printing ink etc. is not specifically limited, Arbitrary printing ink currently used for the decorative sheet which concerns conventionally can be used. Specifically, for example, binder resins such as butyral, acrylic, urethane, polyester, epoxy, alkyd, and polyamide, organic or inorganic dyes or pigments, and extenders and fillers as necessary In addition, a tackifier, a dispersant, an antifoaming agent, a stabilizer and other additives may be appropriately added, and the viscosity adjusted to a desired viscosity with an appropriate dilution solvent can be used.

The adhesive layer 4 is provided as appropriate in order to bond the colored thermoplastic resin layer 1 provided with the pattern layer 2 and the transparent thermoplastic resin layer 3 described later. The adhesive used for the adhesive layer 4 is not particularly limited as long as the above object can be achieved, and a two-component urethane resin adhesive or the like can be used. Coating amount after drying as the coating amount is about 1 to 10 g / ^{m 2} is desirable.

  As the transparent thermoplastic resin layer 3 in the present invention, a polyolefin resin is used as a main agent, and as a polyolefin resin used, a polypropylene resin, a polyethylene resin, or the like is used as a main agent, and one or more kinds of resins are used as a main agent. A single layer or a plurality of layers can be applied. As for the thickness, considering various resistances of the surface when the decorative sheet for flooring is combined with the colored thermoplastic resin layer 1, and the winding suitability as a decorative sheet before being bonded to the wooden flooring 7, 70-150 micrometers is desirable. Further, the transparent resin thermoplastic resin layer 6 may be provided with a concave portion (not illustrated) such as a wood conduit on the surface.

  The surface protective layer 5 provided as appropriate is for improving the surface resistance of the decorative sheet for floors of the present invention. As the resin used for the surface protective layer 5, an ultraviolet curable resin or a two-component urethane resin is preferably used, and a known ultraviolet absorber, light stabilizer, glass beads, or the like may be appropriately added thereto.

There is no restriction | limiting in particular as a method of providing the surface protective layer 5, For example, conventionally well-known arbitrary coating methods, such as a gravure coat method and a roll coater method, can be applied suitably. In addition, it is preferable to apply the above-described resin or the like on the transparent thermoplastic resin layer 3 to an extent of 6 to 15 g / m ² as a coating amount after drying, but particularly limited to these resins and coating amounts. However, it is desirable to appropriately adjust the surface hardness in consideration of the resilience of the impact resistance test and caster resistance test.

  In addition, the decorative sheet of the present invention may be appropriately provided with an uneven pattern (not shown) such as embossing with an embossing roll on the surface thereof. Moreover, you may perform the wiping process etc. which fill the colored resin in the recessed part.

  Although it does not specifically limit as the wood-type flooring 7 which bonds the decorative sheet for floors of this invention, It is prescribed | regulated to a south seawood plywood, a softwood plywood, a particle board, a medium density fiber board (MDF), and Japanese agricultural and forestry standards. Ordinary plywood can be used. Moreover, the base material which consists of wood powder addition olefin resin can also be used. The thickness is preferably about 3 to 25 mm.

The adhesive layer 6 is provided as appropriate for adhering the wooden flooring 7 and the colored thermoplastic resin layer 1. The adhesive used for the adhesive layer 6 may be any material capable of adhering the constituent material used in the wooden flooring 7 and a resin mainly composed of PBT used in the colored thermoplastic resin layer 1 described later. Although not particularly limited, a known aqueous adhesive composed of a two-component urethane-modified vinyl resin, a one-component vinyl acetate resin emulsion-based adhesive, a moisture-curable urethane resin-based hot melt adhesive, or the like can be used. The thermoplastic resin hot melt adhesive may be used.
The adhesive layer 6 can be provided by applying an adhesive to the surface of the wooden flooring 7, but may be provided by applying it to the colored thermoplastic resin layer 1 side of the decorative sheet for flooring. it may be as provided by bonding from the provided. The weight of the coating after drying is preferably about 3 to ²⁰ g / m ² from the viewpoint of adhesiveness.

  As the colored thermoplastic resin layer 1, a colored PBT film having a thickness of 150 μm (100 parts by weight of PBT, 10 parts by weight of a copolyester resin (“PET-G” manufactured by Eastman Chemical Co., USA)), 0.3 weight of an elastomer (polycaprolactone) The wood pattern was printed with a two-component curable urethane resin gravure ink (manufactured by Toyo Ink Manufacturing Co., Ltd .: “Lamister”) as a pattern layer 2 on one side of the image pattern layer 2 using a gravure printing machine.

Thereafter, a two-component urethane resin adhesive having a polyester polyol as a main component and isophorone diisocyanate as a curing agent is used as the adhesive layer 4 on the pattern layer 2 so that the coating amount after drying becomes ² g / m ^2. The transparent thermoplastic resin layer 3 is coated with a transparent polypropylene resin and an adhesive resin (maleic acid-modified polypropylene resin). The transparent polypropylene resin has a thickness of 80 μm and the adhesive resin has a thickness of 20 μm. rESIN was coextruded laminate so that the picture pattern layer 2 side.

A recoat layer made of a two-component urethane resin is provided on the surface of the transparent thermoplastic resin layer 3 so that the thickness after drying is 1 g / m ^2, and urethane acrylate (Daicel 100 parts of “Ebecryl 4858” manufactured by UCBI Co., Ltd., 20 parts of pentaerythritol tetraacrylate (“PETA-K” manufactured by Daicel UCBI Co., Ltd.), “Ebecryl BZO” manufactured by Daicel UCBI Co., Ltd. ]) 0.5 part, 0.5 part of benzotriazole-based UV absorber, 0.5 part of hindered amine-based light stabilizer and 2 parts of glass beads were used, and this was made to have a thickness of 5 μm. And then cured by ultraviolet irradiation with a metal halide lamp to obtain a floor decorative sheet.

  The above steps were all performed on one line, but the steps of unwinding from the roll and winding up on the roll could be performed without any problem.

A lauan plywood having a thickness of 12 mm is used as the wooden flooring 7, and a two-part aqueous emulsion adhesive (“Rikabond” (“BA-10L” and “BA-11B” manufactured by Chuo Rika Kogyo Co., Ltd.) is used as the adhesive layer 2 on this surface. ”100 parts by weight: mixed at 5 parts by weight), and this was coated in a wet state at 100 g / m ² , and then the colored thermoplastic resin layer 1 side of the decorative sheet was bonded with a laminator for 12 hours. curing to obtain a decorative material with a floor decorative sheet of the present invention.

<Comparative Example 1>
A decorative sheet for flooring was obtained in the same manner as in Example 1 except that the number of parts by weight of the elastomer of the colored thermoplastic resin layer 1 was changed to 0 part by weight.

<Comparative Example 2>
A floor decorative sheet was obtained in the same manner as in Example 1 except that the weight of the copolymerized polyester resin of the colored thermoplastic resin layer 1 was 20 parts by weight, and a floor decorative material was obtained.

<Comparative Example 3>
A decorative sheet for floor was obtained in the same manner as in Example 1 except that the number of parts by weight of the elastomer of the colored thermoplastic resin layer 1 was 0.6 parts by weight, and a decorative material for floor was obtained.

<Comparative Example 4>
A floor decorative sheet was obtained in the same manner as in Example 1 except that the weight of the copolymer polyester resin of the colored thermoplastic resin layer 1 was changed to 1 part by weight to obtain a floor decorative material.

<Comparative Example 5>
A decorative sheet for floor was obtained in the same manner as in Example 1 except that the thickness of the colored thermoplastic resin layer 1 was 250 μm to obtain a decorative material for floor.

<Comparative Example 6>
A decorative sheet for floor was obtained in the same manner as in Example 1 except that the thickness of the colored thermoplastic resin layer 1 was 25 μm, and a decorative material for floor was obtained.

<Caster resistance test>
On the floor decorative material obtained in Example 1 and Comparative Examples 1 to 6, a double caster made of polycarbonate (diameter 40 mm, 1 wheel width 9 mm, 2 wheel width 18 mm) was loaded with a 25 kg weight. (About 245 N) 10,000 times (1 stroke 20 cm or more, 5,000 reciprocations), the caster was moved at a speed of 20 cm / sec. The subsequent traces were observed.

<Impact resistance test>
The cosmetic materials obtained in Example 1 and Comparative Examples 1 to 6 were tested according to the DuPont falling ball test (JIS K5400), which is essentially a coating film evaluation method. However, as an evaluation method, a weight was dropped from a height of 300 mm, and the amount of dents in the flooring was measured and the surface was observed.

<Winding suitability test>
The visual evaluation at the time of lamination | stacking with the transparent thermoplastic resin layer as an upper base at the time of the printing to the base coloring PBT sheet | seat of the floor decorative sheet of this invention was performed.

<Surface condition test>
It was subjected to external observation of the floor decorative sheet of the present invention.

<JAS Type Immersion Test>
It was carried out sequentially applies a test to the Japan Agricultural Standards of plywood.

<Interlayer adhesion test>
It was observed interlayer adhesion after JAS One class immersion test.

<Appropriate test>
When printing on the colored thermoplastic resin layer 1 of the floor decorative sheet of the present invention, ink deposition was observed. The results are shown in Table 1.

  The floor decorative sheet of the present invention is used in homes, stores, offices, gymnasiums, etc., and has excellent surface strength such as impact resistance, caster resistance, dimensional stability, winding ability of decorative sheets, and dents. It can be used as a decorative sheet.

It is explanatory drawing which shows the structure of the cross section of one Example of the decorative sheet for floors of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Colored thermoplastic resin layer 2 ... Pattern pattern layer 3 ... Transparent thermoplastic resin layer 4 ... Adhesive layer 5 ... Surface protective layer 6 ... Adhesive layer 7 ... Wood type flooring

Claims (2)

  In a decorative sheet in which a pattern layer and a transparent thermoplastic resin layer are provided in this order on a colored thermoplastic resin layer, the colored thermoplastic resin mainly comprises a polybutylene terephthalate resin, and 100 parts by weight of the polybutylene terephthalate resin. On the other hand, a decorative sheet for floors comprising 5 to 15 parts by weight of a copolyester resin and 0.2 to 0.5 parts by weight of an elastomer resin.   The floor decorative sheet according to claim 1, wherein the colored thermoplastic resin layer has a thickness of 50 to 200 µm.