JP6876289B2 - 化粧シートおよび化粧シートの製造方法 - Google Patents
化粧シートおよび化粧シートの製造方法 Download PDFInfo
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- JP6876289B2 JP6876289B2 JP2019214771A JP2019214771A JP6876289B2 JP 6876289 B2 JP6876289 B2 JP 6876289B2 JP 2019214771 A JP2019214771 A JP 2019214771A JP 2019214771 A JP2019214771 A JP 2019214771A JP 6876289 B2 JP6876289 B2 JP 6876289B2
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- Prior art keywords
- decorative sheet
- layer
- transparent resin
- nucleating agent
- polypropylene resin
- Prior art date
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Description
まず、蒸留水100重量部、造核剤としてのリン酸エステル金属塩系造核剤(アデカスタブNA−11、ADEKA社製)0.7重量部、造核剤内包ベシクルの外膜を構成する物質としてのホスファチジルコリン0.05重量部を混合したリン脂質懸濁液をガラスシリンジに入れ、当該ガラスシリンジを任意の孔径のメンブレンフィルターを挟んだエクストルーダーの両側にセットする。このエクストルーダーを任意の温度下にて、両側にセットしたガラスシリンジのシリンジを交互に動作させて、任意の回数についてメンブレンフィルターを通過させて造核剤を内包する造核剤内包ベシクルを得た。
超臨界逆相蒸発法を用いた造核剤を内包する造核剤内包ベシクルの調製について説明する。まず、メタノール100重量部、造核剤としてのリン酸エステル金属塩系造核剤(アデカスタブNA−11、ADEKA社製)82重量部、造核剤内包ベシクルの外膜を構成する物質としてのホスファチジルコリン5重量部を60℃に保たれた高圧ステンレス容器に入れて密閉し、圧力が20MPaとなるように二酸化炭素を注入して超臨界状態とした後、激しく攪拌混合しながらイオン交換水を100重量部注入する。容器内の温度および圧力を超臨界状態に保持した状態で15分間攪拌後、二酸化炭素を排出して大気圧に戻すことによって造核剤を内包したリン脂質からなる単層膜の外膜を具備する造核剤内包ベシクルを得た。
以下に、本発明の化粧シート1における透明樹脂層4としての透明樹脂シート4の具体的な製膜方法について説明する。ペンタッド分率が97.8%、メルトフローレートが15g/10min(230℃)、分子量分布MWD(Mw/Mn)が2.3の高結晶性ポリプロピレン樹脂に対して、ヒンダードフェノール系酸化防止剤(イルガノックス1010:BASF社製)を500PPMと、ベンゾトリアゾール系紫外線吸収剤(チヌビン328:BASF社製)を2000PPMと、ヒンダードアミン系光安定化剤(キマソーブ944:BASF社製)を2000PPMと、前記造核剤内包ベシクルを1000PPMとを添加した樹脂を溶融押出機を用いて厚さ100μmの透明樹脂シート4を押出成形する。透明樹脂シート4の製膜法は、上記の溶融押出法に限定するものではなく、所定の厚さに安定して成膜できる方法であればいかなる方法を採用してもよいので、例えば、インフレーション製膜法やカレンダー製膜法などを採用することができる。なお、製膜された透明樹脂シート4は、押出製膜時の冷却条件をコントロールすることにより、結晶性ポリプロピレン樹脂の結晶部における、擬六方晶系部を0,5,10または20重量%、単斜晶系部を100,95,90または80重量%とし、当該結晶部の球晶の平均粒径を5未満,5,10,50,100,500,1000,1500,2000または3000nmとしたものを得ることができる。
4.09=4π(R/λ)sin(θmax/2)
実施例1においては、上記透明樹脂シート4として、メルトフローレートが3,5,10,30または40g/10min(230℃)の高結晶性ポリプロピレン樹脂を用いて作製した造核剤内包ベシクルを含有する透明樹脂シート4を具備する化粧シート1とした。なお、透明樹脂シート4は、結晶部における擬六方晶系部と単斜晶系部との存在比率が、擬六方晶系部20重量%、単斜晶系部80重量%とされている。具体的な化粧シート1の作製方法を以下に説明する。
◎:非常に良好な透明性、耐擦傷性または耐後加工性を有する
○:良好な透明性、耐擦傷性または耐後加工性を有する
×:透明性、耐擦傷性または耐後加工性に劣る
実施例2においては、上記透明樹脂シート4として、結晶性ポリプロピレン樹脂の結晶部における擬六方晶系部と単斜晶系部との構成比率を、擬六方晶系部0,5,10および20重量%、単斜晶系部100,95,90および80重量%とし、球晶の平均粒径を5未満,5,10,50,100,500,1000,1500または2000nmとして製膜したものを用いた化粧シート1とした。なお、化粧シート1は、実施例1と同様の方法により作製した。得られた各化粧シート1についてホフマンスクラッチ試験およびスチールウールラビング試験にて表面硬度の評価を行った。
<ホフマンスクラッチ試験>
ホフマンスクラッチ試験は、ホフマンスクラッチハードネステスター(BYK−Gardner社製)を用いて、1200gの荷重にて、木質基材に貼り合せた各化粧シート1の表面を一定の速度で引っ掻き、化粧シート1の表面の傷つきの有無を目視にて判定した。
<スチールウールラビング試験>
スチールウールラビング試験は、木質基材に貼り合せた各化粧シート1の表面に対し、スチールウールを当接させた状態で治具を用いて固定し、当該治具に500gの荷重をかけたまま一定の速度で、距離50mm、50往復の条件にて擦らせて、化粧シート1の表面の傷つきの有無を目視にて判定した。スチールウールは、ボンスター#0(日本スチールウール(株)製)を丸めて使用した。
得られたホフマンスクラッチ試験の結果を表2、スチールウールラビング試験の結果を表3に示す。なお、表2および表3の記号の説明は下記の通りである。
◎:非常に良好な透明性、耐擦傷性または耐後加工性を有する
○:良好な透明性、耐擦傷性または耐後加工性を有する
×:透明性、耐擦傷性または耐後加工性に劣る
2 原反層、基材シート
3 インキ層
4 透明樹脂層、透明樹脂シート
4a エンボス模様
5 トップコート層
6 プライマー層
7 接着層
8 隠蔽層
B 基材
Claims (5)
- 少なくとも原反層、透明樹脂層、トップコート層がこの順に位置する化粧シートであって、
前記原反層はポリプロピレン樹脂を主成分とし、
前記透明樹脂層はアイソタクチックペンタッド分率(mmmm分率)が95%以上である結晶性ポリプロピレン樹脂を90〜100重量%の成分として含み、
前記透明樹脂層の前記結晶性ポリプロピレン樹脂からなる結晶部の球晶の平均粒径が2000nm以下であり、
前記透明樹脂層は、さらにベシクルに造核剤を内包させた造核剤内包ベシクルを添加して形成されており、
前記トップコート層は熱硬化型樹脂および光硬化型樹脂を混合した材料を主成分とすることを特徴とする化粧シート。 - 前記結晶性ポリプロピレン樹脂は、230℃におけるメルトフローレート(MFR)が3〜40g/10minであり、分子量分布(MWD=Mw/Mn)が4以下であることを特徴とする請求項1に記載の化粧シート。
- 前記造核剤内包ベシクルが、リン脂質からなる単層膜の外膜を具備することを特徴とする請求項1または請求項2に記載の化粧シート。
- 前記透明樹脂層の厚さが、20μm以上、250μm以下であることを特徴とする請求項1乃至請求項3のいずれか1項に記載の化粧シート。
- 少なくとも原反層、透明樹脂層、トップコート層がこの順に位置する化粧シートであって、前記原反層はポリプロピレン樹脂を主成分とし、透明樹脂層はアイソタクチックペンタッド分率(mmmm分率)が95%以上である結晶性ポリプロピレン樹脂を90〜100重量%の成分として含み、前記透明樹脂層の前記結晶性ポリプロピレン樹脂からなる結晶部の球晶の平均粒径が2000nm以下である化粧シートの製造方法において、前記透明樹脂層は、ベシクルに造核剤を内包させた造核剤内包ベシクルを添加して形成されており、前記トップコート層は熱硬化型樹脂および光硬化型樹脂を混合した材料を主成分として形成されていることを特徴とする化粧シートの製造方法。
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