JP7449055B2 - resin laminate - Google Patents

Description

The present invention relates to a resin laminate.

In recent years, many techniques for decorating building materials with ink have been developed (for example, see Patent Document 1).

For example, Patent Document 1 discloses a patent relating to a decorative sheet in which a transparent resin layer and a surface protection layer are laminated in this order, and at least a backer layer is laminated on the back surface of a base sheet.

Furthermore, for example, Patent Document 2 discloses a patent in which a convex portion is provided on one side of a metal base material, and a molten resin composition is injected onto the convex surface of the metal base material to mechanically develop an anchor effect. ing.

JP2016-64629A JP2009-51131A

However, if a dimensional change occurs in the resin laminate due to heat or water, peeling may occur between the layers when shear force is applied in a direction perpendicular to the stacking direction.

When a dimensional change occurs due to heat or water, the amount of dimensional change is proportional to the size of the object. In a laminate of two types of materials with different coefficients of linear expansion and rates of dimensional change due to water absorption, assuming that one has a fixed end and the other has a self-supporting end, the difference in dimensional change is greatest at the end of the free end. The largest shear force will be generated. This force is also generated at the bonding interface between the two materials.

An object of the present invention is to provide a resin laminate that can suppress peeling between layers.

In order to achieve the above object, a resin laminate according to a first invention includes a surface material, a base material, and a decorative layer. The surface material is made of a transparent resin material. The base material is formed of a resin material. The decorative layer is placed between the surface material and the base material, and is formed by an inkjet printing method. The thickness of the surface material is 0.1 mm or more and 3 mm or less. The thickness of the base material is 1 mm or more and 5 mm or less. The elastic modulus of the base material is greater than the elastic modulus of the surface material.

By making the elastic modulus of the base material larger than the elastic modulus of the surface material in this manner, the surface material follows the deformation of the base material even when a dimensional change occurs in the base material.

Therefore, peeling between the base material and the decorative layer or between the decorative layer and the surface material can be suppressed.

The resin laminate according to the second invention is the resin laminate according to the first invention, and the elastic modulus of the surface material is 1.5 GPa or less.

Thereby, the surface material can be made to follow the dimensional changes of the base material, and peeling between the layers can be suppressed.

The resin laminate according to the third invention is the resin laminate according to the first invention, in which the elastic modulus of the surface material is 1.0 GPa or less.

Thereby, the surface material can be made to follow the dimensional changes of the base material, and peeling between the layers can be suppressed.

The resin laminate according to the fourth invention is the resin laminate according to the first invention, in which the thickness of the decorative layer is 10 μm or more and 100 μm or less.

In this way, peeling of the decorative layer provided with a predetermined thickness from the surface material or base material can be suppressed.

The resin laminate according to the fifth invention is the resin laminate according to the first invention, wherein the surface material is at least one selected from acrylic resin, polyolefin resin, polycarbonate resin, or polyester resin. It is made of a material containing.

Thereby, a surface material that is transparent and has a predetermined elastic modulus can be formed.

According to the present invention, it is possible to provide a resin laminate that can suppress interlayer peeling.

FIG. 1 is a perspective view of a resin laminate according to an embodiment of the present invention. FIG. 2 is a sectional view of the decorative panel in FIG. 1. A partially enlarged view of FIG. 2. FIG. 2 is a perspective view of the surface material in the resin laminate of FIG. 1 viewed from the first surface side. FIG. 2 is a perspective view of the surface material of the decorative panel of FIG. 1 viewed from the second surface side. FIG. 2 is a cross-sectional view of the surface material in the decorative panel of FIG. 1. FIG. 2 is a perspective view of the base material in the decorative panel of FIG. 1 viewed from the side on which the surface material is placed. FIG. 8 is a perspective view of the base material in the decorative panel of FIG. 1 seen from the opposite side of FIG. 7; 1 is a flow diagram showing a method for manufacturing a resin laminate according to an embodiment of the present invention. (a) (b) Cross-sectional views for explaining the manufacturing method of the resin laminate shown in FIG. 9. (a) (b) Cross-sectional views for explaining the manufacturing method of the resin laminate shown in FIG. 9. FIG. 10 is a cross-sectional view for explaining a method of manufacturing the resin laminate shown in FIG. 9; FIG. 3 is a diagram showing a table of the results of Examples 1 to 3 and Comparative Example 1. FIG. 3 is a sectional view of a resin laminate in a modification of the embodiment according to the present invention.

Hereinafter, the resin laminate of the present invention will be explained in detail based on the drawings.
<Configuration>
(Outline of resin laminate)
FIG. 1 is a perspective view of a resin laminate 10 of this embodiment. FIG. 2 is a cross-sectional view of the resin laminate 10 of this embodiment. FIG. 3 is an enlarged view of the S section in FIG. 2.

Further, in the following description, the up-down direction corresponds to the up-down direction in FIG. 2, but the direction is not limited to this, and the direction changes depending on the position where the resin laminate 10 is arranged.

The resin laminate 10 of this embodiment is, for example, a tile, a panel, a sheet, etc., and is used as a decorative or decorative panel, a decorative or decorative tile, a decorative or decorative sheet, or the like. Further, the resin laminate 100 may be used for flooring, etc.

The resin laminate 10 includes a surface material 1, a decorative layer 2, and a base material 3.

The surface material 1 is made of a transparent resin material. The base material 3 is formed of a resin material. Decorative layer 2 is arranged between surface material 1 and base material 3. Note that FIG. 2 shows the stacking direction F.

(Surface material)
FIG. 4 is a perspective view of the surface material 1 viewed from above. FIG. 5 is a perspective view of the surface material 1 viewed from below. FIG. 6 is a cross-sectional view of the surface material 1.

The surface material 1 is not particularly limited as long as it is made of a transparent resin material, and it is more preferably made of a highly transparent resin material.

Materials for the surface material 1 include, for example, acrylic resins such as acrylonitrile-styrene copolymer, polymethyl methacrylate resin, polyolefin resins such as polyethylene, polycarbonate resins, polyester resins such as polyethylene terephthalate, and polystyrene. It can be formed from a material containing at least one selected one.

The surface material 1 has a plate-shaped main body part 11 and a side wall part 12. The main body portion 11 is formed in a rectangular shape. The side wall portion 12 is formed to be inclined to widen from the peripheral edge of the main body portion 11 . The main body portion 11 and the side wall portion 12 are integrally formed. The surface material 1 has a first surface 1a (also referred to as an upper surface or front surface) and a second surface 1b (also referred to as a lower surface or back surface).

The second surface 1b of the surface material 1 includes an inner surface 11b (also referred to as a lower surface or back surface) of the main body portion 11 and an inner wall surface 12b of the side wall portion 12.

A recess 1c surrounded by an inner surface 11b and an inner wall surface 12b is formed on the second surface 1b of the surface material 1. The side wall portion 12 has an end surface 12e facing the base material 3, as shown in FIG.

Decorative layer 2, which will be described later, is provided on inner surface 11b, inner wall surface 12b, and end surface 12e.
The thickness W1 of the surface material 1 is set to 0.1 mm or more and 3 mm or less, but the thickness W1 of the surface material 1 is preferably 0.1 mm or more and 1 mm or less.

Further, the elastic modulus of the surface material 1 is smaller than that of the base material 3. The elastic modulus of the surface material is preferably 1.5 GPa or less, more preferably 1.0 GPa or less.

For example, assuming an object with a length of 150 mm, a width of 10 mm, a thickness of 5 mm, and a modulus of longitudinal elasticity of 2.25 GPa, the force applied in the length direction when extended by 3 mm is calculated using Hooke's law. , 1600N.

On the other hand, if the same shape has a longitudinal elastic modulus of 1 GPa, the force applied in the longitudinal direction will be 710 N. By reducing the elastic modulus in this way, the force applied in the longitudinal direction becomes smaller.

Furthermore, if the width and thickness of the same length are halved to 2.5 mm, the force applied in the length direction will be halved. In this way, by reducing the thickness, the force applied in the length direction can be halved.

Further, by making the elastic modulus of the surface material 1 smaller than that of the base material 3, it becomes possible to relax the shear force in the direction perpendicular to the stacking direction F within a certain section.

Note that the surface material 1 can be created by injection molding, press molding, vacuum forming, or the like.

(decorative layer)
The decorative layer 2 is formed with various patterns, colors, etc., and decorates the resin laminate 10. The decorative layer 2 is formed on the second surface 1b (including the inner surface 11b and the inner wall surface 12b) and the end surface 12e of the surface material 1, as shown in FIGS. 2 and 3. The decoration by the decoration layer 2 can be visually recognized from the outside through the transparent surface material 1.

The decorative layer 2 can be printed on the second surface 1b of the surface material 1 in a non-contact manner using an inkjet printer. The decoration layer 2 is formed of ink that can be ejected with an inkjet printer.

In this case, the second surface 1b and end surface 12e of the surface material 1 may be printed directly, or the second surface 1b and end surface 12e of the surface material 1 may be subjected to primer treatment or electric discharge treatment to improve adhesion. You can also print on it. Further, these treatments may be performed on the decorative layer 2 after printing.

The ink ejected by the inkjet printer is made using a known technique. For example, UV or EB curable ink that has a monomer as its main component and contains one or more of other additives such as oligomers, colorants, dispersants, photopolymerization initiators, and surfactants (cited in the Journal of the Imaging Society of Japan) Vol. 49, No. 5, UV inkjet curing characteristics and polymers, Vol. 34, November issue (1985) Electron beam curing resins).

Alternatively, for example, permeation, evaporation, drying, acid polymerization drying, thermosetting ink obtained by dissolving (or dispersing) a known colorant (dye or pigment) together with a binder resin in a solvent (or dispersion medium). May be used. You may use these in combination.

The decorative layer 2 is formed by printing on the second surface 1b and end surface 12e of the surface material 1 using an inkjet printer.

The thickness W2 (see FIG. 3) of the decorative layer 2 is preferably set to 10 μm or more and 100 μm or less, more preferably 10 μm or more and 40 μm or less.

(Base material)
FIG. 7 is a perspective view of only the base material 3 viewed from above. FIG. 8 is a perspective view of the base material 3 viewed from below.

As shown in the figure, the base material 3 supports the surface material 1. As shown in FIG. 3, the base material 3 is arranged on the surface 2b of the decorative layer 2 opposite to the surface 2a on the surface material 1 side.

The base material 3 is formed on the surface 2b of the decorative layer 2 by insert molding.

The base material 3 has a base portion 31 and a convex portion 32. The base portion 31 is formed into a rectangular plate shape. The convex portion 32 has a rectangular shape and is formed on one surface of the base portion 31 (the surface on the surface material 1 side or the upper surface).

The convex portion 32 is formed in a shape to fit into the concave portion 1c of the surface material 1, and is formed in a trapezoidal shape when viewed in cross section. The convex portion 32 has a surface 321 (upper surface) having the same shape as the inner surface 11b of the main body portion 11 of the surface material 1, and a side surface 322 extending downward from the surface 321 in a widening manner.

The side surface 322 is formed in the same shape as the inner wall surface 12b of the side wall portion 12 of the surface material 1, and more specifically, it is formed in the same shape as the decorative layer 2 formed on the surface of the inner wall surface 12b. The convex portions 32 and the concave portions 1c of the surface material 1 form a protruding portion on the resin laminate 10.

Furthermore, a groove-shaped recess 311 is formed on the surface of the base portion 31 around the convex portion 32 . In this groove-shaped recess 311, an end portion 2e (see FIG. 2) of the decorative layer 2 formed on the end surface 12e of the side wall portion 12 of the surface material 1 is arranged.

The base material 3 is made of a resin material, and although this resin material is not particularly limited, it is preferably a material that is easily elastically deformed in order to absorb the impact that the resin laminate 10 receives, for example.

Such a material can be formed from at least one resin material selected from vinyl chloride resins such as PVC, olefin resins such as polyethylene, styrene resins such as ABS resins, and the like. Further, from the viewpoint of adhesion of the decorative layer 2 with ink, it is preferable to use a polar resin material.

The thickness W3 of the base material 3 is set to 1 mm or more and 5 mm or less, but preferably 2 mm or more and 5 mm or less.

<Method for manufacturing resin laminate>
Next, a method for manufacturing the resin laminate 10 of this embodiment will be described.

FIG. 9 is a flow diagram showing a method for manufacturing the resin laminate 10 of this embodiment. 10(a), FIG. 10(b), FIG. 11(a), FIG. 11(b), and FIG. 12 are cross-sectional views for explaining the method for manufacturing the resin laminate 10.

First, in step S10, a surface material 1 as shown in FIGS. 4 to 6 is created by injection molding, press molding, vacuum forming, or the like.

Next, in step S20, as shown in FIG. 10(a), ink 130 is ejected from the inkjet printer 120 onto the second surface 1b and end surface 12e of the surface material 1, and the ink is applied onto the second surface 1b and end surface 12e. The coating is applied to form a decorative layer 2, as shown in FIG. 10(b).

Next, in step S30, the base material 3 is formed on the decorative layer 2 by insert molding.

Specifically, as shown in FIG. 11(a), the surface material 1 and the decorative layer 2 are placed in a mold 200. The mold 200 includes a first mold 201 and a second mold 202.

A gate 210 is formed in the first mold 201 for injecting a resin material into the mold. A surface material 1 and a decorative layer 2 are arranged in the second mold 202. In this embodiment, two gates 210 are formed.

As shown in FIG. 11(b), after the surface material 1 and the decorative layer 2 are placed in the second mold 202, the first mold 201 and the second mold 202 are closed. Thereafter, a resin material is injected into the mold 200 from the gate 210, and the base material 3 is formed as shown in FIG. The created resin laminate 10 is then taken out from the mold 200.

<Example>
Next, the resin laminate 10 of this embodiment will be described using examples.

Resin laminates with varying modulus of elasticity of the surface material were immersed in water to verify the occurrence of peeling between the surface material and the decorative layer or between the decorative layer and the base material.

In Examples 1 to 3 and Comparative Example 1, the decorative layer was formed using ink.
The base materials used in Examples 1 to 3 and Comparative Example 1 had a thickness of 2 mm, an elastic modulus of 2.3 GPa, and were made of AES (acrylonitrile/ethylene-propylene-diene/styrene) resin. used.

In addition, the surface materials used in Examples 1 to 3 and Comparative Example 1 are all made of PMMA (polymethyl methacrylate) resin, are transparent, and are formed to a thickness of 0.5 mm, but the elasticity of each material varies. The rates are different. The elastic modulus of the surface material of Example 1 is 0.5 GPa, the elastic modulus of the surface material of Example 2 is 0.9 GPa, and the elastic modulus of the surface material of Example 3 is 1.5 GPa. Further, the elastic modulus of the surface material of Comparative Example 1 is 3.3 GPa.

In Examples 1 and 2, there was no initial peeling, but peeling occurred on the 14th day after the resin laminate was immersed in water. The location where peeling occurred was between the decorative layer and the base material (indicated by C in FIG. 13).

In Example 3, there was no initial peeling, but peeling occurred on the 7th day after the resin laminate was immersed in water, and the location where peeling occurred could not be determined.

In Comparative Example 1, there was initial peeling, and the peeling location was between the surface material and the decorative layer (indicated by A in FIG. 13).

As described above, when the elastic modulus of the base material is larger than that of the surface material, initial peeling does not occur and the water immersion result can be maintained for 7 days or more.

<Other embodiments>
The embodiments of the resin laminate and the method for manufacturing the resin laminate according to the present invention have been described above, but the present invention is not limited to the above embodiments, and may be modified as appropriate without departing from the spirit thereof. It is possible.

(A)
In the above embodiment, the side wall portion 12 is formed on the surface material 1, but the surface material 1 may be plate-shaped without having the side wall portion. In this case, it may be a decorative panel whose center is not raised. FIG. 14 is a cross-sectional view showing a resin laminate 20 that is not raised.

As shown in FIG. 14, the resin laminate 20 includes a surface material 21, a decorative layer 22, and a base material 23. The surface material 21 is plate-shaped, and compared to the surface material 1, the recess 1c is not provided.

Furthermore, the decorative layer 22 is formed over the entire surface of the surface material 21 on the base material 23 side. The base material 23 is formed into a plate shape, and is not provided with convex portions 32 and the like compared to the base material 23.

(B)
In the embodiment described above, the decorative layer 2 is also formed on the end surface 12e of the side wall portion 12, but the decorative layer 2 is not formed on the end surface 12e, and the decorative layer 2 is formed on the inner surface 11b and the inner wall surface 12b. may be formed.

(C)
In the above embodiment, the base material 3 is in direct contact with the decorative layer 2, but in order to suppress peeling between the decorative layer 2 and the base material 3, an adhesive layer is formed between the decorative layer 2 and the base material 3. may be provided.

(D)
In the above embodiment, two gates 210 are formed, but the number is not limited to two, and furthermore, the location is not limited to the location shown in FIG. 11(b).

(E)
Further, the components in the above-described embodiments can be appropriately replaced with well-known components without departing from the spirit of the present invention.

The resin laminate of the present invention has the effect of suppressing interlayer peeling, and is useful as decorative tiles, decorative panels, decorative tiles, decorative panels, and the like.

1: Surface material 2: Decorative layer 3: Base material 10: Resin laminate

Claims (4)

A surface material made of transparent resin material,
A base material formed of a resin material,
a decoration layer disposed between the surface material and the base material and formed by an inkjet printing method,
The thickness of the surface material is 0.1 mm or more and 3 mm or less,
The thickness of the base material is 1 mm or more and 5 mm or less,
The longitudinal elastic modulus of the base material is greater than the longitudinal elastic modulus of the surface material,
The surface material is formed by injection molding a material containing at least one selected from acrylic resin, polyolefin resin, polycarbonate resin, or polyester resin.
Resin laminate. The longitudinal elastic modulus of the surface material is 1.5 GPa or less,
The resin laminate according to claim 1. The longitudinal elastic modulus of the surface material is 1.0 GPa or less,
The resin laminate according to claim 1. The thickness of the decorative layer is 10 μm or more and 100 μm or less,
The resin laminate according to claim 1.

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