JPH06171057A - Laminated sheet and its manufacture - Google Patents

Abstract

PURPOSE:To provide a laminated sheet(intermediate product and finished product) which consists of comparatively freely selected types of sheet looks more presentable than a conventional laminated sheet due to the clear contrast of an uneven pattern. CONSTITUTION:A sheet which is an intermediate product consists of a transparent or a translucent PVC sheet 4 junctioned on one side of a UV-curable adhesive 3 layer, and a coat of primer 2 which is a thermosensitive adhesive formed on the surface of the other side with an uneven pattern q.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laminated sheet (and a laminated sheet as an intermediate product thereof) for use as a floor, a decorative wall, a decorative board, etc., in which an uneven pattern (embossing) can be seen, and a manufacturing method thereof It is about.

[0002]

2. Description of the Related Art Recent laminated sheets used for decorative boards include those having a concavo-convex pattern under a transparent or translucent surface layer. Even if the surface is smooth, the pattern inside is not flat, so it is used as a high-grade plate material with a deep aesthetic appearance.

An example of such a laminated sheet is disclosed in JP-A-3-
No. 51128 is disclosed. In the laminated sheet (decorative sheet) of the publication, the harder sheet (that is, the softening temperature is higher or the ionizing radiation curing degree is higher) of the two superposed sheets has an uneven pattern in advance. Both the sheets are adhered with the surface having an uneven pattern as the joint surface (interface).

The present inventors also invented a laminated sheet obtained by joining two sheets with an ultraviolet-curing adhesive,
An application has already been filed (Japanese Patent Application No. 3-321167). Two sheets including a transparent or translucent sheet (at least one sheet has an uneven pattern) are bonded with the same adhesive with the uneven surface inside.

[0005]

The laminated sheet of the former (Japanese Patent Laid-Open No. 3-51128) shown as the prior art is as follows.
An uneven pattern on the harder of the two sheets is a necessary condition for the pattern to be clear. That is, if the sheet having the uneven pattern is softer than the other sheet, the pattern is broken when the both sheets are bonded by heat fusion or the like. Therefore, in the above-mentioned laminated sheet, the sheet having the uneven pattern has to be higher than the other sheet to some extent in terms of hardness, which is a limitation, and there is an inconvenience that the material of each sheet cannot be freely selected.

On the other hand, the latter laminated sheet using an ultraviolet-curable adhesive has no restriction on the hardness of each sheet. If you use the same adhesive (thickness should be more than the depth of the uneven pattern) with the uneven surface inside, you do not have to heat the sheet to a high temperature, so the hardness of each sheet and its difference This is because, regardless of this, a laminated sheet can be obtained without breaking the uneven pattern.

However, the latter laminated sheet is also the same as the former in that a sheet having an uneven pattern must be used in advance, which imposes a restriction on sheet selection. In addition, the embossing applied to the molded resin sheet using an embossing roll has certain limits in terms of its fineness and sharpness of the unevenness, so this point is also a limitation (limit) on the aesthetic aspect of the finished laminated sheet. There is also that.

The object of the present invention is to provide a laminated sheet which can be freely constructed due to restrictions on hardness and can be formed by using a sheet having no uneven pattern, and which has a clear uneven pattern and thus has a better finished appearance than before. (Intermediate products and finished products)
And a manufacturing method thereof.

[0009]

A laminated sheet (intermediate product; hereinafter referred to as sheet A) according to claim 1 of the present invention.
Is one in which a transparent or semi-transparent sheet is bonded to one surface of a layer of ionizing radiation curable resin, and an uneven pattern is formed on the other surface to form a heat-sensitive adhesive coating on the surface. The ionizing radiation curable resin is a resin that has a property of being cured by being irradiated with ionizing radiation (that is, ultraviolet rays, electron beams, X-rays, γ rays, etc.), and is a polymer or oligomer having a radical-polymerizable double bond. , Whose main component is a monomer.

The laminated sheet of claim 2 (finished product or a product close to it; hereinafter referred to as sheet B) has a thermoplastic resin sheet bonded to the surface of the heat-sensitive adhesive coating of sheet A of claim 1 above. It is a thing. As for the sheet B, it is preferable that at least one of the heat-sensitive adhesive film and the thermoplastic resin sheet has a glittering property. Glittering property refers to the property of reflecting and shining light, and is brought about by mixing mica, pearl foil, metal powder and the like.

According to a fourth aspect of the present invention, in the method for producing the sheet A, a heat-sensitive adhesive coating is applied onto a mold-releasing sheet having an uneven pattern and solidified, and an ionizing radiation curable resin is applied thereon. , Further stacking transparent or translucent sheets, irradiating with ionizing radiation to cure the resin layer, and then peeling off the shaping sheet −
It is characterized by

In order to manufacture the sheet B, the thermoplastic resin sheet is overlaid on the surface of the heat-sensitive adhesive film of the sheet A obtained as described above and heated (that is, hot pressing). It is good to adhere (for example, by a heat lamination method).

[0013]

According to the sheet A of the present invention described in claim 1, the side of the transparent (or semi-transparent; the same applies hereinafter) will be described as the upper side, for example. The heat-sensitive adhesive film is formed by providing an uneven pattern on the lower surface of the layer. Such a laminated sheet A has the following features in operation.

A) The transparent sheet and the ionizing radiation curable resin can be joined by irradiating with ionizing radiation at the uncured stage of the resin without applying heat or pressure. There are no restrictions on material selection in terms of heat and hardness.

B) The concavo-convex pattern, which is the main part of the appearance as a decorative board, is provided on one surface of the layer of ionizing radiation curable resin, not on a transparent sheet. Therefore, it is not necessary to use a transparent sheet having an uneven pattern in advance. Moreover, a dense and sharp uneven pattern can be easily formed on the layer of the resin in the uncured stage, and the pattern is cured as it is by the irradiation of ionizing radiation. That is,
A sharp uneven pattern can be imparted to the sheet A very easily.

C) In order to make this intermediate sheet A as a finished product (or a product close to it), other sheets (vinyl chloride, acrylic, A thermoplastic resin sheet such as urethane) may be joined as a base sheet, but the joining is extremely easy. That is, first, the mating sheet may not be provided with the uneven pattern. Further, since the heat-sensitive adhesive film is already present, the joining operation itself is easy (see the action of claims 2.5). Based on these, the colors and materials of the base sheets to be combined with the same sheet A can be freely changed, and various kinds of finished products can be obtained.

The sheet B of claim 2 is obtained by joining the above sheet A with a thermoplastic resin sheet as a base sheet. This joining can be easily performed as described above, but the finished sheet B is made of a transparent sheet with the transparent sheet and the ionizing radiation curable resin (transparent or semi-transparent), which are transparent from the outer surface. You can see uneven patterns (light diffusely reflected on the surface) and heat-sensitive adhesive film (thermoplastic resin sheet if the film is transparent or translucent). The non-planar internal pattern can be seen from the outer surface, which has a deep aesthetic suitable for high-grade board materials. This sheet B has a base sheet integrated under a concavo-convex pattern, and can be used as it is as a finished product for a decorative board or the like, but it can be further integrated with other sheets or a protective film on the outermost surface. It is also good to attach such as.

Since the sheet B is obtained based on the sheet A, the sheet B has the functional characteristics as described in a), b), and c) above. There is also a great feature in that the above-mentioned clear uneven pattern does not collapse during the joining of the above. That is, although heat and pressure (heating / pressurization) are required to join the thermoplastic resin sheet to the sheet A, the cured ionizing radiation curable resin having an uneven pattern has heat resistance and deformation resistance due to so-called three-dimensional crosslinking. Since the property is extremely high, the concavo-convex pattern is not deformed even in such a joining process, and therefore the thermoplastic resin sheet is exclusively deformed and follows the concavo-convex pattern. Further, since the heat-sensitive adhesive coating is provided on the surface of the uneven pattern, the thermoplastic resin sheet is surely adhered. These points mean that, in addition to the point a) described above for the sheet A, there is no thermal / hardness restriction in the material selection of the thermoplastic resin sheet.

If a material having a glittering property is used as a part of the sheet B as in claim 3, the aesthetic appearance when viewed from the transparent sheet side is further improved. This is because light reflection increases on the surface of the heat-sensitive adhesive coating or the thermoplastic resin sheet along the uneven pattern, and the three-dimensional effect of the uneven pattern becomes more vivid.

According to the manufacturing method of claim 4, the above-mentioned (claim 1) sheet A can be manufactured reasonably and smoothly. That is, first, as described above, by forming a heat-sensitive adhesive coating on the uneven surface of the patterning sheet having an uneven pattern and applying an ionizing radiation curing resin, the uneven pattern with the above-mentioned film is formed. Therefore, a clear uneven pattern can be easily obtained. As the shaping sheet, use is made of paper, PET (polyethylene terephthalate), metal sheet, etc., on which irregularities (concavities and convexities opposite to the irregularity pattern on sheet A) have been formed beforehand (depending on the material etc., repeated use). However, the ionizing radiation curable resin can
Since it is applied in a liquid state where it is not cured yet, a precise and sharp uneven pattern that exactly corresponds to the unevenness is obtained.

Secondly, as described above, the ionizing radiation curable resin and the transparent sheet are adhered by superimposing the latter while the former is uncured and then curing the former, so that they are laminated. The process can be performed smoothly. This is because for this curing, ionizing radiation may be irradiated from the transparent sheet side, heat and pressure are not particularly required, and the transparent sheet allows ionizing radiation to pass through well. As described above, there are no restrictions on the hardness of the transparent sheet.

Thirdly, a release sheet having releasability is
Since it is peeled off after the ionizing radiation curing resin has cured,
Without losing the integrity of the transparent sheet with the ionizing radiation curable resin and the heat-sensitive adhesive film, expose the uneven surface with the heat-sensitive adhesive film smoothly and use it for mounting to other base sheet etc. You can

According to the method of claim 5, the sheet B is
(Laminate sheet according to claims 2 and 3) can be obtained smoothly. The ionizing radiation curable resin having a concavo-convex pattern undergoes so-called three-dimensional crosslinking at the time of curing as described above, and has heat resistance
This is because the deformation resistance is extremely high, and even when the thermoplastic resin sheet is bonded while applying heat as described above, the above-mentioned sharp uneven pattern does not collapse. Therefore,
The concavo-convex pattern of the ionizing radiation curable resin is not deformed, and the thermoplastic resin sheet is exclusively deformed by heating and pressing to follow the concavo-convex pattern and adheres integrally with the sheet A by the action of the heat-sensitive adhesive coating. Since the ionizing radiation curable resin has sufficient heat resistance and deformation resistance, there are almost no thermal or hardness restrictions on the material of the thermoplastic resin sheet.

[0024]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention is introduced in FIGS. 1 (a) to 1 (f) are cross-sectional views (FIG. 1 (f)) of a laminated sheet A which is an intermediate product, and schematic diagrams sequentially showing the manufacturing process thereof, and FIGS. 2 (a) and 2 (b) are FIG. 3 is a schematic diagram showing a step of forming the above-mentioned sheet A into a laminated sheet B as a finished product (decorative plate). Hereinafter, the manufacturing process will be described with reference to the drawings while concretely showing materials and the like.

FIG. 1 (a): First, as the shaping sheet 1, a strip-shaped release paper (manufactured by Dai Nippon Printing Co., Ltd.) having an uneven pattern p on its upper surface and having its surface easily peeled off is used. The concavo-convex pattern p is, for example, a leather-like diaphragm having a maximum depth of about 10 μm.

1 (b) and 1 (c): A primer 2 which is a heat-sensitive adhesive film is thinly coated on the upper surface of the shaping sheet 1 and solidified (FIG. 1 (c) shows the state after solidification). As the primer 2, an acrylic type treating agent (trade name “Luck Skin”, transparent, manufactured by Seiko Kasei Co., Ltd.) was used, and the thickness after solidification was about 2 μm.

FIG. 1 (d): On the coating of primer 2,
UV (ultraviolet) curing adhesive 3 which is a type of ionizing radiation curing resin (trade name "SEICA BEAM T-000, manufactured by Dainichi Seika"
5 ", transparent. Apply modified urethane acrylic). The thickness is about 20 μm, which exceeds the depth of the uneven pattern p.

FIG. 1 (e): PV on UV curable adhesive 3
After overlapping the transparent sheets 4 of C, the ultraviolet rays are irradiated to cure the adhesive 3. PVC sheet 4 used
Has a thickness of 0.1 mm and a plasticizer (DOP) content of 2
It is 0 PHR. The superposition on the adhesive 3 is carried out by using a roller 7 as shown in the figure, and continuously applying a light pressure so that air is not caught between the roller 7 and the adhesive 3. The irradiation of ultraviolet rays is performed by the irradiation lamp 8 from above the transparent PVC sheet 4. After the adhesive 3 is hardened, the underlying patterning sheet 1 is peeled off. On the peeled surface of the shape-imparting sheet 1, a concavo-convex pattern q opposite to that applied to the sheet 1 is faithfully transferred and formed.

FIG. 1 (f): The strip-shaped sheet A is cut into a tile-shaped sheet A by cutting it into a length and a width according to the use. That is, the strip-shaped sheet A in which the coating of the primer 2, the layer of the UV curable adhesive 3 and the PVC sheet 4 are sequentially overlapped from the bottom by the above steps according to FIGS.
Is continuously obtained, and is cut into a predetermined length and width so that it can be easily used on a floor or the like, and in combination with various base sheets 11 (described later) to obtain an arbitrary aesthetic appearance.

FIG. 2 (a): A thermoplastic resin base sheet 11 is adhered to the surface of the sheet A obtained as described above having the uneven pattern q (the coating of the primer 2 is present). As described above, as the base sheet 11, various materials having different hues and textures can be used. In this example, a glittering sheet containing titanium-coated mica (thickness: 0.2 mm, plasticizer 2
(0 PHR, titanium coated mica has 10 PHR)
Was used as the base sheet 11. Since the bonding was performed by heating to 180 ° C. by a laminating embossing machine, the base sheet 11 was deformed and laminated along the uneven pattern q of the sheet A. At that time, the surface of the PVC sheet 4 is subjected to flat embossing (mirror finish).

FIG. 2 (b): Through the above steps, a finished laminated sheet B as a decorative plate is obtained. The finished sheet B is a high-quality decorative plate with a flat outer surface (mirror surface), and the uneven pattern q with glitter can be seen inside.

Although one embodiment has been introduced above, the present invention is not limited to this. This is because, for example, the following implementation is possible.

A) It is also possible to use a semi-transparent adhesive for each transparent layer, such as coloring the UV-curing adhesive 3 semi-transparently with a paint.

(B) In the step of FIG. 2 (a), a laminated sheet having a double emboss (uneven pattern) on the outside and inside is obtained by applying an emboss other than a mirror surface on the surface of the PVC sheet 4. Is also possible.

(C) The step of FIG. 2 (a) does not necessarily have to be performed after the sheet A is made into a tile shape, and it is of course possible to continuously perform it on the belt-shaped sheet A. Needless to say, as shown in FIG.
It is also possible to perform the steps corresponding to (a) to (f) by using the shaped sheet 1 which is tile-sized in advance or a similar PVC sheet 4 or the like.

(D) It goes without saying that materials other than those in the above embodiments can be used as the material for each layer. Examples of usable ones are as follows.

Primer 2: A heat-sensitive adhesive having a property of adhering to both the material of the other side of the sheet A (base sheet 11 etc.) and the ionizing radiation curable resin.
Resins such as vinyl chloride, vinyl acetate and urethane can be used.

PVC sheet 4: polyvinyl chloride, AB
A transparent or translucent sheet of S resin, acrylic resin, polycarbonate resin, polyethylene terephthalate, polybutylene terephthalate, or the like can be used.

Base sheet 11: A thermoplastic resin such as polyvinyl chloride, ethylene-vinyl acetate polymer, ABS resin or acrylic resin can be used.

[0040]

The present invention has the following advantages.
First, the laminated sheet (sheet A) of claim 1 is not a) restricted in terms of heat and hardness in terms of material selection.

B) It is not necessary to use a transparent sheet having an uneven pattern in advance, and it is possible to form an extremely clear uneven pattern.

C) A variety of finished products can be obtained by joining various kinds of base sheets having different colors and textures to one sheet A, and the joining is easy.

The laminated sheet (sheet B) according to claim 2 has the advantages of the above a), b), and c) as it is, and d) only the thermoplastic resin sheet is deformed to give a clear uneven pattern of the sheet A. Since it can be completed without breaking, it has a particularly beautiful aesthetic suitable for high-grade board materials.

E) There are almost no restrictions on the thermal and hardness properties of the thermoplastic resin sheet.

Further, in the laminated sheet (sheet B) according to claim 3, f) the three-dimensional effect of the concavo-convex pattern is more vividly observed, and the appearance is further improved.

According to the manufacturing method described in claim 4, the sheet A can be manufactured reasonably and smoothly. That is, 1) Since the uneven pattern is formed by applying the ionizing radiation curable resin on the patterning sheet having the uneven pattern, a clear uneven pattern can be easily obtained.

2) Since the transparent sheets are overlapped while the ionizing radiation curable resin is uncured and then the former is cured to bond the two, the two can be easily laminated without requiring heat or pressure. it can.

3) Since the patterning sheet is peeled off after the ionizing radiation curable resin is cured, the uneven surface with the heat-sensitive adhesive coating should be exposed smoothly and used for bonding to another base sheet or the like. You can

Further, when the sheet B is manufactured by the method of claim 5, 4) a sheet in which a sharp uneven pattern is not broken and is hardly affected by the thermal and hardness properties of the thermoplastic resin sheet. B can be obtained.

[Brief description of drawings]

1 (a) to 1 (f) are schematic diagrams sequentially showing a manufacturing process of a laminated sheet A as an intermediate product which is an embodiment of the present invention.

2 (a) and 2 (b) are schematic diagrams sequentially showing steps of forming the sheet A of FIG. 1 into a laminated sheet B as a finished product (decorative plate).

[Explanation of symbols]

 1 Imprinting Sheet 2 Primer (Heat Sensitive Adhesive) 3 UV Curing Adhesive (Ionizing Radiation Curing Resin) 4 PVC Sheet (Transparent or Translucent Sheet) 11 Base Sheet (Thermoplastic Resin Sheet) pq Concavo-convex Pattern

Claims (5)

[Claims] 1. A transparent or semi-transparent sheet is bonded to one surface of a layer of ionizing radiation curable resin, and an uneven pattern is provided on the other surface, and a heat-sensitive adhesive coating is formed on the surface. Laminated sheet characterized by 2. A laminated sheet in which a thermoplastic resin sheet is joined to the surface of the heat-sensitive adhesive film in the laminated sheet according to claim 1. 3. The laminated sheet according to claim 2, wherein at least one of the heat-sensitive adhesive film and the thermoplastic resin sheet is provided with glitter. 4. A heat-sensitive adhesive film is applied and solidified on a mold-releasing shape-imparting sheet having an uneven pattern, an ionizing radiation curing resin is applied thereon, and a transparent or semitransparent sheet is superposed. In addition, a method for producing a laminated sheet, which comprises irradiating ionizing radiation to cure a layer of the same resin, and then peeling off the above-mentioned patterning sheet. 5. A method for producing a laminated sheet, which comprises laminating a thermoplastic resin sheet on the surface of the heat-sensitive adhesive film of the laminated sheet obtained according to claim 4 and bonding the laminated sheet by heating.