JPH09267462A - Decorative sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a decorative sheet having a distinct matte tone by providing a pattern layer on a surface of a base material sheet composed of a light diffusing resin layer wherein a mat agent particle is dispersed by kneading in transparent resin and the matting agent-containing resin is lamination-formed by co- extrusion, and a transparent resin layer containing no matting agent. SOLUTION: The objective decorative sheet 8 is obtained by providing a pattern layer 3 onto a surface of a base material sheet 10 composed of a light diffusing resin layer 1 wherein a matting agent particle 13 is dispersed by kneading in transparent resin and the matting agent-containing resin is lamination-formed by co-extrusion, and a transparent resin layer 2 containing no-matting agent. Functions of the layer developing light diffusing properties and the transparent resin layer developing processability and strength of the film are divided into respective different layers, and multi-layers are formed by co-extrusion of molten resin of the same kind. Thereby, interlayer bond strength between a matte layer and the transparent resin layer is strengthened and a uniform stable matte tone can be obtained by preventing convection and sedimentation by precipitation of the matting agent particle 13 in a film making process of the base material sheet 13.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a decorative sheet having a matte (matte) texture and a method for producing the same.

[0002]

2. Description of the Related Art A conventional technique will be described with reference to the drawings. FIG. 4 is a sectional view showing an example of a conventional decorative sheet. FIG. 5: is sectional drawing which shows another example of the conventional decorative sheet. Conventionally, there have been the following three decorative sheets as a polyester decorative sheet having a matte surface.

As shown in FIG. 4, a decorative sheet 30 in which a pattern layer is formed by printing or the like on a single-layer polyester resin sheet 31 in which matting agent particles 13 are uniformly stuck. A decorative sheet 34 using a polyester resin sheet 32 containing no matting agent, the surface of which is sandblasted 33 as shown in FIG. A decorative sheet using a polyester resin sheet having a cured coating layer of an ink containing a matting agent on its surface.

[0004]

In the conventional decorative sheet as described above, since the luster is lowered, if the amount of the matting agent added in the base sheet is increased, it becomes clouded and a clear design effect cannot be obtained. In order to obtain transparency, if the sheet thickness is made thin, the sheet strength will decrease and it will not be practical. There was a problem of cutting during printing.

Similarly, even if the amount of the matting agent added is increased in order to reduce the luster, the strength of the base sheet is impaired, which causes a practical problem. In addition, ink is missing in secondary processing such as printing, and good decoration cannot be performed. (The degree of matte tone obtained is limited by itself.) That is, there is a problem that low gloss, high transparency, and strength of the sheet do not stand up to each other.

Further, in the conventional decorative sheet as described above, the mat effect is low and it is not possible to express a beautiful matte texture. Since a sharp concave portion is formed on the surface layer, dirt entering the concave portion does not easily fall (feels rough). Further, there is a problem that such a sharply-roughened uneven portion has a low mechanical strength and therefore has a low scratch resistance.

In the conventional decorative sheet as described above, the matting agent causes convection and sedimentation during the application of the matte ink, resulting in non-uniform dispersion, resulting in a change in luster during application and uneven coating (glossiness). Unevenness) and the quality is not stable. (It is difficult to dry and cure the matting agent while uniformly dispersing it in the coating film.)

[0008] Further, there are drawbacks that the adhesion strength with the polyester resin is insufficient, or the mat ink layer is cracked or peeled off by post-processing such as bending due to a difference in elongation. There is a problem in that the strength tends to decrease (the quality control is difficult and the moldability is affected) due to the decrease in the binding force of the matting agent particles near the surface due to the inclusion of bubbles in the coating film and the curing shrinkage of the binder.

[0009]

In order to solve the above problems, in the present invention, as shown in FIG. 1, a matting agent particle 13 formed by lamination by coextrusion of a molten thermoplastic resin is used as a transparent resin. A base material sheet 10 comprising a light diffusing resin layer 1 kneaded and dispersed therein and a transparent resin layer 2 made of a transparent resin and containing no matting agent, has a pattern layer 3 on the surface of the transparent resin layer 2 side. We have developed a decorative sheet 8 characterized by the following.

The base sheet in the present invention includes a thermoplastic resin layer containing a matting agent (light diffusing resin layer) and a transparent thermoplastic resin layer containing no matting agent (transparent resin layer).
By constructing as a multi-layer sheet by co-extrusion molding in the molten state, the functions of the layer that exhibits light diffusivity and the transparent resin layer that exhibits the processability and strength of the film were divided into separate layers. In addition, the same type of molten resin was coextruded to form multiple layers to strengthen the interlayer adhesive strength between the matte layer and the transparent resin layer.

Since the fine irregularities on the surface contribute to the luster, the matting agent is added only to the surface side of the thickness of the base sheet. In addition, the back surface side was formed with a transparent resin layer containing no matting agent to prevent a decrease in strength and a decrease in transparency that accompany matte coating.

Since the surface of the light diffusion layer is based on a thermoplastic resin and has a smooth shape with an arcuate cross section, it is excellent in stain resistance and soft touch can be obtained.

In the process of forming the base sheet, the matting agent particles do not cause convection or separation and sedimentation, so that a uniform and stable matte texture can be obtained, and the secondary processing (printing,
It has become possible to manufacture decorative sheets with excellent moldability). Although the reason is unknown, the decorative sheet having the constitution of the present invention has a specular glossiness that depends on the angle, and the glossiness increases with the angle.

[0014]

Embodiments of the present invention will be described below in detail with reference to the drawings. FIG. 1 is a step view showing an example of a decorative sheet according to the present invention. FIG. 2 is a sectional view showing an application example of the decorative sheet according to the present invention. FIG. 3 is a sectional view showing an application example of the decorative sheet according to the present invention.

In the decorative sheet of the present invention, the resin forming the base sheet 10 is a thermoplastic resin which is solid at room temperature, and a transparent thermoplastic resin capable of coextrusion molding of a molten resin, for example, Thermoplastic polyester resins such as polyethylene terephthalate, polybutylene terephthalate, polyethylene terephthalate / isophthalate copolymers, polyolefin resins such as polyethylene, polypropylene and polymethylpentene, polyvinyl fluoride, polyvinylidene fluoride, polytetrafluoroethylene, Polyfluoroethylene resin such as ethylene / tetrafluoroethylene copolymer, polyamide resin such as nylon-6, nylon-6,6, polyvinyl chloride, vinyl chloride / vinyl acetate copolymer, ethylene / vinyl alcohol copolymer Polymer, ethylene / acetic acid Cycloalkenyl copolymer vinyl resins,
Cellulosic resins such as cellulose triacetate and cellophane,
Acrylic resin ((meth) acryl) made of poly (meth) acrylate, poly (meth) acrylate, butyl poly (meth) acrylate, methyl (meth) acrylate / butyl (meth) acrylate copolymer, etc. Means acrylic or methacrylic), polystyrene, acrylonitrile / styrene copolymer, styrene resin such as acrylonitrile / butadiene / styrene copolymer (ABS), resin such as polycarbonate, polyarylate, or polyimide. .

It is not always necessary to select the same resin for the resin containing the matting agent and the transparent resin not containing the matting agent. However, in order to obtain sufficient interlayer strength, it is better to select the same resin. preferable.

The thickness of the base sheet 10 (coextruded multilayer film) is about 10 to 300 μm, preferably 20 to 100 μm. Further, in order to effectively express a clear matte design, if the thickness of the light diffusing resin layer 1 becomes thicker, the transmitted light is diffused and attenuated to lower the transparency. Is preferred. However, the thickness should be at least the particle size of the matting agent.

Next, in the light diffusing resin layer 1 exhibiting a matt effect, a matting agent (light diffusing agent) made of particles or foil pieces having a particle size of about 0.5 to 30 μm, such as calcite, is used. Calcium carbonate, porous silica called siloid, inorganic substances such as barium sulfate, aluminum hydroxide, mica, silicon oxide, alumina, polycarbonate, polystyrene,
A matting agent (matting agent particles 13) made of an organic material such as acrylic or polyurethane is added to the resin in the light diffusing resin layer by about 0.1 to 5% to form a resin layer made of a light diffusing resin layer. And so on.

The light-diffusing resin layer 1, which is the resin layer on the side that imparts a matt effect, is matted to such an extent that it has a gloss level of 25% or less in terms of 60-degree gloss of JIS Z-8741, and preferably 60. It is set to 12% or less in the gloss method. The layer as a whole is a layer which is transparent and has a property of diffusing transmitted light.

Of the substrate sheet 10, the light diffusing resin layer 1
The layer (transparent resin layer 2) on the opposite side of the (mat layer) has a smooth surface property with no matting agent added, and is formed in a state suitable for processing such as printing. In addition, corona treatment or various kinds of easy-adhesion primer coating or the like can be performed to strengthen the adhesion of the printing ink or the like, if necessary.

The pattern layer 3 is formed of a printing ink layer or a partial metal thin film layer. The printing ink layer is formed on the transparent resin layer side of the substrate sheet in the form of a pattern layer, a solid layer or a combination thereof. As the ink used for forming the printing ink layer, a pigment, a coloring agent such as a dye, an extender pigment, a solvent, a stabilizer, or
A mixture of a plasticizer, a catalyst, a curing agent and the like is used.
Here, the vehicle is appropriately selected from a thermoplastic resin, a thermosetting resin, an ionizing radiation curable resin and the like according to the application, required physical properties, printability and the like.

Examples of the thermoplastic resin include (i) cellulose derivatives such as ethyl cellulose, cellulose nitrate, cellulose acetate, ethyl hydroxycellulose, and cellulose acetate propionate; and (b) styrene resins such as polystyrene and poly α-methylstyrene. Alternatively, styrene copolymers, acrylic resins such as (c) poly (meth) acrylic acid methyl, poly (meth) acrylic acid ethyl, and poly (meth) acrylic acid butyl, (d) polyvinyl chloride, polyvinyl acetate, vinyl chloride・ Vinyl acetate copolymer, vinyl polymer such as polyvinyl butyral, (e) rosin, rosin-modified maleic acid resin, rosin-modified phenol resin, rosin ester resin such as polymerized rosin, coumarone resin, vinyltoluene resin, polyamide resin, etc. Examples include natural or synthetic resins.

As the thermosetting resin, phenol resin, urea resin, diallyl phthalate resin, melamine resin, guanamine resin, unsaturated polyester resin, polyurethane resin, epoxy resin, aminoalkyd resin, melamine / urea co-condensation resin. There are resins, silicone resins, polysiloxane resins, etc., and if necessary, crosslinking agents, curing agents such as polymerization initiators, polymerization accelerators, solvents, viscosity modifiers,
Add extender pigment. Usually, isocyanate is unsaturated polyester resin, polyurethane resin, amine is epoxy resin, peroxide such as methyl ethyl ketone peroxide, radical initiator such as azobisisobutyronitrile, organic sulfonate as a curing agent. Unsaturated polyester resins are often used for unsaturated polyesters. As the isocyanate, divalent or higher valent aliphatic or aromatic isocyanate can be used, but aliphatic isocyanate is preferable from the viewpoint of preventing thermal discoloration and weather resistance. Specific examples include tolylene diisocyanate, xylene diisocyanate, 4,4-diphenylmethane diisocyanate, hexamethylene diisocyanate, lysine diisocyanate, and the like.

The printing ink layer is formed by printing, but it may be formed by another method such as handwriting. The pattern can be printed on the surface film by using a known method such as the gravure method and the screen method using the above-described ink.

As the ink pigment, carbon black,
Known coloring pigments such as titanium dioxide, quinacridone, isoindolinone, and cyanine blue, pearl pigments such as titanium dioxide-coated mica, etc. are used, and patterns and patterns include wood pattern, stone pattern, leather pattern, cloth pattern, etc. Natural products, polka dots, striped patterns, abstract patterns such as geometric figures, or combinations thereof are arbitrary.

The partial metal thin film layer is formed by a known method. For example, an ink of a water-soluble resin such as polyvinyl alcohol or starch is printed in advance on a region where a metal film is unnecessary on a base sheet, a metal film is formed on the entire surface, and then washed with water to remove the water-soluble property. A method of removing only the metal film directly above the area where the resin ink is present is used.

As the metal, aluminum, chromium,
Gold, silver, copper, etc. are used to form a film by vapor deposition, sputtering, or the like.

The minimum necessary basic constitution of the present invention is as described above, but it is formed as a composite decorative sheet laminated with a vinyl chloride resin sheet, a steel plate or plywood 7, synthetic paper 20, or glass. Things are possible. (Illustrated in FIGS. 2 and 3)

As a use of the present invention, a surface decorative material is laminated on the surface of various members. As the adherend, a metal plate such as iron and aluminum, a wood veneer, a wood plywood, a wood plate such as a wood fiber board, a ceramic plate such as glass and ceramics, ALC
Examples thereof include a plate material such as a cement board, a plate material such as a resin plate such as polyvinyl chloride and a phenol resin, or a three-dimensional shaped article (molded product) made of the above-mentioned various materials.

As a method for laminating these various members, for example, a method of laminating by pressing with a pressure roller onto a plate-shaped substrate with an adhesive layer interposed therebetween is described in Japanese Patent Publication No. 50-19132. Similarly, insert the decorative sheet with the transparent resin layer side facing the cavity side, insert it between the male and female molds for injection molding, close both molds, and inject the molten resin from the male mold gate. After that, the resin sheet is cooled and the decorative sheet is adhered and laminated on the surface simultaneously with the molding of the resin molded article, so-called injection molding simultaneous laminating method, as described in JP-B-56-45768, JP-B-60-58014 and the like. In addition, so-called vacuum press lamination, in which a decorative sheet is placed on the surface of the molded product so as to face or be placed with an adhesive layer in between, and the decorative sheet is laminated on the surface of the molded product by a pressure difference due to vacuum suction from the molded product side. Method, Japanese Patent Publication No. 61-5 As described in Japanese Patent Publication No. 95, etc., while a decorative sheet is supplied in the major axis direction of a columnar base material such as a cylinder or a polygonal column via an adhesive layer, a plurality of rollers in different directions are used to form a columnar shape. A decorative sheet is sequentially pressure-bonded and laminated on a plurality of side faces forming a body, as described in a so-called lapping method, Jpn. Kokai No. 15-31122, JP-A-48-47972, and the like. First, the decorative sheet is laminated on the plate-shaped base material via the adhesive layer, and then on the surface of the plate-shaped base material opposite to the decorative sheet, the interface between the decorative sheet and the plate-shaped base material is reached, V-shaped cross section or U
A so-called V in which a V-shaped groove is cut, and then an adhesive is applied to the groove, and then the groove is bent to form a box body or a columnar body.
There are cutting or U-cut processing methods, etc.

These surface-coated members are used for interiors of buildings such as wall surfaces, floors, ceilings, decorative materials, furniture surface materials, light electric / OA equipment cabinets, surface materials for vehicle interior materials such as automobiles, etc. To be

[0032]

Embodiments of the present invention will now be described in detail with reference to the drawings.

Example 1 In FIG. 1, as a base sheet 10, a light diffusing resin layer 1 containing 4 parts by weight of silica having an average particle size of 0.5 μm in polyethylene terephthalate resin, and a transparent resin layer of polyethylene terephthalate resin alone. 2 was manufactured as a multi-layer film integrated by coextrusion in the molten state.
The thickness of the substrate sheet was 60 μm, of which the thickness of the light diffusing resin layer 1 was 12 μm and the thickness of the transparent resin layer 2 was 48 μm.

A pattern is formed on the transparent resin layer 2 side of the substrate sheet 10 by gravure printing with an ink "NL-ALFA" (trade name, manufactured by The Inktech Co., Ltd.) using a two-component curing type urethane resin as a binder. As the pattern layer 3, the decorative sheet 8 of the present invention as shown in FIG. 1 was formed.

Comparative Example 1 In FIG. 4, as the base sheet, a polyethylene terephthalate "X42 (trade name, manufactured by Toray)" kneaded with single-layer matting agent particles 13 having a thickness of 26 μm was used. Two-component curing type ink "NL-ALFA" (product name manufactured by The Inktech) by gravure printing on one side
To form a pattern layer 3 to obtain a decorative sheet as shown in FIG.

Comparative Example 2 In FIG. 4, a polyethylene terephthalate “X43 (trade name, manufactured by Toray)” kneaded with single-layer matting agent particles 13 having a thickness of 26 μm was used as the base sheet. Two-component curing type ink "NL-ALFA" (product name manufactured by The Inktech) by gravure printing on one side
To form a pattern layer 3 to obtain a decorative sheet as shown in FIG.

Comparative Example 3 In FIG. 4, a polyethylene terephthalate “X44 (trade name, manufactured by Toray)”, which is a single layer of matting agent particles 13 having a thickness of 26 μm, is used as the base sheet. Two-component curing type ink "NL-ALFA" (product name manufactured by The Inktech) by gravure printing on one side
To form a pattern layer 3 to obtain a decorative sheet as shown in FIG.

Comparative Example 4 In FIG. 4, a polyethylene terephthalate “X45 (trade name, manufactured by Toray)”, which is a single layer of matting agent particles 13 having a thickness of 26 μm, is used as the base sheet. Two-component curing type ink "NL-ALFA" (product name manufactured by The Inktech) by gravure printing on one side
To form a pattern layer 3 to obtain a decorative sheet as shown in FIG.

Comparative Example 5 As a base material sheet, a polyester film having a particle size of 15 μm was used.
7 parts by weight of a silica matting agent of m in a two-component curing type polyurethane resin binder is applied to a thickness of 15 μm, and a mat-coated sheet is used. One side of the base sheet is gravure-printed to form a two-component curing type. Ink "N
A pattern was formed with "L-ALFA" (trade name, manufactured by The Inktech Co., Ltd.) as a pattern layer to obtain a decorative sheet.

[Performance Evaluation Test-1] Decorative sheets of Comparative Examples 1 to 5 and Example 1 in which a single-layer matte agent kneaded matte PET and a coated PET were used as a base sheet.
Table 1 shows the results of comparison of various physical properties with the decorative sheet of No. 1. In Table 1, Ra represents the center line average roughness, Rt represents the maximum roughness, and Sm represents the average interval of the irregularities. Both are based on JIS-B-0601. In addition, the decorative sheet of Example 1 was superior to the decorative sheet of Comparative Example 5 in stain resistance and scratch resistance. (Below margin)

[0041]

[Table 1]

[Performance Evaluation Test-2]

In FIG. 2, a polyester urethane two-component curing adhesive "DLU-10" was gravure reverse coated on the pattern layer 3 of the decorative sheet 8 made in Example 1.
0 "(trade name, manufactured by The Inktech Co., Ltd.) is applied so that the thickness when dried is 5 g / m ^2, and the colored PV is 0.1 mm.
The decorative sheet 1 of FIG. 2 which is dry laminated with the C sheet 5
When 1 was attached to a steel sheet with a known two-component curing type polyurethane-based adhesive, a decorative steel sheet provided with a matte design having a uniform and soft touch was obtained. The appearance of the surface was visually judged. This product has an organic texture and a soft texture, and has a design effect that is completely matt.
Further, it has the characteristic that the specular reflection glossiness increases as the incident angle of the incident light increases, and it has various textures as a decorative steel sheet. Further, even when the Erichsen squeezing process was performed, the cellophane tape was not peeled off, crack whitening did not occur, and there was no problem in appearance.

In FIG. 2, a polyester urethane two-component curing adhesive "DLU-10" was gravure reverse coated on the pattern layer 3 of the decorative sheet 8 made in Example 1.
0 "(trade name, manufactured by The Inktech Co., Ltd.) is applied so that the thickness when dried is 5 g / m ^2, and the colored PV is 0.1 mm.
The decorative sheet 1 of FIG. 2 which is dry laminated with the C sheet 5
When 1 was attached to a plywood with a known two-component curing type polyurethane adhesive, a decorative plywood provided with a matte design having a uniform and soft touch was obtained. This product has an organic texture and a soft texture, and has a design effect that is completely matt. Further, the glossiness due to specular reflection increases with an increase in the incident angle of incident light, and the decorative plywood has various textures.

[Performance Evaluation Test-3] Using a vinyl acetate emulsion adhesive, the decorative sheet of Example 1 was laminated on a lauan plywood having a thickness of 10 mm with the transparent resin layer on the plywood side, and V Even after the cutting process, there was no crack or break in the bent portion.

On the other hand, when the decorative sheets of Comparative Examples 1 to 5 were similarly made into a decorative steel plate or a decorative plywood, none of them had a semi-glossy and soft texture, and depending on the viewing angle. The glossiness was unchanged.

Further, the decorative sheet of Comparative Example 5 was similarly prepared as follows.
When the Erichsen squeezing process is applied to the decorative steel sheet, when the processed film is pasted with a Nichiban Co., Ltd. cellophane tape industrial 18 mm width, the cellophane tape is peeled off, Peeling occurred, causing a problem in appearance.

Similarly, when the decorative sheet of Comparative Example 5 was likewise made into a decorative plywood and subjected to V-cutting, cracks and partial exfoliation of the coating film occurred in the mat coating layer.

[0049]

EFFECT OF THE INVENTION The decorative sheet of the present invention is a matte decorative sheet having a clear design effect that can be adjusted in luster and can be drawn or V-cut without impairing transparency and sheet strength. I got it.
(For example, the thickness of the base film is 85 μm, the gloss is 9%, and the light transmittance is 85%.) Characteristically, low gloss (matte), high transparency, and mechanical strength of the sheet stand together. Since a thermoplastic resin sheet in which a spherical resin is kneaded is used as a base, and the surface of the light diffusion layer has an arc-shaped smooth convex shape, excellent stain resistance and a soft touch can be obtained. Also, the specular reflection glossiness is the incident angle (= reflection angle)
It increases with time and gives a glossy appearance that varies depending on the viewing angle. A matte texture with stable quality and no appearance defects due to uneven gloss can be obtained. It is now possible to manufacture a decorative sheet that has excellent printability and excellent secondary processing (formability, etc.). (Because it is printed on the transparent resin layer side with no matting agent added)

[Brief description of drawings]

FIG. 1 is a sectional view showing an example of a decorative sheet according to the present invention.

FIG. 2 is a sectional view showing an application example of a decorative sheet according to the present invention.

FIG. 3 is a sectional view showing another application example of the decorative sheet according to the present invention.

FIG. 4 is a cross-sectional view showing an example of a conventional decorative sheet.

FIG. 5 is a cross-sectional view showing another example of a conventional decorative sheet.

[Explanation of symbols]

 1 Light-diffusing resin layer 2 Transparent resin layer 3 Pattern layer 4 Adhesive layer 5 Colored base layer (colored PVC) 6 Adhesive layer 7 Steel plate or plywood 8 Decorative sheet 10 Base sheet 11 Decorative sheet 12 Decorative base material 13 Mat Agent particles 14 Composite decorative sheet 20 Synthetic paper (decorative base material) 30 Decorative sheet 31 Polyester resin sheet 32 Polyester resin sheet 33 Sand blasting 34 Decorative sheet

Claims (1)

[Claims] 1. A light-diffusing resin layer formed by laminating and molding a melted thermoplastic resin by kneading and dispersing matting agent particles in a transparent resin, and a transparent resin layer made of a transparent resin and containing no matting agent. A decorative sheet having a pattern layer on the surface of the transparent resin layer side of a substrate sheet comprising