JPH1044330A - Decorative material and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide heat resistance not to be susceptible to burning even by being brought into contact with the fire of a cigarette, etc., to be excellent in folding resistance and adhesiveness, and to make the generation of warpage difficult by holding a heat conducting layer between a substrate layer and a surface layer and dispersing a heat conducting material in a binder resin in the heat conducting layer. SOLUTION: In a decorative material, at least a heat conducting layer 2 which is formed by dispersing a heat conducting material in a binder resin is held between a substrate layer 1 which constitutes the back of the decorative material and is to be a core material and a surface resin layer 5 which constitutes the surface of the decorative material. It is necessary for the heat conducting material to use a material having higher thermal conductivity than an ordinary resin, and aluminum powder is used appropriately. The substrate layer 1 and the surface resin layer 5 are composed of a resin selected from polyvinyl chloride, polyolefin, polyester, polyacrylate and ionomer. Besides, the heat conducting layer 2 is formed, for example, by a method in which coating liquid in which the heat conducting material is dispersed in the binder resin which is melted or dissolved in a solvent is applied on an adjoining constitution layer and other methods.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative material particularly suitable for use as a flooring and a method for producing the same. More specifically, the present invention relates to a decorative material having heat resistance that is less likely to cause burns even when it comes into contact with cigarette fire and the like, and also has excellent bending resistance and adhesion, and can be easily manufactured, and a method of manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, for example, stores such as department stores and shopping malls, corporate offices and factories, schools,
The flooring of buildings, such as public facilities such as government offices, underground shopping malls, and stations, that require a high level of abrasion resistance and durability that cannot be obtained with wooden flooring, as well as aesthetic design, have a limited amount of resources. There are expensive, unstable quality and difficult to replace with natural stone,
A decorative material made by printing a desired beautiful design on a synthetic resin such as polyvinyl chloride resin by printing or the like can be stably supplied in all aspects of quality, quantity, and price, and is widely used as a floor material that is easy to construct. Have been.

[0003] One of the drawbacks of the synthetic resin decorative material compared to natural stone materials is heat resistance. In other words, compared to wall materials, flooring materials for buildings are, for example, cigarette butts (the practice of littering cigarettes by smokers is not easy to change), flaming matches, cooking utensils and tools. By placing or falling high temperature objects such as
There are many opportunities to be exposed to high fever. However, the heat resistance of the above synthetic resin is remarkably inferior to that of natural stones, and there is a problem that burns are easily generated by contact of cigarettes with fire or the like.

[0004] As a material capable of solving the above problems and preventing burns, there is a decorative material having a structure in which an aluminum foil having excellent heat conductivity is sandwiched between resin layers. In this method, even if a cigarette fire or the like comes into contact with the surface, the aluminum foil quickly diffuses the heat to the surroundings and suppresses a rise in the temperature of the contact portion, thereby preventing the occurrence of burns. However, it is difficult to obtain the adhesion between the aluminum foil and the resin layer, it is easy to peel off due to the deterioration of the adhesive over time, or if it is bent by mistake during construction, the folds will not return to the original position and it will not be used Poor sex. In addition, there is a problem that warpage may occur due to a difference in thermal expansion coefficient between the aluminum foil and the resin layer.

[0005]

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems in the prior art, and has a heat resistance which does not cause burns even when a cigarette fire or the like comes into contact. Another object of the present invention is to provide a decorative material which is excellent in bending resistance and adhesion, hardly generates warpage, and can be easily manufactured, and a method for manufacturing the same.

[0006]

The decorative material of the present invention is a decorative material having a heat conductive layer sandwiched between a base layer and a surface resin layer, wherein the heat conductive layer is contained in a binder resin. The heat conductive material is dispersed.

[0007] The decorative material of the present invention is characterized in that the heat conductive material is aluminum powder.

[0008] The decorative material of the present invention is characterized in that the base layer and the surface resin layer are made of a resin selected from a polyvinyl chloride resin, a polyolefin resin, a polyester resin, an acrylic resin or an ionomer resin. It is.

The method of manufacturing a decorative material according to the present invention is also directed to a method of manufacturing a decorative material in which a heat conductive layer formed by dispersing a heat conductive material in a binder resin is sandwiched between a base layer and a surface resin layer. Wherein the heat conductive layer is provided by a coating method.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of a decorative material and a method of manufacturing the same according to the present invention will be described below in detail with reference to the drawings. FIG. 1 is a side sectional view showing an embodiment of the decorative material of the present invention.

As shown in FIG. 1, the decorative material of the present invention is formed by bonding between a base layer 1 constituting the back surface of the decorative material and serving as a core and a surface resin layer 5 constituting the surface of the decorative material. A heat conductive layer 2 formed by dispersing a heat conductive material in a binder resin is sandwiched at least, and between the surface resin layer 5 and the heat conductive layer 2 is provided a decorative material for giving a decorative property. It is customary that a picture layer 4 is provided. The heat conducting layer 2 and the picture layer 4 may be provided directly adjacent to each other, or an intermediate layer 3 made of a resin or the like may be provided between them.

The base layer 1 serves as a core material for defining the shape of the decorative material itself and serves as a surface to be adhered to a floor surface such as a concrete casting surface during construction. A material having sufficient strength and good adhesiveness during construction is selected. Specifically, for example, a thick woven fabric or an inorganic material may be used, but it is generally preferable to use a synthetic resin, among which polyvinyl chloride resin, polyolefin resin, polyester resin, acrylic resin or A resin selected from ionomer resins is most preferable because it is excellent in strength, flexibility, workability, and the like and is inexpensive. In addition, a mixture of the above various resins, a copolymer, a composite,
It may be a laminate or the like.

Usually, an organic or inorganic fibrous or powdery filler or coloring agent is added to the base layer 1 for the purpose of improving strength and providing concealment. The thickness is usually in the range of 1 to 5 mm, and about 3 mm is most often used.

The heat conducting layer 2 is formed by dispersing a powdered heat conducting material in a suitable binder resin. The heat conducting material is
It is necessary to use a material having higher thermal conductivity than ordinary resin, and a material having a thermal conductivity of at least 1 W / m · K is preferable. Specifically, for example, aluminum, gold, silver, copper,
Metals and alloys such as brass, iron, nickel, and stainless steel, and inorganic substances such as quartz, alumina, silicon carbide, silicon nitride, boron nitride, diamond, graphite, and carbon fiber can be suitably used. Above all, thermal conductivity is about 100W / m · K
It is preferable to select and use the above materials, and aluminum is most suitable in consideration of price, workability, and the like.

The heat conducting material is usually in the form of a powder such as a sphere, a polyhedron, a plate, a needle, or a fiber in order to secure the heat conducting layer 2 with flexibility that resists bending and does not cause folds. Use If the size of the particles is too small, the heat conduction efficiency is poor and the heat resistance of the decorative material is reduced, and if the size is too large, the flexibility is reduced, and if this is provided by a coating method, the coating suitability is deteriorated. In general, the thickness is preferably in the range of about 1 to 100 μm, although it depends on the type and shape of the heat conductive material.

In particular, when particles of anisotropic shape such as plate, needle, or short fiber are used in the in-plane direction as the heat conducting material, the heat conduction characteristics of the heat conducting layer 2 are large in the in-plane direction. By exhibiting anisotropy, it is possible to realize sufficient heat resistance even with a small mixing ratio of the heat conductive material or a thin heat conductive layer 2.
This effect is further amplified when a material having a large thermal conductivity in the in-plane direction of the plate-like particles or the longitudinal direction of the needle-like or short fiber-like particles, such as graphite, is used as the heat conducting material.

The mixing ratio between the binder resin and the heat conductive material is as follows:
If the amount of the heat conductive material is too small, the heat conduction efficiency is poor and the heat resistance of the decorative material is reduced, and if the amount is too large, the flexibility is reduced. In general, the weight ratio of the heat conductive material is preferably in the range of 20 to 70%, although it depends on the type of the resin and the heat conductive material. Heat conducting layer 2
Is not particularly limited, but is preferably in the range of about 10 to 100 μm.

In addition, the heat conducting layer 2 may have a structure in which a woven or non-woven fabric made of a high heat conducting fiber such as carbon fiber is used as a heat conducting material and impregnated with an appropriate resin. However, this complicates the manufacturing process,
The type of heat conductive material that can be used is also limited, and the resulting decorative material is expensive, and thus cannot be said to be a very suitable embodiment.

The kind of the binder resin is not particularly limited, and any resin can be used. Even if it is the same resin as the resin constituting the base layer 1, the transparent resin layer 5, and the like, it is different. It may be, but if you select and use a resin with excellent thermal adhesion with the resin constituting at least the upper and lower layers,
It is preferable because the respective layers can be directly bonded to each other by a thermal lamination method without using an adhesive or the like to produce a decorative material. Specifically, for example, acrylic resin, polyvinyl chloride resin, polyvinyl acetate resin, polyester resin, urethane resin, polyamide resin, polyvinyl butyral resin, polystyrene resin, styrene butadiene rubber, or a mixture thereof, Polymers and the like can be suitably used.

As a method for forming the heat conductive layer 2, for example, a method in which the heat conductive material is dispersed in a binder resin melted or dissolved in an appropriate solvent to form a film, and then laminated with other constituent layers. Any method can be applied, such as a method of coating a coating solution obtained by dispersing the heat conductive material in a binder resin dissolved in a suitable or molten solvent on an adjacent constituent layer. The method is simple and preferred.

In particular, according to the coating method using a solvent, it can be manufactured easily and with good productivity by using a usual printing machine or coating machine. In the example where fibrous powder particles are used, the heat conductive material particles are easily oriented in the in-plane direction to obtain high heat conductivity in the in-plane direction, and to obtain good heat resistance of the decorative material. Is most preferred because In addition, it is also possible to orientate by stretching or the like after forming into a film, but in order to enable stretching, the mixing ratio of the heat conductive material cannot be increased so much, and the heat conductivity is necessarily reduced. Not so desirable.

The picture layer 4 is provided for imparting a desired design property to the decorative material, and may be a solid printing layer or a coating layer for a simple coloring purpose. It may be substituted by coloring the layer 5 or the like. As the material, any conventionally known printing inks, coating agents, paints and the like which are obtained by dispersing an organic or inorganic dye or pigment in a suitable binder resin can be used.

The pattern layer 4 may be formed by, for example, a gravure printing method, an offset printing method, a flexographic printing method,
Various printing methods such as screen printing and plateless printing, gravure coating, roll coating, knife coating, air knife coating, kiss coating, rod coating, lip coating, spray coating and other coating methods Alternatively, any conventionally known method such as a transfer method can be used.

The pattern layer 4 may be provided directly on the surface of the heat conductive layer 2 provided on the base layer 1 or directly on the back surface of the surface resin layer 5. The resin layer 5 is generally required to have a thickness of about 100 μm or more, and it is difficult to perform direct printing. Therefore, an intermediate layer 3 having a thickness and a material suitable for printing is separately prepared, and the pattern layer 4 is applied thereto. Lamination with another constituent layer is preferable because a decorative plate having excellent print quality can be easily manufactured with high productivity.

In this case, for the same reason as above,
It is preferable that the heat conductive layer 2 be formed on the back surface of the intermediate layer 3 also. At this time, a heat conducting layer may be provided in the same process as the printing of the picture layer using a double-sided in-line printing machine or the like.
By laminating the surface resin layer 5 and the surface resin layer 5 in-line, it is possible to further improve the productivity and reduce the cost.

The material of the intermediate layer 3 may be any material as long as it is in the form of a sheet or a film having excellent printability. For example, paper or the like may be used.
If the material constituting the intermediate layer 3 has low thermal conductivity or the intermediate layer 3 is too thick, the heat on the surface of the decorative material is blocked by the intermediate layer 3 and is not transmitted to the heat conductive layer 2, so that the heat resistance is reduced. Therefore, it is preferable to use a plastic film that has sufficient strength to withstand printing even with a thin thickness and is more excellent in thermal conductivity than paper as the intermediate layer 3. The material may be the same as or different from that of the base layer 1 or the surface resin layer 5, and its thickness is preferably in the range of 10 to 100 μm.

The surface resin layer 5 needs to have sufficient surface physical properties such as abrasion resistance and impact resistance as a material constituting the outermost surface of the decorative material, and has transparency that allows the picture layer 4 to be seen through. It is preferable that the material is provided, and it may be colored and transparent. Specifically, the resin may be the same as or different from the base layer 1, and a resin selected from a polyvinyl chloride resin, a polyolefin resin, a polyester resin, an acrylic resin, or an ionomer resin has strength, flexibility, and processability. It is the most suitable because it is excellent and cheap. Further, a mixture, a copolymer, a composite, a laminate, or the like of the above various resins may be used.

In particular, when the surface resin layer 5 is used as a flooring material, the surface resin layer 5 needs to have a thickness sufficient to withstand abrasion due to long-term use. Since the heat resistance is reduced without being transmitted to the heat conducting layer 2, 1
The thickness is preferably in the range of about 00 to 500 μm. The surface may be provided with an emboss for preventing slippage or imparting a design property, or a top coat layer for improving surface properties.

[0029]

<Example 1> An image pattern layer of an abstract pattern was formed by gravure printing on one surface of an intermediate layer made of a colored polyvinyl chloride resin film having a thickness of 100 µm by a gravure printing method.
On the other surface, a paste ink in which aluminum powder having an average particle diameter of 10 μm was dispersed in a urethane resin at a solid content of 40% by weight was applied to a thickness of 30 μm by knife coating to form a heat conductive layer. A 3 mm thick filler-containing polyvinyl chloride resin sheet is laminated on the heat conducting layer side, and a 200 μm thick transparent polyvinyl chloride resin film is laminated on the picture layer side by thermal laminating to form a base layer and a surface resin layer. Then, a cosmetic material was produced.

Comparative Example 1 A decorative material was prepared in the same manner as in Example 1 except that the heat conducting layer was replaced with a 50 μm thick aluminum foil having a 3 μm thick vinyl chloride resin coating layer on both sides.

<Comparative Example 2> A decorative material having a configuration in which the heat conducting layer was omitted in Example 1 was produced.

<Cigarette Resistance> Using the above three kinds of decorative materials, the cigarette resistance due to the erasing and leaving of cigarettes was compared based on the method described in JIS K 6902. Example 1 and Comparative Example 1 No abnormality occurred in the cosmetic material of Comparative Example 2 after heating for 10 minutes, but the cosmetic material of Comparative Example 2 was clearly inferior to these, and blistering occurred in about 1 minute of heating.

<Bending resistance> Comparing the bending resistance of the above three types of decorative materials, the decorative materials of Example 1 and Comparative Example 2 were naturally restored with respect to slight bending during construction, and Even if it was tightly bent at 90 °, it was naturally restored when left at a constant temperature of 40 ° C. However, the decorative material of Comparative Example 1 could not be restored once bent at the time of construction or the like.

[0034]

As described above, the decorative material of the present invention has a structure in which the heat conductive layer in which the heat conductive material is dispersed in the binder resin is sandwiched between the base layer and the surface resin layer. Even if a high-temperature object such as a cigarette fire comes in contact with the surface, the heat spreads quickly to the surroundings through the heat conducting layer and the rise in the temperature of the contact area is suppressed, so that burns can be prevented. it can. Moreover, since the heat conductive layer has a structure in which the heat conductive material is dispersed in the binder resin, the heat conductive layer has excellent adhesion to the front and back resin layers as compared with a conventional aluminum foil, and easily peels off. In addition, there is no occurrence of unrecoverable folds due to bending at the time of construction, and the workability is excellent. Also, there is no warpage caused by the difference in the coefficient of thermal expansion between the aluminum foil and the resin layer.

In addition, since the heat conducting layer can be provided by a coating method using a coating solution in which the binder resin and the heat conducting material are dispersed in an appropriate solvent, a structure using a conventional aluminum foil is used. The process such as surface treatment of aluminum foil in the above becomes unnecessary, and the heat conducting layer is provided in the same process as the printing of the pattern layer using a double-sided in-line printing machine or the like, and the lamination process with other constituent layers is also performed in-line. This has an excellent advantage that the process can be simplified and the production can be performed efficiently and economically.

[Brief description of the drawings]

FIG. 1 is a side sectional view showing an embodiment of a decorative material of the present invention.

[Explanation of symbols]

 1) Base layer 2) Heat conduction layer 3) Intermediate layer 4) Picture layer 5) Surface resin layer

Claims (4)

[Claims] 1. A decorative material having a heat conductive layer sandwiched between a base layer and a surface resin layer, wherein the heat conductive layer is formed by dispersing a heat conductive material in a binder resin. Makeup material. 2. The decorative material according to claim 1, wherein said heat conductive material is aluminum powder. 3. The method according to claim 1, wherein the base layer and the surface resin layer are made of a resin selected from a polyvinyl chloride resin, a polyolefin resin, a polyester resin, an acrylic resin or an ionomer resin. Cosmetics. 4. A method for producing a decorative material comprising a heat conductive layer in which a heat conductive material is dispersed in a binder resin between a base layer and a surface resin layer, wherein the heat conductive layer comprises: A method for producing a decorative material, which is provided by a coating method.