JPH1044332A - Decorative plate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a decorative plate having excellent design properties by improving weather resistance and stain resistance. SOLUTION: The decorative plate 1 is manufactured by the steps of sequentially superposing a fluororesin film 11, thermoplastic resin film 14 executed with a print pattern 13 and a porous film 15 made of nonwoven fabric of three types of the films via adhesive layers 12 to manufacture a decorative sheet 2, disposing it in a mold (not shown) so that a surface of the fabric 15 of the sheet 2 is brought into contact with a panel base material 16, clamping the mold, then heating and pressurizing it to integrally mold the sheet 2 with the material 16.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a high strength, weather resistant,
The present invention relates to a decorative board for flooring and interior / exterior materials which are required to have stain resistance, nonflammability and the like.

[0002]

2. Description of the Related Art Conventionally, high-strength floors, interior and exterior walls, water tanks, and the like have a panel substrate made of FRP (fiber reinforced plastic) made of a thermosetting resin or a thermoplastic resin filled with glass fiber, and are used as SMC ( It was molded using sheet mold compounding), BMC (bulk mold compounding), or the like. In order to improve the weather resistance and stain resistance of these FRP panels, a method of applying a paint made of a fluororesin has been adopted. In addition, a method of filling a large amount of a filler such as magnesium hydroxide has been adopted in order to add nonflammability.

[0003]

However, it has been difficult to form a uniform coating on a complicated shape by the conventional method of applying a paint made of a fluororesin. Also,
The use of a solvent has been a major problem in the working environment. In addition, in the case of a humid condition such as a water tank, there has been a demand for a mold that does not generate mold or the like or that can easily be removed by wiping or the like even if the mold or the like occurs. Further, in order to solve the above-mentioned problems, a laminate of a sheet made of a fluororesin film and a nonwoven fabric on a panel substrate has a problem in design as an interior / exterior decorative material.

In order to solve these problems, the present invention provides a decorative sheet to be laminated on a panel substrate, which is made of a fluororesin film, a thermoplastic resin film having a printed pattern, and a porous film made of nonwoven fabric or woven fabric. The three types of films are sequentially laminated by an adhesive or heat fusion, and the laminated film is integrally formed so that the non-woven or woven porous film side is in contact with the panel base material, and has high designability and weather resistance. It is an object of the present invention to provide a decorative board excellent in stain resistance.

[0005]

According to the present invention, in order to solve the above-mentioned problems, the structure of the decorative plate is as follows. In a decorative board comprising a decorative sheet and a panel substrate, the decorative sheet is formed by bonding three kinds of films, a fluororesin film, a printed thermoplastic resin film, and a porous film made of a nonwoven fabric or a woven fabric, with an adhesive or heat fusion. The panel base material contains a resin component,
The decorative sheet and the panel base material are laminated and integrated such that the fluororesin film side of the decorative sheet is on the outside, and the porous film side made of a nonwoven fabric or a woven fabric is in contact with the panel base material. Further, a decorative plate is characterized in that the resin component of the panel base material is impregnated into voids of a porous film made of non-woven fabric or woven fabric and integrated.
Further, the decorative panel is characterized in that the panel substrate is FRP (fiber reinforced plastic) made of a thermosetting resin or a thermoplastic resin filled with reinforcing fibers. Furthermore,
The decorative plate is characterized in that the fluororesin film is made of an ethylene-tetrafluoroethylene-based copolymer.

That is, a decorative sheet is manufactured by laminating a decorative sheet on a panel base material such as FRP, and the structure of the decorative sheet is defined as follows.
(Surface) Fluororesin film / adhesive / printed thermoplastic resin film / adhesive / porous film composed of nonwoven fabric, etc./panel substrate. And, with the above configuration, there is a thermoplastic resin film with a printed pattern under the fluororesin film on the surface, so that weather resistance,
At the same time, the surface has excellent stain resistance and high designability,
Since the layer in contact with the panel substrate is a porous film such as a nonwoven fabric, the resin component of the panel substrate permeates the porous film during the molding of the decorative board, and the decorative sheet can be firmly adhered to the panel substrate. . Therefore, it is possible to obtain a decorative board having a high strength, a surface having excellent weather resistance and stain resistance, and a high design property.

[0007]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the drawings. FIG. 1 is a schematic sectional view showing an example of the decorative board of the present invention. FIG. 2 is a schematic sectional view of a decorative sheet used for the decorative board of the present invention. FIG. 3 is an explanatory diagram for producing the decorative board of the present invention.

[0008] As shown in FIG.
Basically, a decorative sheet obtained by laminating a fluororesin film 11, a thermoplastic resin film 14 having a printed pattern 13, and a porous sheet 15 such as a non-woven fabric with an adhesive 12 is used. It is molded integrally with the panel base material 16 so that it comes into contact with it, and the surface has weather resistance,
This is a decorative plate having excellent stain resistance and high design properties.

Hereinafter, a method for producing a decorative board according to the present invention will be described. As shown in FIG.
1. A decorative sheet 2 is produced by laminating a thermoplastic resin film 14 provided with a printed pattern 13 and a porous sheet 15 such as a nonwoven fabric with an adhesive 12. Decorative sheet 2
First, a printing pattern 13 is printed on a thermoplastic resin film 14 such as polyvinyl chloride (hereinafter referred to as PVC) by gravure printing or the like to form a printing film, and the printing surface of the printing film is formed by corona discharge or the like. The treated fluororesin film 11 is dry-laminated with a urethane adhesive 12. Next, on the thermoplastic resin film side of the laminate film, a porous sheet 15 such as a nonwoven fabric is dry-laminated in the same manner as described above to produce a decorative sheet 2.

Further, the decorative sheet 2 and the FRP are molded in a mold such that the nonwoven fabric 15 of the decorative sheet 2 is in contact with a resin composition such as FRP (fiber reinforced plastic). The decorative board 1 is produced by being integrated. At this time, the resin component of the FRP penetrates into the non-woven fabric of the decorative sheet, and then the resin is cured and the decorative sheet 2 and the FRP
Is integrated, the decorative sheet 2 is firmly adhered to the FRP, a beautiful printed pattern is formed on the FRP, and since the surface is a fluororesin film, the decorative sheet 2 is excellent in weather resistance and stain resistance. .

A known fluororesin film is used as the fluororesin film. For example, polytetrafluoroethylene (PTFE), tetrafluoroethylene-
Perfluoroalkyl vinyl ether copolymer (PF
A), tetrafluoroethylene-hexafluoropropylene copolymer (FEP), ethylene-tetrafluoroethylene copolymer (ETFE), polychlorotrifluoroethylene (PCTFE), polyvinylidene fluoride (PVDF), polyvinyl fluoride ( PVF) and the like, and among these, stain resistance, weather resistance, adhesion,
From the viewpoint of suitability for processing such as film formation and lamination, ethylene-
Tetrafluoroethylene copolymer (ETFE) is preferred. In addition, ETFE includes those in which another third component is used in combination as a copolymerization monomer in order to improve physical properties.

[0012] The thickness of the fluororesin film is 10 to 50
μm, preferably 12 to 25 μm
Is good. If the thickness is less than 10 μm, the mechanical strength is reduced, the transportability during the production of the thermal laminate is poor, and the weather resistance is insufficient. On the other hand, when the thickness exceeds 50 μm, the performance becomes excessive in terms of weather resistance and the like, and the cost increases.

When the fluororesin film is laminated with another film, usually, the laminated surface is subjected to an easy adhesion treatment such as corona discharge or the like in order to improve the adhesion. In general, a transparent film is used as the fluororesin film, but it may be colored and used as a transparent or translucent film in order to make the printed pattern of the decorative sheet deep. In addition, a decorative sheet may be formed by forming a printed pattern on the back surface of the fluororesin film together with the thermoplastic resin film.

As the thermoplastic resin film used in the present invention, a film obtained by forming a known thermoplastic resin into a film is used. For example, polyvinyl chloride (hereinafter referred to as PVC), polyethylene terephthalate (PET), polyvinylidene chloride (PVDC), polypropylene (P
P), polyethylene (PE), polystyrene, polycarbonate, polyamide, ethylene-vinyl acetate copolymer, saponified ethylene-vinyl acetate copolymer, polybutylene terephthalate, polymethyl methacrylate, polymethyl methacrylate, polyethyl methacrylate, ABS A film or sheet such as is used. Further, a laminate of these films or sheets can also be used.

[0015] These thermoplastic resin films include:
Any transparent, translucent or opaque film can be used, and a colored film is also used. The colored film is
Titanium oxide, carbon black, red handle,
A film obtained by mixing other pigments, dyes, fillers and the like is used. The thickness of the thermoplastic resin film is
20 to 200 μm is preferred.

Gravure printing is often used as a method for forming a printed pattern on the thermoplastic resin film.
In addition, gravure offset printing, offset printing,
Letterpress printing, letterpress printing, flexographic printing, screen printing,
Electrostatic printing, ink jet printing and the like can be used. Examples of vehicles for printing ink include vinyl resins such as vinyl chloride-vinyl acetate copolymers, acrylic resins such as polymethyl methacrylate, cellulose resins such as nitrocellulose, amino alkyd resins, butyral resins, and polyester resins. An ink is prepared by blending these resins with pigments, dyes, and the like necessary for the ink. As the print pattern, a wood grain pattern such as cedar, zelkova, and cypress, a grain pattern such as marble or granite, or a grain pattern such as silk is used.

As the porous sheet used in the present invention, a non-woven fabric or a woven fabric is often used.
When integrally molded with a panel base material such as P, any material can be used as long as the resin component of the FRP easily penetrates, and is not limited to a nonwoven fabric or a woven fabric. Non-woven fabrics include organic fibers such as polyester, acrylic, nylon, polypropylene, rayon, acetate, polyvinyl chloride, cellulose, pulp, and vinylon, or glass fibers, asbestos, calcium titanate fibers, alumina fibers, silica fibers, and carbon fibers. Nonwoven fabrics and Japanese paper using inorganic fibers such as the above are used. In consideration of cost, physical properties, workability, strength, and the like, a polyester-based nonwoven fabric is preferable.

The nonwoven fabric used in the present invention has a thickness of 0.05 to 0.2 mm and a tensile strength of a normal SMC molding temperature (120 to 160 ° C.). It is preferable that the width is 0 kg / 15 mm or more. When the thickness of the non-woven fabric exceeds 0.2 mm, the resin does not wrap around at the end or the R portion of the molded product at the time of molding, and when the tensile strength is smaller than 2.0 kg / 15 mm width, the resin breaks at the time of molding. Poor adhesion to the panel substrate will occur. Further, when the thickness of the nonwoven fabric is less than 0.05 mm, the resin component of the FRP when integrally molded with the FRP,
The nonwoven fabric is not sufficiently impregnated, and the adhesive strength between the decorative sheet and the panel substrate becomes insufficient. These nonwoven fabrics and the thermoplastic resin film are laminated by a known laminating method. For example, lamination is performed by a dry lamination method using a urethane-based adhesive.

The panel substrate used in the present invention includes:
An FRP made of a thermosetting resin or a thermoplastic resin filled with reinforcing fibers is desirable. Glass fiber as the reinforcing fiber,
Carbon fibers are preferred, but not limited thereto. As the resin component, a thermoplastic resin such as polypropylene, polyamide, or polyester is used in addition to a thermosetting resin such as unsaturated polyester.

As an integral molding method of the decorative sheet and the panel base material, the decorative sheet is placed in advance in a molding die so that the fluororesin film surface of the decorative sheet is on the outside and the nonwoven fabric surface is in contact with the FRP material. Then, there is a method of molding by heating and pressing. In addition, the decorative sheet is preliminarily heated or
There is also a method in which the RP material is temporarily fixed and then pressed and molded in a molding die. Molding conditions such as heating temperature and mold clamping pressure can be performed in the same manner as the conventional FRP material molding conditions.

Further, a decorative sheet is placed on a mold,
Lay a glass fiber substrate (glass mat, glass cloth, etc.) on top of it, and apply an unsaturated polyester resin with a curing catalyst added on it with a brush or spray gun,
There is also a method in which a glass fiber base material is impregnated with an unsaturated polyester resin and cured, and then a mold is removed to obtain a molded product.

Next, the production of the material of the SMC used for the molding of the FRP and its processing method will be described. SMC (Sheet Molding Compound) is a sheet-like molding material in which a reinforcing material such as glass fiber is mixed with a thermosetting resin such as an unsaturated polyester, epoxy, or phenol resin. An FRP product is produced by heating and pressing.

As a method for producing the SMC, for example, a resin prepolymer, a curing catalyst, an accelerator, a curing retarder, an air drying agent, and the like, calcium carbonate, talc, and the like are provided on one surface of a first separator film such as a polyethylene film. , A compound obtained by kneading a filler such as clay is applied by a knife coat method or the like, and a chop strand obtained by cutting a glass roving obtained by bundling glass fibers is sprayed thereon to form a resin compound sheet. . Separately, a resin compound similar to that applied to the first separator film is applied to one surface of the second separator film in the same manner, and then the second separator film is applied to the chop strand surface of the first separator film. Laminate so that the resin compound of the film touches,
A method is adopted in which the laminated sheet is pressurized with a roll, the resin compound is impregnated in the chop strand, defoamed, and then heated and cured to form SMC. SMC
The resin is not particularly limited, but unsaturated polyester and epoxy are often used.

When a decorative board is manufactured using the SMC and the decorative sheet, the nonwoven fabric of the decorative sheet and the SMC are overlapped in a molding die so that the decorative sheet is in contact with the decorative sheet. Is integrally molded. Usually S
The molding conditions of MC are as follows: molding temperature: 120 to 160 ° C., molding pressure: 20 to 100 kg / cm ² , molding time: 5 to 20
Minutes. Molding using the SMC is not limited to a flat plate, but is also used for a molded article having a curved surface such as a bathtub.

[0025]

The present invention will be described below in more detail with reference to examples. (Example 1) As shown in FIG.
As 1, a 25 μm thick transparent ethylene-tetrafluoroethylene copolymer film (“Aflex ETFE” manufactured by Asahi Glass Co., Ltd.) is used, and the back surface thereof is subjected to corona treatment. The thickness of the thermoplastic resin film 14 is 80
μm polyvinyl chloride film (RIKEN Vinyl Industrial Co., Ltd.)
(R type)), and a stone pattern was gravure-printed with an acrylic gravure ink. As the porous sheet 15, a polyester nonwoven fabric having a thickness of 50 μm was prepared.

Next, as shown in FIG. 2, the ethylene-tetrafluoroethylene copolymer film 11 and the printed pattern 1
The PVC film 14 on which No. 3 was formed was dry-laminated using a urethane-based adhesive (main agent: polyol, curing agent: adhesive composed of isocyanate). The application amount of the adhesive was 2 g / m ² as a dry matter. Further, a non-woven fabric 15 is applied to the surface of the PVC film 14 of the laminate film.
Was subjected to dry lamination to produce a decorative sheet 2. The same adhesive was used as above, and the coating amount when dried was 8 g /
It was m ^2.

Further, as described below, the decorative sheet is
The decorative board was produced by integrally molding with MC. As SMC,
The following composition was used. Unsaturated polyester resin (Nippon Reichhall Co., Ltd. “Polylight KC-3”
8 "): 30 parts by weight, styrene monomer: 12 parts by weight,
Calcium carbonate: 40 parts by weight, methyl ethyl ketone peroxide: 1 part by weight, zinc stearate: 1.5 parts by weight, polymer solution for preventing shrinkage: 10 parts by weight.

Then, four SMCs each having a thickness of 4 mm are stacked by peeling off the front and back separate films.
As shown in FIG. 3, four pieces of SMC 17 are arranged on the male mold 19, and the nonwoven fabric 15 of the decorative sheet 2 is placed thereon. Next, the female mold 18 was closed, heated and pressed to perform panel molding. The molding conditions were a mold temperature of 150 ° C., a mold pressure of 50 kg / cm ² , and a molding time of 5 minutes. By the above-mentioned molding, a decorative plate made of FRP was obtained. This decorative plate had no breakage of the decorative sheet, had high designability, and had excellent weather resistance and stain resistance on the surface.

(Embodiment 2) As in Embodiment 1, the thickness 25
An ethylene-tetrafluoroethylene copolymer film having a thickness of μm and a polyvinyl chloride film having a thickness of 80 μm obtained by gravure printing a stone pattern were laminated. A glass cloth (manufactured by Asahi Fiber Glass Co., Ltd.) having a thickness of 120 μm was laminated on this laminated film using an adhesive in the same manner as in Example 1 to produce a decorative sheet 2.

Next, using this decorative sheet, Example 1 was used.
Similarly, the decorative sheet was placed in a mold so that the glass cloth of the decorative sheet was in contact with the SMC, and was integrally molded with the SMC to produce a decorative plate as shown in FIG. The decorative board obtained had high strength, high designability, and had excellent weather resistance and stain resistance on the surface.

[0031]

According to the present invention, a decorative sheet as a decorative surface material is formed by bonding three kinds of films, a fluororesin film, a printed thermoplastic resin film, and a porous film made of nonwoven fabric or woven fabric, to an adhesive. The decorative sheet is integrally formed so that the porous film side made of a nonwoven fabric or woven fabric is in contact with a panel base material such as FRP, so that the decorative sheet has high designability, and is resistant to weathering and contamination. It is possible to obtain an excellent decorative board. And, as described above, the decorative plate has a (surface) fluororesin film / adhesive / thermoplastic resin film having a printed pattern / adhesive / porous film made of nonwoven fabric or woven fabric / panel substrate. Thus, since there is a thermoplastic resin film having a printed pattern under the fluororesin film on the surface, the weather resistance and the stain resistance are excellent and the design is high. In addition, since the layer in contact with the panel substrate is a porous film such as a nonwoven fabric, the resin component of the panel substrate permeates the porous film during the molding of the decorative board, and the decorative sheet is strongly adhered to the panel substrate. Can be. Therefore, the strength is strong,
It is possible to obtain a decorative board having a high design property and a surface having excellent weather resistance and stain resistance, and is useful as a floor material, a wall material for interiors and exteriors.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view showing an example of a decorative board of the present invention.

FIG. 2 is a schematic sectional view of a decorative sheet used for a decorative board of the present invention.

FIG. 3 is an explanatory diagram for producing a decorative board of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Decorative board 2 Decorative sheet 11 Fluororesin film 12 Adhesive layer 13 Printing pattern 14 Thermoplastic resin film 15 Porous sheet (nonwoven fabric) 16 Panel base material 17 SMC 18 Female mold (upper mold) 19 Male mold (Lower mold)

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code Agency reference number FI Technical display location B32B 27/30 B32B 27/30 D

Claims (3)

[Claims] 1. A decorative sheet comprising a decorative sheet and a panel substrate, wherein the decorative sheet is formed by bonding three kinds of films: a fluororesin film, a printed thermoplastic resin film, and a porous film made of nonwoven fabric or woven fabric. The panel base material contains a resin component, and the decorative sheet and the panel base material are bonded to each other with the fluororesin film side of the decorative sheet facing outside, a nonwoven fabric or a woven fabric. The porous film side of the cloth is laminated so as to be in contact with the panel base material, and at the bonding surface of the porous film and the panel base material, the resin component of the panel base material has a void in the porous film made of a nonwoven fabric or a woven fabric. A decorative plate characterized by being impregnated into and integrated into the interior. 2. The decorative board according to claim 1, wherein the panel base material is FRP made of a thermosetting resin or a thermoplastic resin filled with reinforcing fibers. 3. The decorative board according to claim 1, wherein the fluororesin film is made of an ethylene-tetrafluoroethylene-based copolymer.