KR20190096631A - Decoration shee and method for manufacturing the same - Google Patents

Abstract

According to an aspect of the present invention, a decoration sheet which comprises: a resin sheet layer having ASA resin, PMMA resin, or mixed resin thereof, wherein a feature having a three-dimensional effect by a forming roller having a predetermined pattern is formed; and a metal layer formed on the resin sheet layer in which the feature is formed. The feature has roughness (Ra) of 10-100 μm.

Description

Decoration sheet and manufacturing method thereof {DECORATION SHEE AND METHOD FOR MANUFACTURING THE SAME}

The present disclosure relates to a decoration sheet and a method of manufacturing the same.

Polyvinyl chloride (PVC) has the advantages of low cost, flame retardancy, chemical resistance and easy hardness control of the product. Therefore, the Republic of Korea Patent No. 1191014 and the like provides a decorative sheet or edge band for furniture made of such a vinyl chloride resin.

However, since vinyl chloride resin has low weatherability, colorability and weather resistance, the surface easily touches or discolors when used for a long time. In addition, vinyl chloride resin uses a phthalate-based plasticizer which is treated as an environmental hormone estimator. Therefore, vinyl chloride resin is being used as a finishing material for furniture due to environmental problems.

Meanwhile, ABS resin (Acrylonitrile-Butadiene-Styrene Co-Polymer) is also used as a raw material for furniture such as decoration sheets and edge bands due to its low price, excellent impact strength, dimensional stability, environmental friendliness, and colorability. .

However, ABS resins are easily discolored in places exposed to sunlight because of low chemical resistance, weather resistance and weathering resistance. Therefore, the product molded by ABS resin has the trouble of laminating a separate coating film excellent in chemical resistance and weather resistance.

On the other hand, the design of the product has a very high impact on the purchase. Accordingly, most industrial products have various designs implemented on their surfaces. In particular, in order to increase the added value of plastic products, for example, a decorative sheet is attached to the surface to implement the design of natural materials. Decoration sheets are widely used as surface finishing materials for household appliances, automobile interior and exterior materials, furniture and buildings interior and exterior materials. In particular, the decorative sheet having a metallic texture (hair effect) and hairline pattern has been spotlighted as a decorative finishing material by providing a high aesthetic effect.

Republic of Korea Patent No. 1141757 manufactures a decoration sheet by depositing an aluminum layer on a PET film. However, in order to prevent peeling of the PET film, it is necessary to apply a primer between the PET film and the aluminum layer.

In general, a decoration sheet having a hairline metal effect is produced by scraping a hairline pattern directly onto a transparent film using an abrasive paper to implement a hairline, then depositing a metal layer and plywood the base sheet. In order to have a beautiful hairline metallic effect as a surface decoration effect, it must have a distinctive hairline pattern with a metallic texture. In this case, the transparent film should have excellent moldability to have a distinct hairline pattern. That is, the transparent film should have a certain flexibility so that the hairline pattern is well realized through the abrasive paper. In addition, the transparent film should have dimensional stability accompanying the manufacturing process. However, the transparent film has a problem that the dimensional stability has a limitation in the manufacturing process, or the moldability is not clear hairline pattern.

Korean Patent Laid-Open Publication No. 2017-0008222 discloses a composite membrane comprising an acrylonitrile styrene acrylate (ASA) copolymer layer comprising a textured pattern such as a hairline. However, the patent document does not form a feature having a pattern having a three-dimensional three-dimensional feeling in the metal layer and the ASA copolymer layer, and the decoration sheet has limitations in three-dimensionality, expression, and variety.

KR 1191014 B1 KR 1141757 B1 KR 2017-0008222 A

One aspect of the present disclosure is to provide a decoration sheet using an ASA resin and / or PMMA resin in which a feature having a three-dimensional three-dimensional effect with a large roughness Ra is formed.

Another aspect of the present disclosure is to provide a method of manufacturing the decoration sheet.

Decoration sheet according to an embodiment of the present disclosure for achieving the above one aspect,

A resin sheet layer comprising an ASA resin, a PMMA resin, or a mixed resin thereof in which a feature having a three-dimensional three-dimensional effect is formed by a molding roller having a predetermined pattern formed thereon; And

A metal layer formed on the resin sheet layer on which the feature is formed,

Here, the feature may have a roughness Ra of 10 μm to 100 μm.

According to an exemplary embodiment, the thickness of the resin sheet layer may be 50 ㎛ to 1000 ㎛.

According to an exemplary embodiment, the thickness of the metal layer is 1 μm to 5 μm, and the metal of the metal layer may be selected from at least one selected from the group consisting of aluminum, chromium, molybdenum, nickel, stainless steel, copper, silver, gold, and platinum. Can be.

According to an exemplary embodiment, the pattern may be selected from one or more of the group consisting of continuous or intermittent stripes, wave patterns and wood grain patterns.

Method for manufacturing a decoration sheet according to an embodiment of the present disclosure for achieving the above another aspect,

Providing a resin sheet layer comprising an ASA resin, a PMMA resin, or a mixed resin thereof;

Passing the sheet layer through a forming roller having a predetermined pattern to form a feature having a three-dimensional effect on the resin sheet layer; And

Forming a metal layer on the resin sheet layer on which the feature is formed;

Wherein the feature may have a roughness Ra of 10 μm to 100 μm.

According to an exemplary embodiment, the resin sheet layer may be provided using a T die.

According to an exemplary embodiment, the step of forming a three-dimensional three-dimensional feature in the sheet layer is performed by a roller operating at a temperature of 180 ℃ to 300 ℃ and a pressure of 10 kg / cm 2 to 250 kg / cm 2 Can be.

According to an exemplary embodiment, the thickness of the metal layer is 1 μm to 5 μm, and the metal of the metal layer may be selected from at least one selected from the group consisting of aluminum, chromium, molybdenum, nickel, stainless steel, copper, silver, gold, and platinum. Can be.

According to an exemplary embodiment, the pattern may be selected from one or more of the group consisting of continuous or intermittent stripes, wave patterns and wood grain patterns.

The decoration sheet according to the present disclosure may have a three-dimensional feature formed on the resin sheet layer by a forming roller having a predetermined pattern without an adhesive and a transfer film, and a metal layer formed along the feature. The feature may have a roughness Ra of 10 μm or more, so that the decoration sheet according to the present disclosure is excellent in three-dimensional effect and metal effect (metal texture).

1 shows a step of manufacturing a decoration sheet according to an embodiment of the present disclosure and a cross-sectional view of the decoration sheet at each step.
2 is a photograph of a decoration sheet in which a hairline is formed on an ASA resin layer using sand paper according to the related art.
3 is a photograph of a decoration sheet in which a feature having a three-dimensional three-dimensional effect is formed in a metal layer and a resin sheet layer according to an embodiment of the present disclosure.
4 is a photograph of a forming roller according to an embodiment of the present disclosure.

Before describing the disclosure in more detail, the terms or words used in the specification and claims are not to be limited to the common or dictionary meanings, and the concept of terms is appropriately described to best explain the invention. It should be interpreted as meanings and concepts corresponding to the technical spirit of the present disclosure on the basis of the principle that it can be defined. Accordingly, the configuration of the embodiments described herein is only one preferred example of the present disclosure, and does not represent all of the technical ideas of the present disclosure, and various equivalents and modifications that may be substituted for them at the time of the present application may be made. It should be understood that there may be

Hereinafter, exemplary embodiments of the present disclosure will be described in detail so that those skilled in the art may easily implement the present disclosure. In addition, in describing the present disclosure, detailed descriptions of related well-known technologies that may unnecessarily obscure the subject matter of the present disclosure will be omitted.

<Resin sheet layer>

Referring to FIG. 1, a resin sheet layer 10 having a predetermined thickness t1 may be provided. The resin sheet layer may include ASA resin, PMMA resin, or a mixed resin thereof.

The acrylonitrile styrene acrylate (ASA) resin can be any copolymer or blend known in the art consisting primarily of acrylonitrile, styrene and acrylate monomer moieties.

The acrylate used in the ASA resin can be any acrylic ester or acrylic acid known in the art. Preferably, the acrylate may be an alkyl acrylate ester wherein the alkyl moiety is an alkyl moiety having 1 to 10 carbon atoms (C1-C10 alkyl moiety). More preferably, the acrylate may be an alkyl acrylate ester wherein the alkyl moiety is an alkyl moiety having 1 to 8 carbon atoms, even more preferably 4 to 8 carbon atoms. Preferably, the acrylate is butyl acrylate (butyl acrylate ester), ethylhexyl acrylate (ethylhexyl acrylate ester), cyclohexyl acrylate (acrylic acid cyclohexyl ester), methyl acrylate (methyl acrylate ester), ethyl acrylate (Acrylic acid ethyl ester), propyl acrylate (acrylic acid propyl ester) and pentyl acrylate (acrylic acid pentyl ester), heptyl acrylate (acrylic acid heptyl ester), octyl acrylate (acrylic acid octyl ester). Even more preferably, the acrylate may be selected from the group consisting of butyl acrylate, ethylhexyl acrylate and cyclohexyl acrylate. Very preferably, the acrylate may be n-butyl acrylate or 2-ethylhexyl acrylate, in particular n-butyl acrylate.

The acrylate may optionally and preferably be copolymerized with one or more crosslinking monomer (s). Such comonomers are illustratively allyl (meth) acrylates (eg, allyl methacrylate, divinylbenzene, diallyl maleate, diallyl fumarate or diallyl phthalate), triallyl cyanurate, allyl (meth) Comonomers selected from the group consisting of acrylates, more preferably acrylic acid esters of tricyclodecane alcohol and / or dicyclopentadienyl acrylate.

In addition, the acrylate may optionally be selected from, for example, dienes (eg, 1,3-butadiene, isoprene), α-methylstyrene, methacrylonitrile, methyl acrylate, ethyl acrylate, propyl acrylate, methyl methacrylate, ethyl meta It may be copolymerized with one or more other comonomer (s) such as acrylate, phenylmaleimide, acrylamide and / or vinyl methyl ether.

Preferably, the ASA resin as used herein may comprise acrylate, ie acrylate-containing particles, in particulate form. These acrylate-containing particles may preferably comprise a graft base comprising an acrylate and, optionally, one or more comonomers such as those disclosed above by way of example. Preferably, the graft base comprises more than 60% (w / w) acrylate, more preferably more than 70% (w / w) acrylate, even more preferably more than 80% (w / w) acrylic Rate, even more preferably greater than 90% (w / w) acrylate, in particular greater than 95% (w / w) acrylate.

ASA resins used in the present disclosure may be commercially available, for example, Luran S polymer (ASA type available from Styrolution GmbH, Frankfurt am Main, Germany), or Geloy 1020 (General Electric) Can be used.

Polymethyl methacrylate (PMMA) resin is a polymer obtained by polymerizing methyl methacrylate CH ₂ = C (CH ₃ ) COOCH ₃ , and has excellent transparency and light resistance and a good balance of mechanical strength and formability.

As the PMMA resin used in the present disclosure, commercially available ones may be used, and for example, Plexiglas V052 (Altu Glass Co., Ltd.) may be used.

In some embodiments, the resin sheet layer 10 may be prepared by extruding ASA resin and / or PMMA resin by calendering or T dies. An extrusion process using a T die is a manufacturing process of extruding through a laterally straight die to form a sheet. This name is given because the die shape is T-shaped, and the molten ASA and / or PMMA resin is lowered into the die at the portion corresponding to the T-shape, diffused from side to side in the die, and extruded from the transverse portion above the T-shape. do. In order to produce a sheet having a uniform thickness and a wide lateral area, the resin sheet layer 10 can be produced preferably using a T die.

In one embodiment, the thickness t1 of the resin sheet layer 10 is 50 μm to 1000 μm, specifically 100 μm to 800 μm, more specifically 150 μm to 600 μm, most specifically 200 μm. To 400 μm. If the thickness t1 is smaller than 50 μm, the sheet layer may be damaged during the three-dimensional pattern formation process. If the thickness t1 is larger than 1000 μm, the three-dimensional pattern may not be formed in the forming roller.

<Feature with 3D Dimensionality>

The sheet layer is passed between uneven forming rollers having a predetermined pattern, so that the feature H having a three-dimensional three-dimensional effect having a predetermined pattern can be formed as shown in FIG. 1. The pattern may be one or a combination of continuous or intermittent stripes, waves, and wood grain patterns, but is not limited thereto.

Hairline Finish is a post-processing method that makes the metal material cut in one direction to give directional grain, making it more advanced. Aluminum, magnesium, and titanium were sanded or brushed in one direction to give the appearance of hair. In conventional decoration sheets, hairlines are formed using such sandpaper or metal brushes. Therefore, the roughness Ra of the conventional decoration sheet in which the hairline is formed is 0.5 μm to 5 μm, and the conventional decoration sheet does not have a three-dimensional three-dimensional effect.

However, according to the present disclosure, since a feature is formed in the resin sheet layer by a forming roller having a predetermined pattern and a metal layer is formed along the feature, the feature is 10 μm to 100 μm, specifically 20 μm to 90 It may have a three-dimensional three-dimensional feeling with a roughness (Ra) of 30 μm, more specifically 30 μm to 80 μm.

According to the present disclosure, the features of the same pattern may be formed not only in the metal layer but also in the resin sheet layer. Therefore, even if the thin metal layer of 1 micrometer-5 micrometers is formed in a resin sheet layer, since a feature is also formed in a sheet layer, the metal texture which has a three-dimensional three-dimensional feeling of the roughness Ra of 10 micrometers-100 micrometers can be expressed.

In some embodiments, the resin sheet layer is passed through a pair of forming rollers heated to a temperature of 180 ° C to 300 ° C, specifically 200 ° C to 280 ° C, more specifically 220 ° C to 260 ° C. A feature of a predetermined pattern can be formed in 10).

If the temperature of the forming roller is less than 180 ° C the features may not be formed, if greater than 300 ° C the features may collapse.

The pressure of the forming roller may be operated at a pressure of 10 kg / cm 2 to 250 kg / cm 2, specifically 20 kg / cm 2 to 200 kg / cm 2, more specifically 50 kg / cm 2 to 150 kg / cm 2. If the pressure is less than 10 kg / cm 2, it may not be possible to form a feature of uniform roughness, and if the pressure is greater than 150 kg / cm 2, the operation of forming the feature may be impossible.

4 is a photograph of a forming roller according to an embodiment of the present disclosure. The pattern is formed in the center roller, and the resin layer can pass between the roller on which the pattern is formed and the roller on which the pattern is not formed, while contacting the roller on which the pattern is formed.

<Metal layer>

The metal layer 20 is formed on the resin sheet layer 10 to impart a metal effect (metal texture) to the decoration sheet 100, which can be formed by various metal coating methods.

The metal constituting the metal layer 20 may be, for example, one or more selected from the group consisting of aluminum, chromium, molybdenum, nickel, stainless steel, copper, silver, gold, platinum, and the like. In addition, the metal layer 20 may be formed by various methods such as vacuum deposition, sputtering, paste coating, thermal deposition, and the like, and preferably, a sputtering method is applied.

In an exemplary embodiment, the metal layer 20 may be formed of aluminum. The aluminum layer is deposited using a conventional vacuum deposition method, and the metal layer may be formed by vacuum deposition at a vacuum of 10 ⁻² to 10 ⁻⁶ Torr and at a temperature of 300 to 1800 ° C.

The thickness t2 of the metal layer is preferably formed at 1 µm to 5 µm, specifically 2 µm to 4 µm, more specifically at 2.5 µm to 3.5 µm. If the thickness t2 of the metal layer is smaller than 1 µm, the metal texture may not be exhibited. If the thickness t2 is larger than 5 µm, the three-dimensional pattern may not be formed in the resin sheet layer.

FIG. 2 is a photograph of a decoration sheet on which an hairline is formed using sandpaper based on ASA resin according to the prior art, and FIG. 3 is a photograph of a decoration sheet according to an embodiment of the present disclosure.

The roughness Ra of the conventional decoration sheet shown in FIG. 2 is about 5 μm, and the roughness of the decoration sheet according to the present disclosure of FIG. 3 is about 50 μm. Therefore, the decoration sheet according to the present disclosure may exhibit a three-dimensional effect by about 10 times than the conventional decoration sheet.

<Adhesive layer>

In addition, the decoration sheet 100 according to the present disclosure may be applied in a manner of being attached through, for example, an adhesive (adhesive agent) when applied to products such as interior and exterior materials of automobiles, interior materials, furniture and buildings. At this time, the decoration sheet 100 according to the present disclosure, the pressure-sensitive adhesive layer (not shown) formed in the lower portion of the resin sheet layer 10 and the release member (not shown) formed in the lower portion of the pressure-sensitive adhesive layer further laminated It can have a structure. The release member is to be removed from the product after being applied to the product, which may be selected from a plastic film or paper of the release property.

Industrial Applicability

On the other hand, the decoration sheet 100 according to the present disclosure may be used as a surface finish of metal products or plastic products, for example, household appliances, interior and exterior materials of automobiles, interior and exterior materials of furniture and buildings, the product used It is not limited.

In addition, the decoration sheet 100 according to the present disclosure is preferably applied through the insert molding method in the case of plastic injection products. Specifically, when applied to a plastic injection product, after cutting the decoration sheet 100 according to the present disclosure to fit the size and shape of the injection product, and then put the decoration sheet 100 according to the present disclosure in the injection molding machine mold, It is good to apply by the method of injecting and solidifying the molten resin for injection products on the back surface of the decoration sheet 100.

Hereinafter, the present invention will be described in more detail with reference to the following examples, but the scope of the present invention is not limited to the following examples.

Example 1

A feature was formed on the ASA resin sheet layer having a thickness of about 100 μm using the roller shown in FIG. 4, and an aluminum metal layer having a thickness of about 2 μm was deposited to prepare a decoration sheet. The rollers were operated at a temperature of about 200 ° C. and a pressure of about 100 kg / cm 2.

Example 2

A decoration sheet was prepared in the same manner as in Example 1, except that PMMA resin was used instead of ASA resin.

Comparative Example 1

A decoration sheet was prepared in the same manner as in Example 1, except that PVC resin was used instead of ASA resin.

Comparative Example 2

A decoration sheet was prepared in the same manner as in Example 1, except that PET resin was used instead of ASA resin.

Experimental Example

About the decoration sheet obtained by the Example and the comparative example, it is shown in Table 1 by experimenting about weather resistance, moldability, heat resistance, impact resistance, a roughness, etc.

Example 1 Example 2 Comparative Example 1 Comparative Example 2 Weather resistance More than 240 hours More than 230 hours 20 hours 30 hours Formability Moldable Moldable Molding impossible (cracking) Molding impossible (cracking) Heat resistance Maintain initial adhesion Maintain initial adhesion Peeling Peeling Impact resistance pass pass Peeling offshoot Roughness (Ra) 50 μm 45 μm Measurement not possible due to molding Inability to measure due to non-molding

-Weather resistance: Measure the gloss change rate after a certain time using Q-Panel's QUV. (Delta E = 0.3 or less)

-Formability: There should be no crack in the bent part after molding

-Heat resistance: Passed if initial adhesion is maintained after 300 hours at 80 ℃

-Impact resistance: A weight (12.7 mm in diameter, 0.5 kg in weight) is dropped at a height of 20 cm and passes if there is no peeling or cracking from the resin layer of the metal layer.

Roughness: Measured using AFM (atomic force microscopy) (XE-100, PARK system).

Although the present invention has been described in detail through specific examples, it is intended to describe the present invention in detail, and the present invention is not limited thereto, and it should be understood by those skilled in the art within the technical spirit of the present invention. It is obvious that modifications and improvements are possible.

All simple modifications and variations of the present invention fall within the scope of the present invention, and the specific scope of protection of the present invention will be apparent from the appended claims.

Claims (10)

A resin sheet layer comprising an ASA resin, a PMMA resin, or a mixed resin thereof in which a feature having a three-dimensional three-dimensional effect is formed by a molding roller having a predetermined pattern formed thereon; And
A metal layer formed on the resin sheet layer on which the feature is formed,
Wherein the feature has a roughness Ra of 10 μm to 100 μm. The method according to claim 1,
The thickness of the resin sheet layer is a decoration sheet 50㎛ to 1000㎛. The method according to claim 1,
The metal layer has a thickness of 1 μm to 5 μm, and the metal of the metal layer is one or more selected from the group consisting of aluminum, chromium, molybdenum, nickel, stainless steel, copper, silver, gold and platinum. The method according to claim 1,
Wherein said pattern is one or more selected from the group consisting of continuous or intermittent stripes, waves, and wood grain patterns. Providing a resin sheet layer comprising an ASA resin, a PMMA resin, or a mixed resin thereof;
Passing the sheet layer through a forming roller having a predetermined pattern to form a feature having a three-dimensional effect on the resin sheet layer; And
Forming a metal layer on the resin sheet layer on which the feature is formed;
Wherein the feature has a roughness Ra of 10 μm to 100 μm. The method according to claim 5,
And the resin sheet layer is provided using a T die. The method according to claim 5,
Forming a feature having a three-dimensional three-dimensional feeling in the sheet layer is a manufacturing method of a decoration sheet is performed by a roller operating at a temperature of 180 ℃ to 300 ℃ and a pressure of 10 kg / cm 2 to 250 kg / cm 2. The method according to claim 5,
The resin sheet layer has a thickness of 50 μm to 1000 μm. The method according to claim 5,
The metal layer has a thickness of 1 μm to 5 μm, and the metal of the metal layer is one or more selected from the group consisting of aluminum, chromium, molybdenum, nickel, stainless steel, copper, silver, gold and platinum. The method according to claim 5,
The pattern is a method of producing a decoration sheet at least one selected from the group consisting of continuous or intermittent stripes, wave patterns and wood grain patterns.

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