WO2008018715A1 - High glossy sheet having aluminum foil - Google Patents

High glossy sheet having aluminum foil Download PDF

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Publication number
WO2008018715A1
WO2008018715A1 PCT/KR2007/003693 KR2007003693W WO2008018715A1 WO 2008018715 A1 WO2008018715 A1 WO 2008018715A1 KR 2007003693 W KR2007003693 W KR 2007003693W WO 2008018715 A1 WO2008018715 A1 WO 2008018715A1
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WO
WIPO (PCT)
Prior art keywords
film
layer
aluminum foil
high glossy
glossy sheet
Prior art date
Application number
PCT/KR2007/003693
Other languages
French (fr)
Inventor
Jongyeoul Park
Jangwon Lee
Original Assignee
Kangnam Chemical Co., Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kangnam Chemical Co., Ltd filed Critical Kangnam Chemical Co., Ltd
Publication of WO2008018715A1 publication Critical patent/WO2008018715A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/09—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/406—Bright, glossy, shiny surface

Definitions

  • the present invention relates to a high glossy sheet which is attached to a plate such as an aluminum plate, an iron plate, a steel plate, and the like to show a metal effect, and more particularly, to a sheet which does not include a polyvinyl chloride (PVC) film but includes an aluminum film which is provided with a pattern such as a hairline on a surface thereof and is directly attached to a plate so as to be environment- friendly, significantly reduce the number of processes and manufacturing costs, have a surface almost similar to that of a metal plate, and be applied as a finish material of building materials, furniture, and electronic appliances, and the like.
  • PVC polyvinyl chloride
  • a metal such as a stainless steel plate is used as a finish material for an elegant appearance.
  • the metal requires very high costs, and fingerprint marks remain or a scratch easily occurs on a surface of the metal, so that there is problem in that a user cannot easily manage the metal.
  • a high glossy sheet in which a polyvinyl chloride (PVC) film layer, an adhesive layer, an aluminum-deposited thin film layer, a hairline-processed polyethylene terepthalate (PET) film layer, and a top-coating layer are sequentially disposed from bottom to top is well known.
  • This sheet shows an appearance having the texture and color similar to that of the metal plate through the hairline-processed PET film layer and the aluminum-deposited thin film layer, and obtains physical properties such as an anti-fingerprint property and a scratch resistance through a coating on the surface.
  • adhesion between the aluminum thin film layer and the PET layer is weak, there is a problem in that the two layers of the sheet can be easily separated from each other when the sheet is manufactured.
  • 2006-78530 discloses a method of providing a primer for improving the adhesion between the aluminum thin film layer and the PET film layer.
  • providing the primer layer between the two layers improves the adhesion between the aluminum-deposited thin film layer and the PET film layer, it may cause an increase in the number of processes and the cost of materials.
  • the hairline pattern cannot be implemented. Therefore, the primer treatment has to be performed so as not to thoroughly fill the valleys and peaks with the primer. However, this may cause a problem in that firm adhesion between the PET and the deposited layer cannot be obtained.
  • the aforementioned conventional sheets commonly include the hairline- processed PET in order to have the texture similar to that of the metal surface.
  • the hairline process which is performed on the PET only technologically continuous hairline can be formed, so that design implemented in the conventional sheets is very limited. Therefore, it is difficult to implement a beautiful appearance to be similar to that of the natural metal material having irregular hairlines.
  • the conventional sheets include PVC films on most of layers. This is because the adhesion of the PVC film is excellent when the sheet having the PVC film is attached to a cold rolled steel plate or a plated steel plate that is widely used for building materials and electronic appliances through an adhesive, and the cost thereof is cheap.
  • the PVC film emits large amounts of dioxin when it is burned.
  • the dioxin is a colorless carcinogen that is ranked by World Health Organization (WHO) in 1992 as a first grade carcinogen that can be inherited and is classified by World Wildlife Fund (WWF) as an affirmative environmental hormone. Even if very small amounts of the dioxin are accumulated in the human body, it may cause fatal results. Therefore, the use of the PVC is restricted all over the world, and a demand for an environment- friendly material for the high glossy sheet to replace the PVC increases.
  • WHO World Health Organization
  • WWF World Wildlife Fund
  • the conventional sheet may have an environment-friendly film instead of the PVC film.
  • the environment-friendly film is applied, the cost of the high glossy sheet significantly increases.
  • an object of the present invention is to provide a high glossy sheet in which a separation phenomenon does not occur, various surfaces can be designed, and a surface almost similar to that of a metal plate can be implemented.
  • Another object of the present invention is to provide a high glossy sheet which does not include a polyvinyl chloride (PVC) film so as to be environment-friendly and significantly reduce the number of processes and manufacturing costs.
  • PVC polyvinyl chloride
  • Another object of the present invention is to provide a high glossy sheet which implements various colors at a low cost.
  • a high glossy sheet which is attached to a plate and shows an appearance similar to that of a metal surface, including: a polyethylene terepthalate (PET) film disposed at the top layer; an adhesive layer applied to a lower surface of the PET film layer; an aluminum foil disposed at a lower surface of the adhesive layer; and a primer layer applied to a lower surface of the aluminum foil.
  • PET polyethylene terepthalate
  • the high glossy sheet according to the present invention is attached to an aluminum plate, a cold rolled steel plate, or a plated steel plate by using an adhesive.
  • the high glossy sheet according to the present invention includes the aluminum foil manufactured by a rolling process, a problem of separation at an interface between a deposited layer and a PET caused by a low coherence between particles of the conventional aluminum deposited layer or a weak metal deposition adhesion between the PET layer and the primer layer can be solved.
  • the high glossy sheet according to the present invention has a good adhesive when directly attached to an aluminum plate, an iron plate, a cold rolled steel plate, or a plated steel plate through the adhesive. Therefore, a process of forming a thermoplastic resin film, particularly a polyvinyl chloride (PVC) film on a conventional high glossy sheet can be omitted, so that the high glossy sheet is environment-friendly, processes can be simplified, and manufacturing costs can be significantly reduced.
  • PVC polyvinyl chloride
  • various patterns such as a hairline and the like may be formed on an upper surface of the aluminum foil layer.
  • the pattern formed on the upper surface of the foil layer may be formed by forming the pattern on a roller and transferring the pattern on the roller to the upper surface thereof.
  • patterns such as the hairline and the like are provided to the aluminum foil unlike in a conventional sheet. Therefore, as compared with a hairline-processed PET film, types of the patterns that can be formed are not limited, and the patterns are more natural in appearance.
  • a UV cured resin or a thermosetting resin layer may be formed on the upper surface of the PET film, and the resin layer may include a pigment for representing a sheet color.
  • the adhesive layer may include a pigment.
  • a pigment is mixed with a UV cured resin or a thermosetting resin layer applied to the top surface of the sheet to provide a color.
  • a pigment is applied to the adhesive. Therefore, although the UV cured resin or the thermosetting resin layer is not applied to the top surface of the sheet, various colors can be provided. Accordingly, a lower-cost high glossy sheet having various colors can be provided to meet various demands.
  • an adhesive layer may be additionally formed on a lower portion of the primer layer, and a film which is selected from among a PET film, a polyethylene (PE) film, a propylene (PP) film, and a nylon (NY) film to be disposed at a lower portion of the adhesive layer.
  • a film which is selected from among a PET film, a polyethylene (PE) film, a propylene (PP) film, and a nylon (NY) film to be disposed at a lower portion of the adhesive layer.
  • the PET, PE, PP, or NY film is provided to the lower portion so that a rough feeling is not externally shown although a surface of the aluminum plate, the cold rolled plate, or the plated steel plate is rough.
  • a high glossy sheet which is attached to a plate and shows an appearance similar to that of a metal surface, including: a PET film disposed at the top layer; an adhesive layer applied to a lower surface of the PET film layer; an aluminum foil disposed at a lower surface of the adhesive layer; an adhesive layer applied to a lower surface of the aluminum foil; and a thermoplastic resin film disposed at a lower surface of the adhesive layer.
  • the high glossy sheet does not include an aluminum-deposited layer, so that high-mix low- volume manufacturing can be applied.
  • the high glossy sheet includes the aluminum foil, and various surface patterns can be provided thereto in the manufacturing processes, so that design degree of freedom significantly increases as compared with the hairline-processed PET film, and natural expression of the patterns can be implemented.
  • thermoplastic resin film may be one of the PET, PE, PP, NYLON, and the PVC films.
  • the high glossy sheet according to the present invention does not includes a metal-deposited layer, so that a separation phenomenon between a polyethylene terepthalate (PET) film and a deposited layer, which is a problem of a conventional high glossy sheet does not occur, high-mix low- volume manufacturing can be applied, and LOT deviation is significantly reduced.
  • PET polyethylene terepthalate
  • a surface process of providing texture to the high glossy sheet is not performed on the PET film, and the surface process is performed by transferring a pattern formed on a roller when an aluminum foil is rolled. Therefore, various patterns such as a hairline and the like can be formed, and a natural appearance similar to that of a metal surface can be obtained.
  • the high glossy sheet according to the present invention does not includes a thermoplastic resin such as a polyvinyl chloride (PVC) film on a lower layer, and a primer treatment is performed on the aluminum foil and the primer-treated aluminum foil is directly attached to a steel plate, so that the number of processes and the cost of materials can be significantly reduced.
  • a thermoplastic resin such as a polyvinyl chloride (PVC) film
  • PVC polyvinyl chloride
  • FIG. 1 is a cross-sectional view illustrating a high glossy sheet according to a first embodiment of the present invention.
  • FIG. 2 is a cross-sectional view illustrating a high glossy sheet according to a second embodiment of the present invention.
  • FIG. 3 is a cross-sectional view illustrating a high glossy sheet according to a related art.
  • thermosetting resin 101 which includes acrylic polyol polymerized resin of from 60 to 90 wt% and urethane curing agent of from 10 to 40 wt% is applied, and the PET film 102 applied with the thermosetting resin 101 is thermally cured at a temperature of 6O 0 C.
  • a polyurethane-based adhesive 103 to which a translucent pigment of from 1 to 10 wt% is added is distributively applied, and a aluminum foil 104 which is hairline-processed by using a dry lamination method to have a thickness of from 8 to 25 D is attached thereto.
  • a thermal curing process is performed on the above-constructed structure for about from three to five days.
  • a polyurethane-based primer 105 is applied on a lower surface of the aluminum foil 104. Accordingly a high glossy sheet 100 having the cross-section as illustrated in FIG. 1 is manufactured.
  • thermosetting resin 101 that is a top coating material applied on the top layer of the high glossy sheet 100 according to the first embodiment of the present invention is employed to provide surface characteristics such as a scratch resistance that the PET film 102 lacks and is selectively employed as needed.
  • a UV cured resin such as acryl, methacryl vinyl group allyl group, and the like can be used.
  • pigments can be distributed and mixed to be applied to the PET film 102.
  • the pigments that are distributed and included in the adhesive 103 are employed to provide various colors to the high glossy sheet. Any pigment that has a good dispersive property and is translucent so that a hairline pattern 106 formed on the aluminum foil 104 under the adhesive 103 is shown through the PET film can be applied.
  • the aluminum foil 104 is manufactured by rolling an aluminum plate.
  • various patterns are formed on a roller that is used for the rolling, so that the patterns on the roller are transferred to a surface of the rolled aluminum foil when the rolling is performed so as to form a surface pattern such as the hairline, or the like.
  • the aluminum foil that is rolled to have a thickness of from 8 to 50 D is processed through a degreasing and softening process of rolling oil. If needed, the thickness can be increased.
  • the primer 105 is a monomer of a polymer included in a primer layer and includes a polyester copolymer which is manufactured to include adipic acid of from 20 to 30 wt%, terephthalic acid of from 10 to 20 wt%, isophthalic acid of from 10 to 15 wt%, ethylene glycol of from 25 to 30 wt%, and neopentyl glycol of from 20 to 25 wt%.
  • adipic acid of from 20 to 30 wt%
  • terephthalic acid of from 10 to 20 wt%
  • isophthalic acid of from 10 to 15 wt%
  • ethylene glycol of from 25 to 30 wt%
  • neopentyl glycol of from 20 to 25 wt%.
  • thermosetting resin 201 which includes acrylic polyol polymerized resin of from 60 to 90 wt% and urethane curing agent of from 10 to 40 wt% is applied, and the PET film202 applied with the thermosetting resin 201 is thermally cured at a temperature of 6O 0 C.
  • a polyurethane-based adhesive 203 to which a translucent pigment of from 1 to 10 wt% is added is distributively applied, and a aluminum foil 104 which is hairline- processed by using a dry lamination method to have a thickness of from 8 to 25 D is attached thereto.
  • a polyurethane-based adhesive 205 is applied and dried. Thereafter, a linear low density polyethylene (LLDPE) film 206 having a thickness of about 80D is attached thereto. Accordingly a high glossy sheet having the cross-section as illustrated in FIG. 2 is manufactured.
  • LLDPE linear low density polyethylene
  • a UV cured resin 301 is applied, and the PET film 302 applied with the UV cured resin is illuminated with UV to be cured. Thereafter, on the other surface of the PET film 302, a hairline 307 pattern is formed.
  • a primer layer 303 which is formed by coating a toluene solution in which a polyester-based primer that is manufactured by polymerizing adipic acid of 25wt%, terephthalic acid of 15wt%, isophthalic acid of 13wt%, ethylene glycol of 27wt%, and neopentyl glycol of 22wt%, is dissolved, on the surface with the hairline 307, and drying the coated surface to have a thickness of 0.7D.
  • an aluminum vacuum-deposited layer 304 having an average thickness of 400A is formed thereon by performing a vacuum deposition process at a temperature of 10 torr 142O 0 C, a polyure thane adhesive 305 is applied on a lower surface of the deposited layer, and a PVC film 306 having a thickness of 105D is attached thereto. Accordingly, a conventional high glossy sheet 300 having the cross-section as illustrated in FIG. 3 is manufactured.
  • the high glossy sheets manufactured as described above according to the first and second embodiments of the present invention and the comparative example are attached to a GI steel plate (Galvanized steel plate) using a polyurethane-based adhesive, and a visual inspection, an Erichsen test, a boiling water resistance test for 100 0 CxI hour, and a spraying test of a salt water resistance for 250 hours are performed, and results thereof are illustrated in Table 1.
  • the high glossy sheets according to the present invention have good appearances without the rainbow phenomenon.
  • the deposited layer is damaged by heat and pressure in the manufacturing processes, a color tone around the damaged deposited layer is not clear, and the rainbow phenomenon occurs as an oil film is formed.
  • the pattern of the high glossy sheet according to the comparative example is not natural as compared with the high glossy sheets including the hairline- processed aluminum foils that have metal surfaces according to the first and second embodiments of the present invention.
  • the PET since the PET and the aluminum foil according to the first and second embodiments of the present invention are completely unified by the adhesive, the forcible separation cannot be achieved. On the contrary, in the comparative example, the PET is separated.
  • the aluminum foil is treated with the primer and directly attached to the GI steel plate, the Erichsen test, the boiling water resistance test, and the spraying test of a salt water resistance show better or the same results as compared with the comparative example.

Abstract

Provided is a high glossy sheet which is attached to a plate such as an aluminum plate, an iron plate, a steel plate, and the like to show a metal effect. An object of the present invention is to provide a sheet which is environment-friendly, significantly reduces the number of processes and manufacturing costs, has a surface almost similar to that of a metal plate. In order to accomplish the object, the present invention provides a high glossy sheet which is attached to a plate and shows an appearance similar to that of a metal surface, including: a polyethylene terepthalate (PET) film disposed at the top layer; an adhesive layer applied to a lower surface of the PET film layer; an aluminum foil disposed at a lower surface of the adhesive layer; and a primer layer applied to a lower surface of the aluminum foil.

Description

Description HIGH GLOSSY SHEET HAVING ALUMINUM FOIL
Technical Field
[1] The present invention relates to a high glossy sheet which is attached to a plate such as an aluminum plate, an iron plate, a steel plate, and the like to show a metal effect, and more particularly, to a sheet which does not include a polyvinyl chloride (PVC) film but includes an aluminum film which is provided with a pattern such as a hairline on a surface thereof and is directly attached to a plate so as to be environment- friendly, significantly reduce the number of processes and manufacturing costs, have a surface almost similar to that of a metal plate, and be applied as a finish material of building materials, furniture, and electronic appliances, and the like. Background Art
[2] Conventionally, in building construction and manufacturing of electronic appliances, a metal such as a stainless steel plate is used as a finish material for an elegant appearance. However, the metal requires very high costs, and fingerprint marks remain or a scratch easily occurs on a surface of the metal, so that there is problem in that a user cannot easily manage the metal.
[3] As a replacement, as illustrated in FIG. 3, a high glossy sheet in which a polyvinyl chloride (PVC) film layer, an adhesive layer, an aluminum-deposited thin film layer, a hairline-processed polyethylene terepthalate (PET) film layer, and a top-coating layer are sequentially disposed from bottom to top, is well known. This sheet shows an appearance having the texture and color similar to that of the metal plate through the hairline-processed PET film layer and the aluminum-deposited thin film layer, and obtains physical properties such as an anti-fingerprint property and a scratch resistance through a coating on the surface. However, since adhesion between the aluminum thin film layer and the PET layer is weak, there is a problem in that the two layers of the sheet can be easily separated from each other when the sheet is manufactured.
[4] In order to solve the aforementioned problem, Korean Patent Application No.
2006-78530 discloses a method of providing a primer for improving the adhesion between the aluminum thin film layer and the PET film layer. However, although providing the primer layer between the two layers improves the adhesion between the aluminum-deposited thin film layer and the PET film layer, it may cause an increase in the number of processes and the cost of materials.
[5] In addition, during a primer treatment that is performed on the hairline-processed
PET layer, when peaks and valleys of the hairline are thoroughly filled with the primer, the hairline pattern cannot be implemented. Therefore, the primer treatment has to be performed so as not to thoroughly fill the valleys and peaks with the primer. However, this may cause a problem in that firm adhesion between the PET and the deposited layer cannot be obtained.
[6] Moreover, the aforementioned conventional sheets commonly include the hairline- processed PET in order to have the texture similar to that of the metal surface. In this case, in a hairline process which is performed on the PET, only technologically continuous hairline can be formed, so that design implemented in the conventional sheets is very limited. Therefore, it is difficult to implement a beautiful appearance to be similar to that of the natural metal material having irregular hairlines.
[7] Furthermore, the conventional sheets include PVC films on most of layers. This is because the adhesion of the PVC film is excellent when the sheet having the PVC film is attached to a cold rolled steel plate or a plated steel plate that is widely used for building materials and electronic appliances through an adhesive, and the cost thereof is cheap.
[8] However, the PVC film emits large amounts of dioxin when it is burned. The dioxin is a colorless carcinogen that is ranked by World Health Organization (WHO) in 1992 as a first grade carcinogen that can be inherited and is classified by World Wildlife Fund (WWF) as an affirmative environmental hormone. Even if very small amounts of the dioxin are accumulated in the human body, it may cause fatal results. Therefore, the use of the PVC is restricted all over the world, and a demand for an environment- friendly material for the high glossy sheet to replace the PVC increases.
[9] In addition, the conventional sheet may have an environment-friendly film instead of the PVC film. However, when the environment- friendly film is applied, the cost of the high glossy sheet significantly increases.
[10] In addition, in a deposition-type sheet product, the PVC film which forms the lowest layer of the sheet is shown though a deposited layer, so that a color of the PVC film may affect the outer appearance. Therefore, the color and the texture of the surface cannot have various types and a design diversity is limited.
[11] In addition, in a metal deposition process, a uniform deposition density and a uniform PVC color cannot be easily accomplished, so that a LOT color deviation occurs. In addition, due to characteristics of the deposition process which is generally performed at a speed of 500M per minute, the deposition process is not appropriate to high-mix low- volume manufacturing.
[12] In addition, since the manufacturing process of the conventional sheet is complex, productivity decreases. In addition, since manufacturing losses occur per each process, the yield is low, and an initial production cost is high. Disclosure of Invention Technical Problem
[13] In order to solve a problem of the aforementioned deposition-type high glossy sheet having the metal thin film, an object of the present invention is to provide a high glossy sheet in which a separation phenomenon does not occur, various surfaces can be designed, and a surface almost similar to that of a metal plate can be implemented.
[14] Another object of the present invention is to provide a high glossy sheet which does not include a polyvinyl chloride (PVC) film so as to be environment-friendly and significantly reduce the number of processes and manufacturing costs.
[15] Another object of the present invention is to provide a high glossy sheet which implements various colors at a low cost. Technical Solution
[16] According to an aspect of the present invention, there is provided a high glossy sheet which is attached to a plate and shows an appearance similar to that of a metal surface, including: a polyethylene terepthalate (PET) film disposed at the top layer; an adhesive layer applied to a lower surface of the PET film layer; an aluminum foil disposed at a lower surface of the adhesive layer; and a primer layer applied to a lower surface of the aluminum foil.
[17] The high glossy sheet according to the present invention is attached to an aluminum plate, a cold rolled steel plate, or a plated steel plate by using an adhesive.
[18] Since the high glossy sheet according to the present invention includes the aluminum foil manufactured by a rolling process, a problem of separation at an interface between a deposited layer and a PET caused by a low coherence between particles of the conventional aluminum deposited layer or a weak metal deposition adhesion between the PET layer and the primer layer can be solved.
[19] In addition, since a primer treatment is performed on the lower portion of the aluminum foil, the high glossy sheet according to the present invention has a good adhesive when directly attached to an aluminum plate, an iron plate, a cold rolled steel plate, or a plated steel plate through the adhesive. Therefore, a process of forming a thermoplastic resin film, particularly a polyvinyl chloride (PVC) film on a conventional high glossy sheet can be omitted, so that the high glossy sheet is environment-friendly, processes can be simplified, and manufacturing costs can be significantly reduced.
[20] In addition, since an aluminum deposition process is omitted, problems that occur in the conventional aluminum deposition process can also be omitted.
[21] In addition, various patterns such as a hairline and the like may be formed on an upper surface of the aluminum foil layer. The pattern formed on the upper surface of the foil layer may be formed by forming the pattern on a roller and transferring the pattern on the roller to the upper surface thereof. As described above, patterns such as the hairline and the like are provided to the aluminum foil unlike in a conventional sheet. Therefore, as compared with a hairline-processed PET film, types of the patterns that can be formed are not limited, and the patterns are more natural in appearance.
[22] In addition, in order to protect an upper surface of the PET film layer, a UV cured resin or a thermosetting resin layer may be formed on the upper surface of the PET film, and the resin layer may include a pigment for representing a sheet color.
[23] In addition, the adhesive layer may include a pigment. For the conventional sheet, a pigment is mixed with a UV cured resin or a thermosetting resin layer applied to the top surface of the sheet to provide a color. However, according to the present invention, a pigment is applied to the adhesive. Therefore, although the UV cured resin or the thermosetting resin layer is not applied to the top surface of the sheet, various colors can be provided. Accordingly, a lower-cost high glossy sheet having various colors can be provided to meet various demands.
[24] In addition, an adhesive layer may be additionally formed on a lower portion of the primer layer, and a film which is selected from among a PET film, a polyethylene (PE) film, a propylene (PP) film, and a nylon (NY) film to be disposed at a lower portion of the adhesive layer.
[25] The PET, PE, PP, or NY film is provided to the lower portion so that a rough feeling is not externally shown although a surface of the aluminum plate, the cold rolled plate, or the plated steel plate is rough.
[26] According to another aspect of the present invention, there is provided a high glossy sheet which is attached to a plate and shows an appearance similar to that of a metal surface, including: a PET film disposed at the top layer; an adhesive layer applied to a lower surface of the PET film layer; an aluminum foil disposed at a lower surface of the adhesive layer; an adhesive layer applied to a lower surface of the aluminum foil; and a thermoplastic resin film disposed at a lower surface of the adhesive layer.
[27] As described above, the high glossy sheet does not include an aluminum-deposited layer, so that high-mix low- volume manufacturing can be applied. In addition, the high glossy sheet includes the aluminum foil, and various surface patterns can be provided thereto in the manufacturing processes, so that design degree of freedom significantly increases as compared with the hairline-processed PET film, and natural expression of the patterns can be implemented.
[28] The thermoplastic resin film may be one of the PET, PE, PP, NYLON, and the PVC films.
Advantageous Effects
[29] As described above, the high glossy sheet according to the present invention does not includes a metal-deposited layer, so that a separation phenomenon between a polyethylene terepthalate (PET) film and a deposited layer, which is a problem of a conventional high glossy sheet does not occur, high-mix low- volume manufacturing can be applied, and LOT deviation is significantly reduced.
[30] In addition, a surface process of providing texture to the high glossy sheet is not performed on the PET film, and the surface process is performed by transferring a pattern formed on a roller when an aluminum foil is rolled. Therefore, various patterns such as a hairline and the like can be formed, and a natural appearance similar to that of a metal surface can be obtained.
[31] In addition, the high glossy sheet according to the present invention does not includes a thermoplastic resin such as a polyvinyl chloride (PVC) film on a lower layer, and a primer treatment is performed on the aluminum foil and the primer-treated aluminum foil is directly attached to a steel plate, so that the number of processes and the cost of materials can be significantly reduced.
[32] In addition, the PVC film is not used, so that the high glossy sheet uses environment-friendly materials. Brief Description of the Drawings
[33] FIG. 1 is a cross-sectional view illustrating a high glossy sheet according to a first embodiment of the present invention.
[34] FIG. 2 is a cross-sectional view illustrating a high glossy sheet according to a second embodiment of the present invention.
[35] FIG. 3 is a cross-sectional view illustrating a high glossy sheet according to a related art.
[36] Description of Reference Numerals and Signs
[37] 100, 200: high glossy sheet
[38] 101, 201: thermosetting resin
[39] 102, 202: PET film
[40] 103, 203: adhesive
[41] 104, 204: aluminum foil
[42] 105: primer
[43] 106,207: hairline
[44] 205: adhesive
[45] 206: LLDPE film
Best Mode for Carrying Out the Invention
[46] Hereinafter, exemplary embodiments of the present invention will be described in detail. However, the invention may be embodied in many different forms without departing from the spirit and scope of the present invention and should not be construed as being limited to the embodiments set forth herein.
[47] [Embodiment 1]
[48] On a surface of a transparent polyethylene terepthalate (PET) film 102 which has a degree of haze of 6%, a light transmittance of 92% or more, a gloss of 160% or more, and a thickness of about 25D, a thermosetting resin 101 which includes acrylic polyol polymerized resin of from 60 to 90 wt% and urethane curing agent of from 10 to 40 wt% is applied, and the PET film 102 applied with the thermosetting resin 101 is thermally cured at a temperature of 6O0C. Next, on the other surface of the PET film 102 applied with the thermosetting resin 101, a polyurethane-based adhesive 103 to which a translucent pigment of from 1 to 10 wt% is added is distributively applied, and a aluminum foil 104 which is hairline-processed by using a dry lamination method to have a thickness of from 8 to 25 D is attached thereto. Next, at a temperature of from 50 to 60 0C, a thermal curing process is performed on the above-constructed structure for about from three to five days. Thereafter, a polyurethane-based primer 105 is applied on a lower surface of the aluminum foil 104. Accordingly a high glossy sheet 100 having the cross-section as illustrated in FIG. 1 is manufactured.
[49] The thermosetting resin 101 that is a top coating material applied on the top layer of the high glossy sheet 100 according to the first embodiment of the present invention is employed to provide surface characteristics such as a scratch resistance that the PET film 102 lacks and is selectively employed as needed. Instead of the thermosetting resin, a UV cured resin such as acryl, methacryl vinyl group allyl group, and the like can be used. In addition, in order to provide various colors to the high glossy sheet 100, pigments can be distributed and mixed to be applied to the PET film 102.
[50] The pigments that are distributed and included in the adhesive 103 are employed to provide various colors to the high glossy sheet. Any pigment that has a good dispersive property and is translucent so that a hairline pattern 106 formed on the aluminum foil 104 under the adhesive 103 is shown through the PET film can be applied.
[51] The aluminum foil 104 is manufactured by rolling an aluminum plate. In this case, various patterns are formed on a roller that is used for the rolling, so that the patterns on the roller are transferred to a surface of the rolled aluminum foil when the rolling is performed so as to form a surface pattern such as the hairline, or the like. The aluminum foil that is rolled to have a thickness of from 8 to 50 D is processed through a degreasing and softening process of rolling oil. If needed, the thickness can be increased.
[52] The primer 105 is a monomer of a polymer included in a primer layer and includes a polyester copolymer which is manufactured to include adipic acid of from 20 to 30 wt%, terephthalic acid of from 10 to 20 wt%, isophthalic acid of from 10 to 15 wt%, ethylene glycol of from 25 to 30 wt%, and neopentyl glycol of from 20 to 25 wt%. Mode for the Invention
[53] [Embodiment 2]
[54] On a surface of a transparent PET film 202 which has a degree of haze of 6%, a light transmittance of 92% or more, a gloss of 160% or more, and a thickness of about 25D, a thermosetting resin 201 which includes acrylic polyol polymerized resin of from 60 to 90 wt% and urethane curing agent of from 10 to 40 wt% is applied, and the PET film202 applied with the thermosetting resin 201 is thermally cured at a temperature of 6O0C. Next, on the other surface of the PET film 202 applied with the thermosetting resin 201, a polyurethane-based adhesive 203 to which a translucent pigment of from 1 to 10 wt% is added is distributively applied, and a aluminum foil 104 which is hairline- processed by using a dry lamination method to have a thickness of from 8 to 25 D is attached thereto.
[55] On a lower surface of the aluminum foil 204, a polyurethane-based adhesive 205 is applied and dried. Thereafter, a linear low density polyethylene (LLDPE) film 206 having a thickness of about 80D is attached thereto. Accordingly a high glossy sheet having the cross-section as illustrated in FIG. 2 is manufactured.
[56] [Comparative Example]
[57] On a surface of a transparent PET film 302 which has a degree of haze of 6%, a light transmittance of 92% or more, a gloss of 160% or more, and a thickness of about 25D, a UV cured resin 301 is applied, and the PET film 302 applied with the UV cured resin is illuminated with UV to be cured. Thereafter, on the other surface of the PET film 302, a hairline 307 pattern is formed. A primer layer 303 which is formed by coating a toluene solution in which a polyester-based primer that is manufactured by polymerizing adipic acid of 25wt%, terephthalic acid of 15wt%, isophthalic acid of 13wt%, ethylene glycol of 27wt%, and neopentyl glycol of 22wt%, is dissolved, on the surface with the hairline 307, and drying the coated surface to have a thickness of 0.7D. Thereafter, after drying the primer layer 303, an aluminum vacuum-deposited layer 304 having an average thickness of 400A is formed thereon by performing a vacuum deposition process at a temperature of 10 torr 142O0C, a polyure thane adhesive 305 is applied on a lower surface of the deposited layer, and a PVC film 306 having a thickness of 105D is attached thereto. Accordingly, a conventional high glossy sheet 300 having the cross-section as illustrated in FIG. 3 is manufactured.
[58] The high glossy sheets manufactured as described above according to the first and second embodiments of the present invention and the comparative example are attached to a GI steel plate (Galvanized steel plate) using a polyurethane-based adhesive, and a visual inspection, an Erichsen test, a boiling water resistance test for 1000CxI hour, and a spraying test of a salt water resistance for 250 hours are performed, and results thereof are illustrated in Table 1.
[59] Table 1
Figure imgf000009_0001
[60] As shown in the test results, in the visual inspection with the naked eyes, the high glossy sheets according to the present invention have good appearances without the rainbow phenomenon. On the contrary, according to the comparative example using the deposited layer, the deposited layer is damaged by heat and pressure in the manufacturing processes, a color tone around the damaged deposited layer is not clear, and the rainbow phenomenon occurs as an oil film is formed. In addition, although not shown in the table, the pattern of the high glossy sheet according to the comparative example is not natural as compared with the high glossy sheets including the hairline- processed aluminum foils that have metal surfaces according to the first and second embodiments of the present invention.
[61] In addition, as a result of the Erichsen test (the GI steel plate to which the sheet is attached is inserted between dies, a punch including a steel ball having a radius of 20mm punches the GI steel plate into depths of 6mm and 8mm, and separation of the sheet is inspected by the naked eyes) for testing an adhesion of the sheet attached to the GI steel plate, when the steel ball is pressed into the depth of 6mm, the separation phenomenon does not occur in the sheets according to the first and second embodiments of the present invention and the comparative example. However, when the steel ball is pressed into the depth of 8mm, the separation phenomenon occurs in a portion of an interface between the PET and the deposited layer according to the comparative example while the sheets according to the first and second embodiments of the present invention have good appearances.
[62] In addition, in the test of pressing into the depth of 8mm and forcibly separating the
PET, since the PET and the aluminum foil according to the first and second embodiments of the present invention are completely unified by the adhesive, the forcible separation cannot be achieved. On the contrary, in the comparative example, the PET is separated.
[63] In the boiling water resistance test performed at a temperature of 1000C for 1 hour, the rainbow phenomenon due to water permeation occurs at a side portion of the sheet according to the comparative example while the sheets according to the first and second embodiments of the present invention have good appearances.
[64] In the spraying test of a salt water resistance for 250 hours, the sheets according to the embodiments of the present invention and the comparative example show good results.
[65] As described above, according to the first and second embodiments of the present invention, although the aluminum foil is treated with the primer and directly attached to the GI steel plate, the Erichsen test, the boiling water resistance test, and the spraying test of a salt water resistance show better or the same results as compared with the comparative example.

Claims

Claims
[1] A high glossy sheet which is attached to a plate and shows an appearance similar to that of a metal surface, comprising: a PET (polyethylene terepthalate) film disposed at the top layer; an adhesive layer applied to a lower surface of the PET film layer; an aluminum foil disposed at a lower surface of the adhesive layer; and a primer layer applied to a lower surface of the aluminum foil, wherein a pattern is formed on an upper surface of the aluminum foil layer.
[2] The high glossy sheet of claim 1, wherein a UV cured resin or a thermosetting resin layer is formed on an upper portion of the PET film.
[3] The high glossy sheet of claim 1, wherein the adhesive layer includes a pigment.
[4] The high glossy sheet of claim 2, wherein the resin layer includes a pigment.
[5] The high glossy sheet of any one of claims 1 to 4, further comprising an adhesive layer which is applied to a lower portion of the primer layer and a film which is selected from among a PET film, a polyethylene film, a propylene film, and a nylon film to be disposed at a lower portion of the adhesive layer.
[6] A high glossy sheet which is attached to a plate and shows an appearance similar to that of a metal surface, comprising: a PET film disposed at the top layer; an adhesive layer applied to a lower surface of the PET film layer; an aluminum foil disposed at a lower surface of the adhesive layer; an adhesive layer applied to a lower surface of the aluminum foil; and a thermoplastic resin film disposed at a lower surface of the adhesive layer, wherein a pattern is formed on an upper surface of the aluminum foil layer.
[7] The high glossy sheet of claim 6, wherein the thermoplastic resin film is one of a polyethylene film, a propylene film, a PET film, a nylon film, and a PVC (polyvinyl chloride) film.
PCT/KR2007/003693 2006-08-10 2007-08-01 High glossy sheet having aluminum foil WO2008018715A1 (en)

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CN103648767A (en) * 2011-04-05 2014-03-19 Lg电子株式会社 Panel with anti-fingerprint property and manufacturing method thereof
US20140335320A1 (en) * 2011-12-28 2014-11-13 Lg Hausys. Ltd High gloss molding sheet having metallic effect using ultraviolet curable resin layer and a method for manufacturing the same
WO2016112574A1 (en) * 2015-01-14 2016-07-21 李锦荣 New environmental friendly insulation board
CN111409325A (en) * 2020-04-15 2020-07-14 合肥晨乐塑胶有限公司 PVC aluminum foil plate with flame retardant function and processing technology thereof

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KR100901021B1 (en) 2007-08-20 2009-06-04 엘지전자 주식회사 Exterior components for electric home appliance
KR20130111704A (en) * 2012-04-02 2013-10-11 삼성전자주식회사 Finishing materials of appliance

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JP2002120336A (en) * 2000-10-16 2002-04-23 Itoki Crebio Corp Decorative sheet for furniture and decorative top plate using the sheet
JP2003072832A (en) * 2001-08-31 2003-03-12 Toppan Printing Co Ltd Exterior material for lithium ion cell
JP2005349818A (en) * 2004-05-13 2005-12-22 Toyo Kohan Co Ltd Decorative metal sheet

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JP2002120336A (en) * 2000-10-16 2002-04-23 Itoki Crebio Corp Decorative sheet for furniture and decorative top plate using the sheet
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Publication number Priority date Publication date Assignee Title
CN103648767A (en) * 2011-04-05 2014-03-19 Lg电子株式会社 Panel with anti-fingerprint property and manufacturing method thereof
CN103648767B (en) * 2011-04-05 2016-02-10 Lg电子株式会社 There is panel and the manufacture method thereof of anti-fingerprint property
US20140335320A1 (en) * 2011-12-28 2014-11-13 Lg Hausys. Ltd High gloss molding sheet having metallic effect using ultraviolet curable resin layer and a method for manufacturing the same
WO2016112574A1 (en) * 2015-01-14 2016-07-21 李锦荣 New environmental friendly insulation board
CN111409325A (en) * 2020-04-15 2020-07-14 合肥晨乐塑胶有限公司 PVC aluminum foil plate with flame retardant function and processing technology thereof

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