WO2017217518A1 - Decorative member - Google Patents

Abstract

A decorative member for a window frame is provided which has excellent water resistance and thermal insulation and which can suppress the occurrence of warpage. This decorative member has a decorative layer, a non-foamed resin layer and a foamed resin layer, and is characterized in that the total thickness of the decorative layer and the non-foamed resin layer is no more than 50% of the thickness of the foamed resin layer, the compressive elastic modulus of the foamed resin layer is greater than or equal to 15 MPa, the coefficients of linear expansion of the non-foamed resin layer and the foamed resin layer are both less than or equal to 8×10^-5/°C, and the difference between the coefficients of linear expansion of the non-foamed resin layer and the foamed resin layer is within 3×10^-5/°C.

Description

Cosmetic material

The present invention relates to a decorative material. *

Conventionally, woody materials have been used for decorative materials used for windows (bay windows), toilets, and bathrooms (floor materials) (see, for example, Patent Document 1). However, places such as windows, toilets, and bathrooms are used in these places because they have a lot of condensation and water (humidity, urine, etc.), and there are large temperature differences such as hot in summer and cold in winter. If the decorative board is made of wood, the water resistance is inferior, so mold and warp are likely to occur and it cannot be used stably.
In order to satisfy the water resistance of such a decorative material, it is conceivable that the decorative material is composed of a resin material which is a non-woody material, and in particular, a decorative material having a resin foam layer having excellent water resistance and heat insulation is used. Have also been studied (for example, Patent Document 2).

JP 2001-123647 A JP 2008-238728 A

A decorative material having a resin foam layer is a non-woody material, which is excellent in water resistance and can be said to be a decorative material that can solve the above-mentioned conventional problems.
However, in the case of a decorative material made of a resin material that is a non-woody material, warping may occur due to a dimensional change due to the temperature of the resin material. On the other hand, when a foamed resin material is used, there is a problem of poor impact resistance. .
In addition, when a decorative material having a resin foam layer is used as a window frame including a bay window stand, a figurine or a vase with a certain amount of weight may be placed, while when used as a flooring, a toilet bowl, a wash basin Since electrical appliances such as building materials such as washing machines and refrigerators are sometimes placed, load resistance against a dent on the surface of a decorative material due to a long-term load may be a problem.

An object of this invention is to provide the cosmetics which are excellent in water resistance and heat insulation under such a condition, can suppress generation | occurrence | production of curvature, and are excellent in load resistance.

As a result of intensive studies to solve the above-mentioned problems, the present inventors have configured the decorative material to have a non-foamed resin layer and a foamed resin layer with a small shrinkage stress due to heat, and a decorative layer for the thickness of the foamed resin layer; By specifying the ratio of the total thickness of the non-foamed resin layer, the compression modulus of the foamed resin layer, and the linear expansion coefficient of the non-foamed resin layer and the foamed resin layer, load resistance is required while alleviating the effects of heat shrinkage. As a result, the present invention has been completed.

The present invention is a decorative material having a decorative layer, a non-foamed resin layer, and a foamed resin layer, wherein the total thickness of the decorative layer and the non-foamed resin layer is 50% of the thickness of the foamed resin layer. The compression elastic modulus of the foamed resin layer is 15 MPa or more, the linear expansion coefficients of the non-foamed resin layer and the foamed resin layer are both 8 × 10 ⁻⁵ / ° C. or less, and the non-foamed resin The decorative material is characterized in that the difference in coefficient of linear expansion between the layer and the foamed resin layer is within 3 × 10 ⁻⁵ / ° C.

In the decorative material of the present invention, the non-foamed resin layer preferably has a tensile elastic modulus of 180 MPa or more.
Moreover, it is preferable that the said non-foamed resin layer contains an inorganic compound.
Moreover, it is preferable that the thickness of the decorative material of this invention is 5 mm or more.

The decorative material of the present invention has a decorative layer, a non-foamed resin layer, and a foamed resin layer, the ratio of the total thickness of the decorative layer and the non-foamed resin layer to the thickness of the foamed resin layer, and the compression elastic modulus of the foamed resin layer However, since each is prescribed | regulated to the predetermined value, it can provide the cosmetics which are excellent in water resistance, heat insulation, and load resistance, and can suppress generation | occurrence | production of curvature.

It is a schematic diagram which shows the cross section of a preferable example of the decorative material of this invention. It is a schematic diagram which shows the cross section of a preferable example of the decorative material of this invention. It is a schematic diagram which shows the cross section of a preferable example of the decorative material of this invention. It is a schematic diagram which shows the cross section of a preferable example of the decorative material of this invention. It is an example of the elasticity modulus chart which showed the relationship between the load (N) with respect to a test piece, and elongation (%). (A) is sectional drawing of the thickness direction of the decorative material for window frames which is a preferable example of the decorative material of this invention, (b) shows an example of the perspective view of the decorative material for window frames, (c) These are sectional drawings of the thickness direction of the raw material laminated body used when assembling the decorative material for window frames shown to (a) and (b), (d) is a preferable example of the decorative material of this invention. It is sectional drawing which shows the other example of the decorative material for window frames, (e) is sectional drawing which shows another example of the decorative material of this invention. (A) is an example of the decorative material for window frames in which the edge tape is adhered to the side surface of the bent portion, and (b) and (c) are examples of the decorative material for window frames provided with notches on the side surfaces. It is a perspective view which shows an example, respectively. (A) is sectional drawing of the thickness direction of the raw material laminated body used when assembling the decorative material for window frames which is a preferable example of the decorative material of this invention, (b) is preferable of the decorative material of this invention. It is sectional drawing which shows the other example of the decorative material for window frames which is an example. (A) is sectional drawing which shows an example by which the decorative material for window frames which is a preferable example of the decorative material of this invention was constructed to the window of a building, (b) is a preferable example of the decorative material of this invention. BRIEF DESCRIPTION OF THE DRAWINGS It is a top view which shows an example by which the certain window frame decorative material was constructed | assembled to the window of the building, (c) is the window frame decorative material which is a preferable example of the decorative material of this invention applied to the window of the building It is a perspective view which shows an example. (A)-(d) is sectional drawing of the thickness direction of the raw material laminated body used when assembling the decorative material for window frames which is a preferable example of the decorative material of this invention, and the decorative material for window frames. It is a top view which shows an example of the decorative material for window frames which is a preferable example of the decorative material of this invention, and an example by which the decorative material for window frames which is a preferable example of the decorative material of this invention was constructed | assembled to the window of the building. . (A) is a figure explaining the evaluation method of the curvature in the case of using the decorative material which concerns on an Example and a comparative example for a window frame, (b) is a flooring for the decorative material which concerns on an Example and a comparative example. It is a figure explaining the evaluation method of the curvature in the case of using for (floor). It is a figure explaining the load resistance test of the decorative material which concerns on an Example and a comparative example. (A) is a figure explaining the evaluation method of the curvature of the decorative material for window frames concerning this invention, (b) is a figure explaining the evaluation method of the curvature of the decoration material concerning this invention. (A) is sectional drawing which shows the measuring method of the amount of curvature of a mountain state (convex shape), (b) is sectional drawing which shows the measuring method of the amount of curvature of a valley state (concave shape).

The decorative material of the present invention has a decorative layer, a non-foamed resin layer, and a foamed resin layer, and the total thickness of the decorative layer and the non-foamed resin layer is 50% or less with respect to the thickness of the foamed resin layer. It is.
When the total thickness of the decorative layer and the non-foamed resin layer exceeds 50% of the thickness of the foamed resin layer, a large warp occurs in the decorative material of the present invention. The total thickness of the decorative layer and the non-foamed resin layer with respect to the thickness of the foamed resin layer is preferably 3%, preferably 45%, more preferably 10%, and more preferably 30%. is there.

In the decorative material of the present invention, the compression elastic modulus of the foamed resin layer is 15 MPa or more. When the compression elastic modulus is less than 15 MPa, excellent load resistance cannot be obtained, and impact resistance is inferior. From the viewpoint of obtaining excellent load resistance and impact resistance, the compression elastic modulus of the foamed resin layer is more preferably more than 15 MPa and not more than 150 MPa, and still more preferably not less than 20 MPa and not more than 120 MPa. Here, the compression elastic modulus is a value obtained by preparing a test piece using the method described in JIS A9511: 2009 “Foamed plastic heat insulating material” using a foamed resin layer. Specifically, a rectangular parallelepiped test piece having a length of 100 mm, a width of 100 mm, and a thickness of 3 mm was cut out from the foamed resin layer, and the test piece was measured in the thickness direction at a compression speed of 10 mm / min using a tensile / compression tester. Measure the compression modulus perpendicular to Five test pieces are prepared, the compression elastic modulus is measured for each test piece as described above, and the value obtained by arithmetically averaging them is defined as the compression elastic modulus. The thickness of the rectangular parallelepiped test piece is changed to 3 mm instead of the thickness described in JIS.

In the decorative material of the present invention, the non-foamed resin layer and the foamed resin layer both have a linear expansion coefficient of 8 × 10 ⁻⁵ / ° C. or less, and the non-foamed resin layer and the foamed resin layer have a linear expansion coefficient. The difference between the linear expansion coefficients of the expansion coefficients is within 3 × 10 ⁻⁵ / ° C.
When the linear expansion coefficient of the non-foamed resin layer and / or the foamed resin layer exceeds 8 × 10 ⁻⁵ / ° C., the cosmetic material expands and contracts with respect to temperature changes. When the decorative material of the present invention is fitted, problems such as push-up of the fitting portion occur, and on the other hand, in the case of contraction, when two or more decorative materials of the present invention are fitted, the gap between the fitting portions Problems such as opening will occur.
In addition, when the difference in linear expansion coefficient between the non-foamed resin layer and the foamed resin layer exceeds 3 × 10 ⁻⁵ / ° C., the difference in the degree of expansion / contraction of each layer with respect to the temperature change increases. A large warp will occur.
The linear expansion coefficients of the non-foamed resin layer and the foamed resin layer are both preferably 8 × 10 ⁻⁵ / ° C. or less, and more preferably 7 × 10 ⁻⁵ / ° C. or less. Further, the difference between the linear expansion coefficients of the non-foamed resin layer and the foamed resin layer is preferably within 3 × 10 ⁻⁵ / ° C., and preferably within 2 × 10 ⁻⁵ / ° C. More preferred.

Here, the linear expansion coefficients of the non-foamed resin layer and the foamed resin layer were determined by cutting a 145 mm long and 300 mm wide rectangular parallelepiped test piece from each layer member, and using the constant temperature bath, the test piece temperature was 0 ° C. and 40 ° C. Dimensional change in the horizontal direction when each is stabilized is measured, and the dimensional change per unit temperature obtained from the dimensional change is defined as the linear expansion coefficient. In the present invention, the dimensional change in the thickness direction of each layer member is extremely small as compared with the vertical and horizontal dimensional changes, and can be ignored.

Next, a typical structure of the decorative material of the present invention will be described with reference to FIGS.
1 to 3 are schematic views showing a cross section of a preferred decorative material 10 of the present invention.
In the aspect shown by FIG. 1, the decorative material 10 of this invention has the foamed resin layer 1, the non-foamed resin layer 2, and the decoration layer 3 in order. In the embodiment shown in FIG. 2, the decorative layer 3 has the base resin layer 4, and has the adhesive layer 7, the transparent resin layer 5, and the surface protective layer 6 on the pattern layer 33. It has a foamed resin layer 1, a non-foamed resin layer 2, and a decoration layer 3.
3 is the same as the embodiment shown in FIG. 2 except that the non-foamed resin layer 2 has a three-layer structure. The non-foamed layer 2 shown in FIG. The structure has a thermoplastic resin layer 21, a glass component layer 22, and a second thermoplastic resin layer 23 in this order.

(Foamed resin layer 1)
The said foaming resin layer is a layer which mainly provides heat insulation, load bearing, and impact resistance to the decorative material of this invention, and is formed by foaming a foaming resin composition.
The foaming ratio in the foamed resin layer is preferably 5 to 20 times. If it is out of the range, it may not be possible to obtain an excellent heat insulating, load bearing, and impact resistant decorative material. From the viewpoint of obtaining better heat insulation and load resistance, the foaming ratio of the foamed resin layer is more preferably 5 times or more and 15 times or less, and further preferably 5 times or more and 12 times or less.

Further, in the decorative material of the present invention, the compression elastic modulus of the foamed resin layer is 15 MPa or more as described above, but the compression elastic modulus is JIS A9511: 2009 “foamed plastic heat insulating material using the foamed resin layer. It is the value which produced the test piece using a part of method described in ", and measured.
Specifically, a rectangular parallelepiped test piece having a length of 100 mm, a width of 100 mm, and a thickness of 3 mm is cut out from the foamed resin layer, and the test piece is taken from a direction perpendicular to the thickness direction using a tensile / compression tester. The compression elastic modulus is measured at a compression speed of 10 mm / min. Five test pieces are prepared, the compression elastic modulus is measured for each test piece as described above, and the value obtained by arithmetically averaging them is defined as the compression elastic modulus.

The foaming method of the foamed resin composition is not particularly limited, and any known method can be adopted, but foaming by a bead method is preferable from the viewpoint of obtaining a homogeneous foamed resin layer. The bead method uses expanded resin particles (pre-expanded particles) as a raw material, fills the expanded resin particles in a cavity of a mold, and pre-expands particles while secondary-expanding the filled pre-expanded particles with steam. This is a technique of obtaining a foamed resin layer by integrating them by heat fusion.

The resin used for the foamed resin particles is preferably a thermoplastic resin.
Examples of the thermoplastic resin include polyethylene (PE), polypropylene (PP), polystyrene (PS), styrene-modified polyolefin resin, ethylene-vinyl acetate copolymer resin (EVA), and ethylene- (meth) acrylic acid resin. Polyolefin resins such as acrylonitrile-butadiene-styrene copolymer (ABS resin), acrylonitrile-styrene copolymer, polyvinyl chloride resin (PVC), polyvinyl acetate resin, polyvinyl alcohol resin such as polyvinyl alcohol resin, polyethylene terephthalate resin ( Preferred examples thereof include polyester resins such as PET resins), nylons, polyacetal resins, acrylic resins, polycarbonate resins, polyurethane resins and other thermoplastic resins, and copolymers, or mixed resins thereof.
Among these, considering the strength of the resin itself, a polyolefin resin is preferable, and a polystyrene resin is particularly preferable.

The styrene monomer that forms the polystyrene resin is not particularly limited, and any known styrene monomer can be used. Examples include styrene, α-methyl styrene, vinyl toluene, chlorostyrene, ethyl styrene, isopropyl styrene, dimethyl styrene, bromostyrene, and the like. These styrenic monomers may be one kind or a mixture of plural kinds. A preferred styrene monomer is styrene.

The foamed resin particles are usually made into resin particles by absorbing a monomer such as a styrene monomer together with a plasticizer, if necessary, into a seed particle comprising a resin that forms the foamed resin particles, and polymerizing the resin particles. Alternatively, after polymerization, the resin particles are obtained by impregnating a foaming agent and then foaming. Foamed resin particles can be obtained by impregnating particles obtained by suspension polymerization of a monomer such as styrene monomer in an aqueous medium with a foaming agent, or by introducing polystyrene resin into an extruder and melt-kneading together with the foaming agent. Then, it can be obtained by extruding into pressurized circulating water through a die having a small hole and foaming particles obtained by cutting using a rotary cutter in contact with the die.

Examples of the foaming agent include inorganic foaming agents such as sodium bicarbonate, sodium carbonate, ammonium bicarbonate, ammonium carbonate, and ammonium nitrite; N, N′-dimethyl-N, N′-dinitrosotephthalamide, N, N Nitroso compounds such as'-dinitrosopentamethylenetetramine; azo compounds such as azodicarbonamide, azobisformamide, azobisisobutyronitrile, azocyclohexylnitrile, azodiaminobenzene; sulfonyl hydrazides such as benzenesulfonyl hydrazide and toluenesulfonyl hydrazide Compounds: Azide compounds such as calcium azide, 4,4′-diphenyldisulfonyl azide, p-toluenesulfonyl azide and the like are preferred.
In addition, as a blowing agent, as a physical blowing agent, in addition to aliphatic hydrocarbons such as propane, normal butane, isopentane, normal pentane, and neopentane, fluorinated hydrocarbons such as difluoroethane and tetrafluoroethane that have zero ozone destruction coefficient Also preferred are volatile foaming agents such as
These foaming agents can be used alone or in combination.
The addition amount of the foaming agent may be appropriately determined according to the desired expansion ratio and compression modulus, but is preferably 0.5 parts by mass or more and 15 parts by mass or less with respect to 100 parts by mass of the resin, and 1 part by mass or more. 10 parts by mass or less is more preferable.

Examples of the plasticizer include fatty acid ester compounds such as propylene glycol fatty acid ester, glycerin fatty acid ester, sorbitan fatty acid ester, and sucrose fatty acid ester; dibutyl phthalate (DBP), dioctyl phthalate (DOP), diisononyl phthalate (DINP), and the like. Phthalic acid ester compounds; adipic acid ester compounds such as diisobutyl adipate and dioctyl adipate; sebacic acid ester compounds such as dibutyl sebacate and di2-ethylhexyl sebacate; glycerin fatty acid ester compounds such as glycerin tristearate and glycerin tricaprylate; Preferred examples include natural fats and oils such as liquid paraffin, coconut oil, palm oil, and rapeseed oil.
The plasticizer may be added when the monomer is polymerized, or may be added when the foaming agent is impregnated.
The addition amount of the plasticizer may be appropriately determined according to the desired expansion ratio and compression modulus, but is preferably 0.2 parts by mass or more and less than 3 parts by mass with respect to 100 parts by mass of the resin, 0.4 mass More preferably, it is more than 1.6 parts by mass. If the amount of the plasticizer added is 0.2 parts by mass or more, the secondary transition temperature is low, so it is advantageous for pre-foaming and molding at low temperature, and if it is less than 3 parts by mass, the foam is difficult to shrink, Good appearance can be obtained.

The foamed resin particles have a flame retardant, a flame retardant aid, a lubricant, a binding inhibitor, a fusion accelerator, an antistatic agent, a spreading agent, a bubble regulator, and a crosslinking agent within a range that does not impair physical properties. Additives such as fillers, colorants, heat insulation improvers (radiation inhibitors, etc.) may be included.

In the bead method, for example, the foamed resin particles are filled in a cavity of a mold, and the filled pre-foamed particles are preferably steam of 100 ° C. or higher and 150 ° C. or lower, more preferably 100 ° C. or higher and 120 ° C. or lower. A foamed resin layer can be obtained by integrating the pre-expanded particles by thermal fusion while performing secondary foaming using a heating medium such as 10 seconds or more and 40 seconds or less. In this case, the average particle diameter of the foamed resin particles generally used is preferably 0.2 mm or more and 4 mm or less, and more preferably 0.5 mm or more and 2 mm or less. The average particle diameter of the foamed resin particles is defined by JIS Z8801-1 “Test sieve—Part 1: Metal mesh sieve”, and a plurality of types of sieves having different openings. It is obtained by stacking the top of the small sieve so that it becomes a large sieve, putting 100 g of the foamed resin particles into the uppermost sieve, and vibrating the sieve to classify the expandable particles.
Specifically, a value obtained by multiplying the average particle diameter of the foamed resin particles remaining on each sieve sieve by the number ratio is calculated, and the sum of these values is defined as the average particle diameter of the foamed resin particles.
Average particle size = Σ (number ratio on each sieve x average particle size of each sieve particle)
Here, the number ratio is a value obtained from the weight ratio of the expandable particles remaining on each sieve and the size of the openings of each sieve.
Further, in the present invention, the foamed resin layer is not limited to the above-mentioned bead method, and the resin composition for forming the foamed resin layer includes a resin for a foamed resin layer, a foaming agent, a plasticizer, an inorganic filler, and other additives as necessary. An object is obtained by forming a non-foamed resin layer by a film forming method such as an extrusion film forming method using a T-die or a calender film forming method, and then foaming it at about 220 ° C. to 250 ° C. using a heating foaming furnace. You can also

Further, as the foamed resin layer, a commercially available heat-insulating board, for example, a bead method polystyrene foam heat insulating plate, an extrusion method polystyrene foam heat insulating plate, or the like may be used as long as it is within a predetermined expansion ratio and compression elastic modulus. it can.

Although the thickness of the foamed resin layer is somewhat depending on the foaming ratio and the like, it is preferably 3 mm or more and 15 mm or less, more preferably 5 mm or more and 15 mm or less, and further preferably 5 mm or more and 12 mm or less. When the thickness of the foamed resin layer is within the above range, excellent heat insulation, load resistance and impact resistance can be obtained.
Moreover, the thickness of the said foamed resin layer is thicker than the non-foamed resin layer mentioned later. It is thicker than the non-foamed resin layer, so it has excellent heat insulation, load bearing and impact resistance, and stress warpage due to the difference in elongation with other layers such as the non-foamed resin layer. Is less likely to occur.

(Non-foamed resin layer 2)
The non-foamed resin layer is a layer mainly imparting shape stability, water resistance, impact resistance, and scratch resistance to the decorative material of the present invention, and may be a layer having a tensile elastic modulus of 180 MPa or more. preferable. If the tensile modulus is less than 180 MPa, scratch resistance cannot be obtained. From the viewpoint of obtaining scratch resistance, the tensile elastic modulus is preferably from 180 MPa to 3000 MPa, more preferably from 1000 MPa to 3000 MPa, and further preferably from 2000 MPa to 2500 MPa.
Further, when the tensile elastic modulus is within the above range, stress warpage due to a difference in elongation due to temperature or the like with other layers such as a foamed resin layer is less likely to occur. Here, the tensile elastic modulus (E) was prepared by preparing a non-foamed resin layer punched out of a dumbbell-shaped test piece described in JIS K6732 (1996), and using a tensile and compression tester under a temperature condition of 20 ° C. From the first linear portion of the tensile stress-strain curve obtained by measurement under the conditions of a tensile speed of 50 mm / min and a distance between chucks of 80 mm, the calculation was performed according to the following equation.
E = △ p / △ E
E: Tensile modulus Δp: Stress difference due to the original average cross-sectional area between two points on a straight line ΔE: Strain difference between the same two points

The non-foamed resin layer preferably contains a thermoplastic resin.
Examples of the thermoplastic resin include polyvinyl resins such as polyvinyl chloride resin, polyvinyl acetate resin, and polyvinyl alcohol resin, polyethylene, polypropylene, polystyrene, styrene-modified polyolefin resin, ethylene-vinyl acetate copolymer resin (EVA), Polyolefin resin such as ethylene- (meth) acrylic resin, polyester resin such as polyethylene terephthalate resin (PET resin), acrylic resin, polycarbonate resin, polyurethane resin, acrylonitrile-butadiene-styrene copolymer (ABS resin), acrylonitrile Preferable examples include thermoplastic resins such as styrene copolymers, copolymers, and mixed resins thereof. Of these, polyolefin resins, acrylonitrile-butadiene-styrene copolymers, and polyvinyl chloride resins are preferable.

In the present invention, the non-foamed resin layer preferably contains an inorganic compound. By including an inorganic compound, the linear expansion coefficient of the non-foamed resin layer can be reduced, and as a result, warpage of the decorative material of the present invention can be suppressed.
Examples of the inorganic compound include talc, calcium carbonate, silica, mica and the like.
The content of the inorganic compound is preferably 10 parts by mass or more and 70 parts by mass or less with respect to 100 parts by mass of the resin component in the non-foamed resin layer. If it is less than 10 parts by mass, the linear expansion coefficient of the non-foamed resin layer may not be sufficiently reduced, and if it exceeds 70 parts by mass, the tensile elastic modulus of the non-foamed resin layer may be insufficient. . A more preferable range of the content of the inorganic compound is 15 parts by mass or more and 65 parts by mass or less.

The non-foamed resin layer may be composed of one layer or a laminate composed of two or more layers, but is a laminate composed of two or more layers, It is preferable that one layer contains a glass component. That is, the non-foamed resin layer is a laminate composed of two or more layers, preferably at least one layer is a thermoplastic resin layer and the other layer is a glass component layer containing a glass component. . With such a configuration, excellent impact resistance is obtained, and shape stability is improved.
As for the glass component layer containing a glass component, the layer comprised by glass fiber etc. are mentioned preferably, for example.

In the present invention, the non-foamed resin layer is preferably a laminate in which a thermoplastic resin layer and a glass component layer are alternately laminated, and in particular, the first thermoplastic resin layer as shown in FIG. The laminate preferably has a glass component layer and a second thermoplastic resin layer in this order.
When the non-foamed resin layer has a plurality of thermoplastic resin layers, the types of resins forming the plurality of thermoplastic resin layers may be the same or different, and the thickness of the plurality of thermoplastic resin layers May be the same or different.

The thickness of the non-foamed resin layer is preferably 0.3 mm or more and 10 mm or less, and more preferably 1 mm or more and 5 mm or less. When the thickness of the non-foamed resin layer is within the above range, excellent water resistance, impact resistance, and scratch resistance can be obtained. Moreover, it becomes difficult to produce the stress curvature resulting from the difference in elongation by temperature etc. with other layers, such as a foamed resin layer.
Moreover, the thickness of the non-foamed resin layer is thinner than the foamed resin layer as described above. Stress warpage due to a difference in elongation due to temperature or the like with other layers such as a foamed resin layer layer is less likely to occur.

(Decoration layer 3)
The decorative layer is a layer that imparts decorativeness to the decorative material of the present invention, and may be, for example, a uniformly colored concealing layer (solid print layer), or various patterns using ink and a printing machine. Then, the pattern layer formed by printing may be used, or a layer (hereinafter referred to as pattern layer 33) in which the masking layer and the pattern layer are combined. The decorative layer may be a pattern provided by a transfer method or the like, a veneer or a ground board obtained by thinly slicing wood, or a decorative sheet provided with a pattern on a colored base resin layer or base resin layer. But you can. Among them, the decorative sheet shown below is more preferable. As shown in FIG. 2, the “decorative sheet” includes the base resin layer 4 and the pattern layer 33, an arbitrary layer such as the transparent resin layer 5 and the surface protective layer 6 described later, the pattern layer 33 and The thing of the laminated structure which consists of the adhesive bond layer 7 which adhere | attaches the transparent resin layer 5 is preferable.

By providing the concealing layer, the base on which the decorative material of the present invention is provided can be concealed, and when the foamed resin layer, the non-foamed resin layer, etc. are colored or uneven in color, the intended color can be obtained. Give the surface color.
In addition, by providing the above-mentioned pattern layer, a grain pattern simulating the surface of a rock such as a wood grain pattern, marble pattern (for example, travertine marble pattern), a fabric pattern simulating a cloth pattern or a cloth pattern, a tiled pattern, a brick A pattern such as a stacked pattern or a combination of these, such as a parquet or patchwork, can be applied to the decorative sheet. These patterns are formed by multicolor printing with the usual yellow, red, blue and black process colors, as well as by multicolor printing with special colors prepared by preparing the individual color plates constituting the pattern. Is done.

As the ink composition used for the decorative layer, a binder resin in which a colorant such as a pigment or a dye, an extender pigment, a solvent, a stabilizer, a plasticizer, a catalyst, or a curing agent is appropriately mixed is used. The binder resin is not particularly limited, and preferred examples include urethane resins, vinyl chloride / vinyl acetate copolymer resins, vinyl chloride / vinyl acetate / acrylic copolymer resins, acrylic resins, polyester resins, and nitrocellulose resins. It is done.
Any of these binder resins can be used alone or in admixture of two or more.
Examples of the colorant include carbon black (black), iron black, titanium white, antimony white, yellow lead, titanium yellow, petal, cadmium red, ultramarine, cobalt blue, and other inorganic pigments, quinacridone red, and isoindolinone. Organic pigments such as yellow and phthalocyanine blue, metallic pigments composed of scaly foils such as dyes, aluminum and brass, pearlescent pigments composed of scaly foils such as titanium dioxide-coated mica and basic lead carbonate, etc. Are preferred.

The thickness of the decorative layer is usually preferably about 5 μm to 3 mm.
When the decorative layer is a hiding layer (solid printing layer), a pattern layer, a pattern layer combining the hiding layer and the pattern layer, a pattern provided by a transfer method, etc., the thickness is preferably about 20 μm or less, When the decoration layer is a veneer or a ground board, the thickness is preferably about 0.5 mm or more and 3 mm or less, and when the decoration layer is a decorative sheet, the thickness is preferably about 500 μm or less.
If the thickness of the said decoration layer exists in the said range, the design which was excellent in the decorative material of this invention can be provided, and concealment property can be provided.

(Base resin layer 4)
The base resin layer is a layer provided as desired, and is preferably a layer formed of a thermoplastic resin. As said thermoplastic resin, what was illustrated as a thermoplastic resin provided in the said foamed resin layer can be mentioned preferably. Of these, polyolefin resins are preferable, and polyethylene resins and polypropylene resins are more preferable.

The base resin layer may be transparent or colored, and is preferably colored from the viewpoint of concealing the base on which the decorative material is provided. Preferred examples of the colorant used include those exemplified as the colorant used in the decorative layer.

The thickness of the base resin layer is preferably 10 μm or more and 150 μm or less, more preferably 30 μm or more and 100 μm or less, and further preferably 40 μm or more and 80 μm or less. When the thickness of the base resin layer is within the above range, handling is easy and the decorative material of the present invention does not become thicker than necessary.

Moreover, you may add various additives, such as a filler, a flame retardant, a lubricant, antioxidant, a ultraviolet absorber, a light stabilizer, to a base resin layer as needed.

(Transparent resin layer 5)
The said transparent resin layer is an arbitrary layer provided in order to protect a decoration layer, Preferably it is a layer formed with a thermoplastic resin. As a thermoplastic resin, what was illustrated as a thermoplastic resin provided in said foamed resin layer can be mentioned preferably. Among these, polyolefin resins are preferable, and polyethylene resins, polypropylene resins, and ionomer resins are more preferable.

The transparent resin layer is a transparent resin layer so that the decorative layer can be seen through. Here, the term “transparent” is a concept including colorless and transparent as well as colored and translucent.
In addition, various additives such as fillers, flame retardants, lubricants, antioxidants, ultraviolet absorbers, light stabilizers and the like may be added to the transparent resin layer as necessary without impairing its transparency. Also good.

The thickness of the transparent resin layer is preferably 10 μm or more and 400 μm or less, more preferably 30 μm or more and 250 μm or less, and further preferably 50 μm or more and 100 μm or less. When the thickness of the transparent resin layer is within the above range, the decorative layer can be protected, the handling is easy, and the floor decorative material does not become thicker than necessary.

(Surface protective layer 6)
The surface protective layer is a layer provided as desired that imparts surface properties such as impact resistance, load resistance, and scratch resistance to the decorative material of the present invention. The surface protective layer is provided on the outermost surface of the decorative material of the present invention.
The surface protective layer is preferably constituted by applying a resin composition containing a curable resin on the decorative layer, or a transparent resin layer and an adhesive layer that are preferably provided, and curing the resin composition. . By containing the curable resin that has been crosslinked and cured, the surface properties of the decorative material of the present invention can be improved.

Preferred examples of the curable resin used to form the surface protective layer include ionizing radiation curable resins and thermosetting resins. A plurality of these are used, for example, ionizing radiation curable resins and thermosetting resins. A so-called hybrid type may be used together.
Among these, ionizing radiation curable resins are preferable from the viewpoint of increasing the crosslinking density of the resin forming the surface protective layer and improving the surface characteristics, and some of them can be applied without a solvent and are handled. From the viewpoint of ease, an electron beam curable resin is more preferable.

The ionizing radiation curable resin refers to a resin having an energy quantum capable of crosslinking and polymerizing molecules in electromagnetic waves or charged particle beams, that is, a resin that is crosslinked and cured by irradiation with ultraviolet rays or electron beams. . Specifically, it can be appropriately selected from polymerizable monomers, polymerizable oligomers, or prepolymers conventionally used as ionizing radiation curable resins.
As the polymerizable monomer, a (meth) acrylate monomer having a radical polymerizable unsaturated group in the molecule is preferable, and among them, a polyfunctional (meth) acrylate is preferable. The polyfunctional (meth) acrylate is not particularly limited as long as it is a (meth) acrylate having two or more ethylenically unsaturated bonds in the molecule. These polyfunctional (meth) acrylates may be used singly or in combination of two or more.

Next, as the polymerizable oligomer, an oligomer having a radical polymerizable unsaturated group in the molecule, for example, epoxy (meth) acrylate, urethane (meth) acrylate, polyester (meth) acrylate, polyether (meth) An acrylate type etc. are mentioned.
Furthermore, as the above polymerizable oligomer, other polybutadiene (meth) acrylate oligomer having a high hydrophobicity having a (meth) acrylate group in the side chain of the polybutadiene oligomer, and silicone (meth) acrylate having a polysiloxane bond in the main chain Oligomers, aminoplast resin (meth) acrylate oligomers modified from aminoplast resins with many reactive groups in small molecules, or molecules such as novolak epoxy resins, bisphenol epoxy resins, aliphatic vinyl ethers, aromatic vinyl ethers There are oligomers having cationically polymerizable functional groups.

In the present invention, a monofunctional (meth) acrylate can be used in combination with the above polyfunctional (meth) acrylate as long as the purpose of the present invention is not impaired, for the purpose of reducing the viscosity. . These monofunctional (meth) acrylates may be used alone or in combination of two or more.

Examples of the thermosetting resin include epoxy resin, phenol resin, urea resin, unsaturated polyester resin, melamine resin, alkyd resin, polyimide resin, silicone resin, hydroxyl functional acrylic resin, carboxyl functional acrylic resin, amide functional Preferred examples include a functional copolymer and a urethane resin.

Further, examples of the thermosetting resin also include a two-component curable resin, and specifically, a two-component curable resin of a polyol and an isocyanate is preferable.
Here, as said polyol, an acrylic polyol, a polyester polyol, an epoxy polyol etc. are mentioned preferably, for example.
The isocyanate may be, for example, a polyvalent isocyanate having two or more isocyanate groups in the molecule, such as 2,4-tolylene diisocyanate (TDI), xylene diisocyanate (XDI), naphthalene diisocyanate, Aromatic isocyanates such as 4,4'-diphenylmethane diisocyanate, aliphatics such as 1,6-hexamethylene diisocyanate (HMDI), isophorone diisocyanate (IPDI), methylene diisocyanate (MDI), hydrogenated tolylene diisocyanate, hydrogenated diphenylmethane diisocyanate Polyisocyanates such as (or alicyclic) isocyanates are used. Alternatively, adducts or multimers of these various isocyanates, for example, adducts of tolylene diisocyanate, tolylene diisocyanate trimers, and the like are also used.

Moreover, various additives can be contained in the resin composition which comprises the said surface protective layer in the range which does not inhibit the performance.
Examples of the various additives include ultraviolet absorbers (UVA), light stabilizers (HALS, etc.), polymerization inhibitors, crosslinking agents, antistatic agents, adhesion improvers, antioxidants, leveling agents, and thixotropic properties. Agents, coupling agents, plasticizers, antifoaming agents, fillers, solvents and the like.

The thickness of the surface protective layer is preferably 3 μm or more and 40 μm or less, and more preferably 5 μm or more and 20 μm or less. When the thickness of the surface protective layer is within the above range, excellent surface characteristics can be obtained.

(Adhesive layer 7)
The adhesive layer is a layer provided as necessary when laminating the resin layer when the base resin layer and the transparent resin layer are provided.
Examples of the adhesive used in the adhesive layer include a urethane adhesive, an acrylic adhesive, an acrylic / urethane adhesive, a polyester adhesive, a polyester urethane adhesive, a polyamide adhesive, a polystyrene adhesive, and a cellulose adhesive. Preferably mentioned. These adhesives can be used singly or as a mixture of two or more.

The thickness of the adhesive layer is preferably 1 μm or more and 30 μm or less, and more preferably 3 μm or more and 15 μm or less. When the thickness of the adhesive layer is within the above range, good adhesiveness is obtained, and the decorative material of the present invention is not unnecessarily thick.

The decorative material of the present invention having each of the above layers is excellent in impact resistance, heat insulation, water resistance, load resistance, scratch resistance, and ease of construction. It is suitable for watering applications such as window frames and flooring, especially toilets, washbasins and kitchens.
The thickness of the decorative material of the present invention is preferably 5 mm or more, more preferably 6 mm or more and 30 mm or less, from the viewpoint of obtaining excellent impact resistance, heat insulation, water resistance, load resistance, and scratch resistance. More preferably, it is 10 mm or more and 20 mm or less.
Moreover, considering the ease of construction, it is preferable to have the same thickness as the wooden flooring material provided in places other than around the water such as a living room or a corridor.
The thickness of the wood flooring material is usually 8 mm, 12 mm, 15 mm, etc., and 12 mm is a standard thickness.
Depending on the properties of the final product, the decorative material of the present invention may be subjected to actual processing, provision of V-shaped grooves, chamfering on four sides, etc. using a tenoner, a router, or the like.
FIG. 4 shows a structure in which the non-foamed resin layer 2 in the embodiment shown in FIG. 2 of the decorative material of the present invention is provided with a male fruit 8a and a female fruit 8b.
In addition, the decorative material of the present invention preferably has excellent weather resistance. In particular, when used as a decorative material for a window frame as described later, the appearance change is slight even after 4000 hours test in the sunshine weather test. Preferably there is.

The decorative material of the present invention is a decorative material for window frames used for at least a part of a window frame of a building, and the decorative material for window frames includes a foamed resin layer and at least a part of the surface of the foamed resin layer. A coating layer that covers the decorative layer and a non-foamed resin layer on the foamed resin layer side of the decorative layer, and the coating layer is an upper side of the foamed resin layer. It can be suitably used as a decorative material for window frames provided on the surface and the front surface.

In the decorative material for window frames, the covering layer covers at least a part of the surface of the foamed resin layer, and is provided on the upper surface and the near surface of the foamed resin layer.
The upper surface of the foamed resin layer is the upper surface when the window frame decorative material is applied, and the front surface of the foamed resin layer is the window frame decorative material. When constructed, it is the surface opposite to the outer wall surface of the building. As described above, the coating layer is provided on the upper surface and the near surface of the foamed resin layer, so that when the window frame decorative material is applied to the window, the portion that enters the user's field of view It can be set as the aspect by which the coating layer (decoration layer) was provided only in.
FIGS. 10A to 10D are cross-sectional views in the thickness direction of the raw material laminate and the window frame decorative material used when assembling the window frame decorative material which is a preferred example of the decorative material of the present invention.
The window frame decorative material shown in FIG. 10A can be obtained, for example, by the following method.
First, a groove-like cut 106 in a cross-sectional view is provided in the non-foamed resin layer 102 in a state of being laminated on the decoration layer 103, and the foamed resin layer 101 is laminated at a position adjacent to the cut 106. Then, the raw material laminate is folded at the cut portion 106 so that the foamed resin layer 101 is on the inside, and the non-foamed resin layer 102 is attached to the front end surface of the foamed resin layer 101 via pressure bonding or an adhesive. Can be obtained at
Moreover, the decorative material for window frames shown in FIG.10 (b) can be obtained with the following method, for example.
First, in the non-foamed resin layer 102 in a state of being laminated on the decorative layer 103, a groove-like cut is provided in a triangular view in cross section, and the foamed resin layer 101 is laminated at a position adjacent to the cut, and the foamed resin layer 101 The vicinity of the side surface on the cut side is cut out in a trapezoidal shape so as to be a continuous surface with the cut, and a groove-like cut 106 ′ is provided in a triangular view in cross section. Next, another trapezoidal foamed resin layer 101 cut out by the foamed resin layer 101 is laminated on the non-foamed layer 102 through the cut line 106 ′ to produce a raw material laminate. The trapezoidal foamed resin layer 101 is preferably laminated so as to be continuous with the cut-out 106 ′. Then, the foamed resin layer 101 is bent at the cut 106 ′ so that the foamed resin layer 101 is on the inside, and the trapezoidal foamed resin layer 101 is attached to the end surface of the left foamed resin layer 101 on the cut 106 ′ side through pressure bonding or an adhesive. It can be obtained by attaching.
Moreover, the decorative board for window frames shown in FIG.10 (c) can be obtained with the following method, for example.
First, in the non-foamed resin layer 102 in a state of being laminated on the decoration layer 103, two groove-like cuts 106 are formed in a triangle in cross section, and the foamed resin layer 101 is laminated outside the cut 106 provided on the left side. Next, in the vicinity of the side opposite to the non-foamed layer 102 side on the side of the cut 106 of the foamed resin layer 101, a cutout portion 107 having a shape into which the non-foamed layer 102 outside the right cut 106 and the decorative layer 103 can be fitted is provided. A laminate is produced. Next, the foamed resin layer 101 can be obtained by folding the foamed resin layer 101 and the non-foamed layer 102 through pressure bonding or an adhesive, by bending the cut 106 so that the foamed resin layer 101 is on the inside.
Moreover, the decorative board for window frames shown in FIG.10 (d) can be obtained with the following method, for example.
First, two non-foamed resin layers 102 laminated on the decorative layer 103 are provided with two groove-like cuts 106 in a cross-sectional view, and the foamed resin layer 101 is laminated on each of the outer sides of the cuts 106 provided on the left and right. To do. Next, a foamed resin layer 101, a non-foamed layer 102, and a decorative layer 103 provided on the outer side of the right cut 106 are provided in the vicinity of the side opposite to the non-foamed layer 102 side of the cut 106 side of the foamed resin layer 101 provided on the left A cutout portion 107 ′ having a fitting shape is provided to produce a raw material laminate. Next, the left side foamed resin layer 101 is folded inside at the cut 106 so that the left side foamed resin layer 101 is inside, and the left side foamed resin layer 101, the non-foamed layer 102 and the right side foamed resin layer 101 are bonded via pressure bonding or an adhesive. It can be obtained.
In addition, in the decorative material for window frames shown in FIGS. 10C and 10D, the lower surface of the foamed resin layer 101 and the covering layers (the decorative layer 103 and the non-foamed resin layer 102) provided on the lower surface. May form the same surface, or may form a state in which either one protrudes.

In the present invention, the foamed resin layer preferably includes a first region provided with a lower protrusion that protrudes downward from an end on the near side to the vicinity thereof.
FIG. 6 shows an example of a window frame decorative material which is one of the uses of the decorative material of the present invention. 6A is a cross-sectional view in the thickness direction, FIG. 6B shows an example of a perspective view of a window frame decorative material (window frame) 60, and the window frame decorative material (window frame) 60 is shown in FIG. In the vicinity of one end of the decorative material of the present invention in which the non-foamed resin layer 62 and the decorative layer 63 are laminated in this order on the foamed resin layer 61 (the end on the near side), the foamed resin layer 61 is on the inner side. A lower projecting portion (hereinafter also referred to as a bent portion 65) that is folded so as to be formed is formed. The first region provided with the lower protrusion (bent portion 65) is, for example, a region indicated by A in FIG.
For example, as shown in FIG. 6C, such a window frame decorative material 60 has an M-shaped groove-like cut in a non-foamed resin layer 62 laminated on the decoration layer 63. 64 is provided at two locations, and a non-foamed resin layer 62 is laminated between the cuts 64 to produce a raw material laminate, and another foamed resin layer 61 is laminated at a position separated by the thickness of the foamed resin layer 61. After that, the foamed resin layer 61 is bent at the cut 64 so that the foamed resin layer 61 is on the inner side, and the foamed resin layers 61 are bonded to each other through pressure bonding or an adhesive, so that FIG. 6A and FIG. A decorative material for a window frame having the structure as shown can be obtained.
In addition, as another configuration of the window frame decorative material, for example, four groove-like cuts 66 in a sectional view triangle are provided in the non-foamed resin layer 62 in a state of being laminated on the decoration layer 63, and the cuts 66 are provided. A foamed resin layer 61 is bonded onto the non-foamed resin layer 62 at a portion adjacent to the two foamed resin layers 62, and a cutout portion 67 having a shape in which both ends of the middle foamed resin layer 61 can be fitted is provided near the side surfaces of the two foamed resin layers. Then, the window having a structure as shown in FIG. 6 (d) is obtained by bending the cut resin 66 with the foamed resin layer 61 on the inner side and attaching the foamed resin layers 61 to each other through pressure bonding or an adhesive. A decorative material for a frame can be obtained.
Further, as another configuration of the decorative material for window frame, for example, four non-foamed resin layers 62 laminated on the decorative layer 63 are provided with four groove-like cuts 66 in a sectional view triangle, The foamed resin layer 61 (a) is laminated between two cuts 66 provided in the upper part, and the foamed resin layers 61 (b) and 61 (c) are respectively non-foamed resin in portions adjacent to the cuts 66. A cut-out portion 67 ′ having a shape that is fitted on the layer 62 and can be fitted in a position where the side surfaces of the two foamed resin layers 61 (b) and 61 (c) do not contact the middle foamed resin layer 61 (a) is provided. . Then, the foamed resin layer 61 (a) is bent inside at the cut 66 so that the foamed resin layer 61 (a) is on the inside, and the foamed resin layers 61 (b) and 61 (c) are attached to each other through pressure bonding or an adhesive, thereby FIG. Even if the processing dimensions of the foamed resin layers 61 (b) and 61 (c) as shown in (e) are rough, a decorative material for a window frame that can be folded without any trouble can be obtained. Note that the cut portions 67 ′ provided in the foamed resin layers 61 (b) and 61 (c) before being bent at the cut portion 66 are formed in the space 67 after the foamed resin layers 61 (b) and 61 (c) are attached to each other. 'Become.
In the window frame decorative material, as shown in FIGS. 6A to 6E, the covering layers (the non-foamed resin layer 62 and the decorative layer 63) are further provided on the lower protruding portion of the foamed resin layer 61. It is preferably provided on the lower surface, and a portion covering the upper surface of the foamed resin layer 61 of the coating layer and a portion covering the front surface of the foamed resin layer 61 of the coating layer are continuous. It is preferable.
Further, the window frame decorative material includes a portion covering the front surface of the foamed resin layer 61 of the covering layer and a lower projecting portion (bent portion 65) of the lower portion of the foamed resin layer 61 of the covering layer. It is preferable that the portion covering the surface is continuous, the portion covering the upper surface of the foamed resin layer 61 of the coating layer, the portion covering the front surface of the foamed resin layer of the coating layer, and the coating It is preferable that the portion of the layer covering the lower surface of the lower protruding portion of the foamed resin layer is continuous.
Further, both side surfaces in the first region in the foamed resin layer and both side surfaces in the region excluding the first region in the foamed resin layer (region B in FIG. 6B) are on the same plane, The window frame decorative material is preferably rectangular in plan view.
The foamed resin layers provided in FIGS. 6 (c) to 6 (e) and FIGS. 10 (a) to 10 (d) are provided by laminating them with a coating layer in a flat state and then cutting them into a desired shape. Also good.

Note that such a window frame decorative material is provided with an edge tape 71 which is a mouthpiece material on at least one side surface of the bent portion as in the window frame decorative material (window frame) 701 shown in FIG. Preferably it is worn. Examples of the edge tape include Panefuri Band and Marblet S manufactured by Panefuri Industry Co., Ltd. In addition, the decorative layer 3 is attached to the side surface, or the non-foamed resin layer 2 is attached to the side surface, and the decorative layer 3 (the coating layer) is provided on at least one side surface in the first region. May be. In this case, a group consisting of a covering layer covering at least a part of the surface of the foamed resin layer, an edge tape attached to at least one side surface of the first region of the foamed resin layer, a decorative layer, and a covering layer It is preferable that at least one selected more is the same pattern.
Further, the window frame decorative material is provided with a notch 73 on one of the side surfaces to which the edge tape 71 is adhered, as in a window frame decorative material (window frame) 701 shown in FIG. As shown in FIG. 7C, a cutout 73 may be provided on both side surfaces to which the edge tape 71 is attached, like a window frame decorative material (window frame) 702 shown in FIG.
The side edge tape 71 is preferably provided at a location where the notch 73 is not formed.
Moreover, when the notch 73 is provided in one of the side surfaces to which the edge tape 71 is attached, one of both side surfaces in the first region A in the foamed resin layer 61 is the first region A in the foamed resin layer 61. It is preferable that it is L-shaped in plan view that protrudes from one side between both side surfaces in the region B excluding, and when notches 73 are provided on both side surfaces to which the edge tape 71 is adhered, It is preferable that both side surfaces in the first region A of the layer 61 protrude from both side surfaces in the region B excluding the first region A in the foamed resin layer 61 and have a T shape in plan view.
In the present invention, the foamed resin layer may have a trapezoidal shape in plan view as shown in FIG. The foamed resin layer 110 shown in FIG. 11 can be applied to a window provided at a corner, for example, by combining short sides.
The decorative material for window frame, the decorative material has a decorative layer, a non-foamed resin layer and a foamed resin layer, the ratio of the total thickness of the decorative layer and the non-foamed resin layer to the thickness of the foamed resin layer, and foaming Since the compression elastic modulus of the resin layer is defined to a predetermined value, it has excellent water resistance and heat insulation, and has excellent load resistance, and further, near one end of the decorative material. Since it has a bent part, generation | occurrence | production of curvature can be prevented suitably.
In such a window frame decorative material, the foamed resin layer is preferably composed of a plurality of foamed resin members. Specifically, for example, in the case of the configuration shown in FIGS. 6A to 6E, the foamed resin layer is composed of three members, and the configuration shown in FIGS. 8A and 8B is used. In this case, the foamed resin layer is composed of three members. FIG. 8 shows an example of a window frame decorative material which is a preferred example of the decorative material of the present invention, and FIG. 8A assembles a window frame decorative material which is a preferable example of the decorative material of the present invention. It is sectional drawing of the thickness direction of the raw material laminated body used in the case, and as for the decorative material for window frames (window frame), the non-foamed resin layer 82 and the decoration layer 83 were laminated | stacked in this order on the foamed resin layer 81. In the vicinity of one end of the decorative material (the end on the near side), a lower protrusion (hereinafter also referred to as a bent portion) in a state where the foamed resin layer 81 is folded so as to be inside is formed. Yes.
For example, as shown in FIG. 8A, such a window frame decorative material has four groove-like cuts 86 in a triangular view in cross section on the non-foamed resin layer 82 laminated on the decoration layer 83. A foamed resin layer 81 is laminated on the outside of the cut 86, and another foamed resin layer 81 is laminated at a position separated by the thickness of the foamed resin layer 81 to produce a raw material laminate, and then foamed. A window frame makeup having a structure as shown in FIG. 8A is formed by bending the cut portion 86 so that the resin layer 81 is on the inner side, and bonding the foamed resin layers 81 together by pressure bonding or an adhesive. A material can be obtained.
Further, as shown in FIG. 8B, the foamed resin is provided with two groove-like cuts 66 having a triangular cross-sectional view, and the side surfaces are processed into a taper shape so that the edge portions are arranged in the cut 66 parts. After laminating the layers 81 (b) and 81 (c), the foamed resin layers 81 (b) and 81 (c) are bent so that the foamed resin layers 81 (b) and 81 (c) are on the inner side. c) By pasting each other through pressure bonding or an adhesive, a decorative material for a window frame having a structure as shown in FIG. 8B can be obtained.
In addition, the decorative material of the present invention provided with the decorative layer 3 described above has excellent weather resistance. In particular, when the decorative material of the present invention is used for a window frame, the sunshine weather test 4000 with the decorative layer side as the surface is used. Even if time (test conditions described later) is performed, it is preferable that the change in appearance is slight.

[Manufacturing method of cosmetic material]
The decorative material of the present invention can be produced, for example, through the following steps.

(Preparation process of foamed resin layer)
First, the foamed resin layer is prepared.
As described above, the foamed resin layer is preferably formed by a beading method or a film forming method such as an extrusion film forming method using a T die using a resin composition for forming a foamed resin layer or a calendar film forming method. The foaming is performed at a ratio of 20 times or less to produce a compression elastic modulus of 15 MPa or more.
The expansion ratio and compression modulus of the foamed resin layer can be appropriately adjusted depending on the foaming temperature at the time of foaming, the type of resin, the amount of foaming agent and plasticizer used.

(Preparation process of non-foamed resin layer)
Next, the foamed resin layer is prepared.
The non-foamed resin layer is formed by a film forming method such as an extrusion film forming method using a T-die or a calender film forming method so that the tensile elastic modulus is 180 MPa or more.
The tensile elastic modulus of the non-foamed resin layer can be appropriately adjusted depending on the type of resin, the type and amount of inorganic compound used, and the like.

(Decoration layer formation process)
A decorative layer is formed using the ink composition on the non-foamed resin layer or a base resin layer provided as necessary. The ink composition may be applied by a method such as gravure printing, offset printing, screen printing, flexographic printing, or ink jet printing. Moreover, when forming a concealing layer (solid printing layer), it may be formed by various coating methods such as gravure coating, bar coating, roll coating, reverse roll coating, and comma coating.

(Lamination process of transparent resin layer)
The transparent resin layer is preferably formed via an adhesive layer as necessary after the decoration layer is formed. The adhesive layer may be formed by, for example, various coating methods such as gravure coating, bar coating, roll coating, reverse roll coating, and comma coating, extrusion film formation using a T-die, and the like. And the above-mentioned transparent resin is a method of laminating at the same time as film formation by an extrusion film forming method using a T die, a dry lamination method using a film formed in advance by a film forming method such as an extrusion film forming method using a T die or a calendar film forming method. What is necessary is just to form by the method of laminating | stacking by the thermal lamination method.

(Formation process of surface protective layer)
The surface protective layer is a curable resin after the decoration layer forming step or when the transparent resin layer is laminated, after the resin layer lamination step, on the decoration layer or on the transparent resin layer. An uncured resin layer is coated by a known method such as gravure coating, bar coating, roll coating, reverse roll coating, or comma coating so that the thickness after coating is 3 μm or more and 40 μm or less. Then, the uncured resin layer can be formed by applying heat to the uncured resin layer or irradiating it with ionizing radiation such as an electron beam or ultraviolet ray to cure the uncured resin layer.

The heating temperature in the case of thermosetting is appropriately determined according to the resin used.
When an electron beam is used as the ionizing radiation, the acceleration voltage can be appropriately selected according to the resin used and the thickness of the layer, but the uncured resin layer is usually cured at an acceleration voltage of about 70 kV to 300 kV. preferable. The irradiation dose is preferably such that the crosslinking density of the resin layer is saturated, and is usually selected in the range of 5 kGy to 300 kGy (0.5 Mrad to 30 Mrad), preferably 10 kGy to 50 kGy (1 Mrad to 5 Mrad).
The electron beam source is not particularly limited. For example, various electron beam accelerators such as a cockroft Walton type, a bandegraft type, a resonant transformer type, an insulated core transformer type, a linear type, a dynamitron type, and a high frequency type are used. be able to.
When ultraviolet rays are used as the ionizing radiation, those containing ultraviolet rays having a wavelength of 190 nm or more and 380 nm or less are emitted.
There is no restriction | limiting in particular as an ultraviolet-ray source, For example, a high pressure mercury lamp, a low pressure mercury lamp, a metal halide lamp, a carbon arc lamp etc. are used.

(Attaching process of non-foamed resin layer and decorative layer)
When the decorative layer is a decorative sheet, the non-foamed resin layer and the decorative layer can be attached using, for example, a hot-melt adhesive, in addition to a heat-sensitive adhesive and a pressure-sensitive adhesive. As the hot-melt adhesive, for example, a reactive hot-melt adhesive such as a urethane-based reactive hot melt (hereinafter referred to as “PUR-based adhesive”) is preferably exemplified. This PUR adhesive contains a functional group (isocyanate group) that reacts with moisture in the components, and reacts with moisture attached to the substrate and the decorative sheet and moisture given through them after cooling and curing.
After the reaction, it does not melt even when heated and has a high adhesive strength.

(Attaching process of foamed resin layer and non-foamed resin layer)
Adhesion between the foamed resin layer obtained in the preparation step of the foamed resin layer and the non-foamed resin layer forming the decorative layer is the adhesive shown in the adhesive step between the non-foamed resin layer and the decorative layer. Can be used.

A decorative material for a window frame which is a preferred example of the decorative material of the present invention, the decorative material has a decorative layer, a non-foamed resin layer and a foamed resin layer, and the decorative layer and the non-foamed resin layer have a thickness corresponding to the thickness of the foamed resin layer. Since the ratio of the total thickness and the compression elastic modulus of the foamed resin layer are respectively set to predetermined values, the water resistance and the heat insulation are excellent, and the load resistance is also excellent.
FIG. 9 (a) is a cross-sectional view showing an example in which a window frame decorative material, which is a preferred example of the decorative material of the present invention, is applied to a building window, and FIG. 9 (b) is a decorative material of the present invention. FIG. 9C is a plan view showing an example in which a window frame decorative material which is a preferable example of the above is applied to a window of a building, and FIG. 9C is a window frame decorative material which is a preferable example of the decorative material of the present invention. It is a perspective view which shows an example constructed in the window of this.
That is, the decorative material 90 for window frames, which is a preferred example of the present invention, is usually applied to the interior side of the lower portion of the window 93 provided on the outer wall surface 91 of the building via the bonding portion 92 such as mortar.
Although it does not specifically limit as a window of the building in which the decorative material for window frames which is such a preferable example of this invention is constructed, For example, the window frame containing a bay window stand is mentioned suitably.
In addition, the window frame decorative material which is a preferred example of the present invention is used for at least a part of the window frame. For example, in the case of a square window frame, the decorative material for the window frame is applied to any part or all of the four sides of the window frame. A window frame decorative material which is a preferred example of the invention is applied. Especially, it can construct suitably in the lower side of a window frame.

EXAMPLES Next, although an Example demonstrates this invention further in detail, this invention is not limited at all by this example.

(Evaluation and measurement method)
The cosmetic materials obtained in Examples and Comparative Examples were evaluated and measured by the following methods.
(Evaluation of load resistance)
As shown in FIG. 13, four metal jigs 52 each having a square shape with a side of 2 cm square are in contact with the sample surface of the decorative material 51 so that the four metal jigs 52 are equally loaded. Place the weight of the following three conditions and leave it for one week. Then, the pass / fail judgment was made by visually observing the appearance immediately after removing the weight.
In addition, when a remarkable dent mark could not be discriminated, it was judged as “pass”.
Also, if the evaluation is ◎, it is judged that it can be used for flooring, and if it is ○, it is judged that it can be used for the use of window frames other than flooring, and if it is △, a slight dent mark is confirmed. Although it was possible, it was judged that it could be used for the purpose of the window frame.
Condition 1: 80 kg load (pressure: 5 kg / cm ² )
Condition 2: 48 kg load (pressure: 3 kg / cm ² )
Condition 3: 16 kg load (pressure: 1 kg / cm ² )
◎: Passed with condition 1 ○: Passed with condition 2 △: Passed with condition 3 ×: Failed with condition 3

(Evaluation of tensile modulus)
<Preparation of test piece>
The test piece of the non-foamed resin layer from the decorative material according to the example and the comparative example was cut out into a dumbbell type test piece described in JIS K6732 (1996) using an electric saw. After that, the factor (saw cut) that hinders the measurement of the stretching direction was removed with a sandpaper to prepare a test piece.
<Measurement conditions>
The basic measurement conditions were set with reference to the description of JIS K7161-1994 (ISO 527-1: 1993).
That is, for measuring the dimension of the test piece, a digital caliper that can read up to 0.01 mm was used to measure the width and thickness, and the cross-sectional area Smm ² of the test piece was obtained.
The test piece was measured by fixing both ends in the length direction with a gripping tool.
The distance between the grips does not change during a series of tests, but the end of the test piece is gripped by the grips as described above, and the distance between the grips is measured with the above digital calipers. The initial length L0 = 80 mm ± 1%. When the device detected stress at that time exceeded the range of ± 1 MPa, the test piece was re-gripped.
The tensile stress follows the calculation method of the same JIS standard, and the tensile force per unit area calculated based on the initial cross-sectional area is handled in units of MPa.
The tensile elastic modulus is measured in accordance with the same JIS standard as the difference in stress (load) Δp (σ1-σ2) corresponding to the tensile strain value (elongation) ε1 = 0.10% to ε2 = 0.25%. The tensile elastic modulus E was calculated by dividing by the difference ΔE (ε1-ε2). FIG. 5 shows an example of an elastic modulus chart showing the relationship between the load (N) and the elongation (%) for the test piece.
The tensile speed was measured at a setting of 50 mm / min using a measuring device conforming to the JIS standard.
The initial load point ≧ 0.3N was set, and the initial load point was used as the calculation start point, not the test start point.
In the test, measurement using Tensilon RTC-1310A manufactured by A & D was performed five times, and the maximum value and minimum value of the tensile elastic modulus were excluded, and the average value of three points was described.

(Evaluation of linear expansion coefficient)
A 145 mm long and 300 mm wide rectangular test piece was cut out from each layer of the decorative material, and the test piece temperature was stabilized at 0 ° C. and 40 ° C. using a thermostatic chamber (Espec Corp. Build-in Chamber TBL-6E20W0P2T). For the width and length of the piece, the dimensions of a total of three locations including the center and the portion entering 50 mm from the end are measured using a digital caliper that can read up to 0.01 mm.
A dimensional change amount is calculated from the length dimension obtained at each temperature and each location, and a value obtained by dividing by a dimensional value at 0 ° C. is defined as a dimensional change rate: ΔL.
By dividing ΔL obtained above by the temperature change amount: ΔT, the linear expansion coefficient at each measurement location is obtained, and the average value of the linear expansion coefficients at three lengths is defined as the linear expansion coefficient.

(Evaluation of shape stability (evaluation of warpage))
As shown in FIGS. 12 (a) and 12 (b), the window frame decorative material 60 and the decorative materials 50a to 50d are applied on the mortar with a urethane adhesive 55 at a pitch of 300 mm, and applied on the mortar ( For 1 week). The following criteria are prescribed respectively when used for a window frame (FIG. 12 (a)) and when used for a floor (four floors of decorative materials 50a to 50d, FIG. 12 (b)). Each was evaluated. The warpage is the amount of warpage per 300 mm in the length direction, the value of warpage + (plus) is the peak (convex) warpage, and the value of-(minus) is the valley (concave) warpage. It is. As shown in FIGS. 14 (a) and 15 (a), the warp in the mountain state is placed on a specimen (window frame decorative material 60) with a 300 mm long metal prismatic jig 65 and opened at both ends. The measured gap amounts r1 and r2 are average values. As shown in FIGS. 14 (b) and 15 (b), the warp in the valley state is the gap amount r3 formed between the jig 65 and the test body (the decorative material 50c) as in the warp in the mountain state. It is the maximum value. FIG. 14A is a diagram for explaining a method for evaluating the warping of a decorative material for window frames according to the present invention, and FIG. 14B is a diagram for explaining a method for evaluating the warping of a decorative material according to the present invention. FIG. 15A is a cross-sectional view showing a method for measuring the amount of warpage in a mountain state (convex shape), and FIG. 15B is a measurement of the amount of warpage in a valley state (concave shape). It is sectional drawing which shows a method.
<Window frame standard>
After leaving in an environment of 5 ° C. × 3 days, it was left in an environment of 60 ° C. × 3 days, and the width warpage amount at the end of each condition was evaluated according to the following criteria. As the test body, the window frame decorative material 60 shown in FIGS. 6A and 6B was used. In addition, the dimension when the cosmetics 60 for window frames is planarly viewed is 450 mm wide and 900 mm long.
○: ± 0.6 mm or less Δ: 0.6 mm or more, 1 mm or less, or less than −0.6 mm−1 mm or more ×: ± 1 mm or more <floor standard>
After leaving in an environment of 5 ° C. × 3 days, it was left in an environment of 40 ° C. × 3 days, and the amount of width warpage at the end of each condition was evaluated according to the following criteria. The dimensions of the decorative material 50 when viewed in plan are a width of 450 mm and a length of 900 mm, which are arranged side by side as shown in FIG. 12 (b), and the warping is as shown in FIG. 14 (b). One sheet was selected and measured.
○: ± 0.6 mm or less Δ: 0.6 mm or more, 1 mm or less, or less than −0.6 mm, −1 mm or more ×: ± 1 mm or more <Overall evaluation>
As a comprehensive evaluation, the following criteria were used.
◎: Window frame standard ○
○: Window frame standard △ and floor standard ○
△: Floor standard △
×: Floor reference ×

(Weather resistance test)
Sunshine weather meter: WEL-300 (manufactured by Suga Test Instruments Co., Ltd.) was used to visually evaluate the appearance when a test was conducted for 4000 hours by irradiating the sunshine carbon arc light from the decorative layer side under the following conditions. . The test conditions are as follows: 1 cycle for performing step 2 after step 1 below is 2 hours. After 1 cycle, the test is repeated 2000 times in the manner of step 1 of the second cycle, and the following criteria are defined and evaluated. did. In addition, the sunshine carbon arc light is irradiated through both steps 1 and 2.
○: Level in which change is hardly recognized visually Δ: Change is recognizable, but slight level ×: Level in which change can be clearly confirmed-: Not tested <Step 1>
Black panel temperature: 63 ° C, humidity: 50%
Operation time: 1 hour 42 minutes <Step 2>
Tank temperature: 40 ° C, humidity: 90%
Driving time: 18 minutes

Example 1
On a colored polypropylene resin film (thickness: 60 μm, color: white), a 2 μm-thick pattern pattern was formed by gravure printing using an ink composition (acryl urethane).
Next, an adhesive layer having a thickness of 2 μm was formed using an adhesive for urethane dry lamination, and a transparent polypropylene resin film (thickness: 80 μm) was dry laminated on the pattern layer.
A primer layer having a thickness of 1 μm was formed on the transparent polypropylene resin film using a two-component curable urethane resin. Then, an electron beam curable resin composition (acrylate system) is applied onto the primer layer by gravure printing at a coating amount of 15 g / m ² to form a coating film, and the coating film is crosslinked and cured by irradiation with an electron beam. Thus, a surface protective layer (thickness: 15 μm) was formed, and a decorative sheet (thickness: 160 μm) was produced, which was used as a decorative layer.
Next, an ABS resin sheet (tensile elastic modulus: 2400 MPa, thickness: 2 mm) containing 20% by mass of talc is prepared as a non-foamed resin layer, and is opposed to the colored polypropylene resin film (base resin layer) of the decorative sheet. As described above, the non-foamed resin layer and the decorative sheet were attached by dry lamination via an urethane dry laminate adhesive.
Next, EPS resin (foaming agent: butane (7 parts by mass with respect to 100 parts by mass of polystyrene resin), plasticizer; liquid paraffin (0.15 parts by mass with respect to 100 parts by mass of polystyrene resin)) is used as the foamed resin layer. A foamed resin layer (foaming ratio: 10 times, compression elastic modulus: 43 MPa, thickness: 9 mm) prepared by the bead method is prepared, and the non-foamed resin layer and the foamed resin layer on which the decorative sheet is attached are prepared. A decorative material was prepared by sticking using a PUR adhesive.
Table 1 shows the results of evaluating the obtained cosmetic material.

Examples 2 to 8 and Comparative Examples 1 to 3
A cosmetic material was produced in the same manner as in Example 1 except that the foamed resin layer and the non-foamed resin layer shown in Table 1 were used.
Table 1 shows the results of evaluating the obtained cosmetic material.

In Table 1, PVC according to Example 2 and Comparative Example 1 is a vinyl chloride sheet in which a glass fiber resin is added and the linear expansion coefficient is reduced to 5 × 10 ⁻⁵ / ° C. (Example 2 has a thickness of 4 mm). Comparative Example 1 is 5 mm thick), PP according to Examples 3 and 4 is a polypropylene resin sheet containing 45% by mass of talc, and PE according to Examples 5 and 6 and Comparative Example 2 is 20% by mass of talc. The PP resin sheet is a polypropylene resin sheet having a content of an inorganic compound such as talc of less than 10% by mass.
When the decorative material for the window frame having the structure shown in FIG. 6A is manufactured using the decorative material according to the example and the comparative example, since any decorative material is made of non-woody material, the conventional decorative material made of wooden material is used. It was superior in water resistance and heat insulation than the decorative material. Further, in the decorative materials according to the example and the comparative examples 1 and 2, it was possible to suitably prevent the occurrence of warpage, but the window frame decorative material using the decorative material according to the comparative example 3 was greatly warped. .
Moreover, the decorative material according to Example 1 was excellent in the weather resistance test.

ADVANTAGE OF THE INVENTION According to this invention, while being excellent in water resistance and heat insulation, it can suppress that curvature generate | occur | produces, and can obtain the cosmetics which are excellent also in load resistance. The decorative material of the present invention is suitably used for residential flooring, especially flooring for water use such as toilets, washbasins and kitchens, and window frames.

1, 61, 61 (a) to (c), 81, 81 (b), (c), 101, 110 Foamed resin layer 2, 62, 82, 102 Non-foamed resin layer 3, 63, 83, 103 Decorative layer 4 Base resin layer 5 Transparent resin layer
6 Surface protective layer 7 Adhesive layer 8a Male fruit 8b Female fruit 10, 50a-d, 51 Cosmetic material 21 First thermoplastic resin layer 22 Glass component layer 23 Second thermoplastic resin layer 33 Pattern layer 52 Metal jig 55 Urethane Adhesives 60, 701, 702, 90 Window frame decorative material 64, 66, 86, 106, 106 'Cut 65 Bent part 67, 107, 107' Cut part 71 Edge tape 73 Notch 91 Outer wall surface 92 Adhesive part 93 Glass window r1-r3 Clearance amount

Claims (4)

1. A decorative material having a decorative layer, a non-foamed resin layer and a foamed resin layer,
   The total thickness of the decorative layer and the non-foamed resin layer is 50% or less with respect to the thickness of the foamed resin layer,
   The compression elastic modulus of the foamed resin layer is 15 MPa or more,
   The non-foamed resin layer and the foamed resin layer both have a linear expansion coefficient of 8 × 10 ⁻⁵ / ° C. or less, and the difference between the non-foamed resin layer and the foamed resin layer is 3 × 10 ⁻ Cosmetic material characterized by being within ⁵ / ° C.
2. The decorative material according to claim 1, wherein the non-foamed resin layer has a tensile elastic modulus of 180 MPa or more.
3. The decorative material according to claim 1 or 2, wherein the non-foamed resin layer contains an inorganic compound.
4. The decorative material according to claim 1, 2, or 3, wherein the thickness of the decorative material is 5 mm or more.

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