WO2021049611A1 - 化粧材及び化粧部材 - Google Patents
化粧材及び化粧部材 Download PDFInfo
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- WO2021049611A1 WO2021049611A1 PCT/JP2020/034461 JP2020034461W WO2021049611A1 WO 2021049611 A1 WO2021049611 A1 WO 2021049611A1 JP 2020034461 W JP2020034461 W JP 2020034461W WO 2021049611 A1 WO2021049611 A1 WO 2021049611A1
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- layer
- decorative
- resin
- decorative material
- base material
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
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- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin 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
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- B32B27/16—Layered products comprising a layer of synthetic resin specially treated, e.g. irradiated
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- B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
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- C—CHEMISTRY; METALLURGY
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- C—CHEMISTRY; METALLURGY
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- E04F13/0866—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements composed of several layers, e.g. sandwich panels or layered panels
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- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/18—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of organic plastics with or without reinforcements or filling materials or with an outer layer of organic plastics with or without reinforcements or filling materials; plastic tiles
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- C—CHEMISTRY; METALLURGY
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Definitions
- the present invention relates to a decorative material and a decorative member.
- a decorative board may be arranged on the surface of a light electric product; a cabinet of OA equipment or the like;
- the decorative board include a decorative member in which a decorative material is attached to various substrates such as a resin member, a wood member, and a metal member, or a decorative material.
- a decorative material having a structure having a surface protective layer on a base material, for example, a sheet-shaped decorative material (also referred to as a “decorative sheet”) or the like is used.
- a decorative material for example, a plastic product using a decorative sheet using a polyvinyl chloride sheet as a base material and, if necessary, a decorative layer as a decorative treatment, a surface protective layer, or the like is used (for example).
- Patent Document 1 a plastic product using a decorative sheet using a polyvinyl chloride sheet as a base material and, if necessary, a decorative layer as a decorative treatment, a surface protective layer, or the like is used (for example).
- the present invention has been made under such circumstances, and is a decorative material exhibiting excellent long-term adhesion, which has high initial adhesion strength in the construction process, excellent construction suitability, does not cause peeling even after long-term use, and It is an object of the present invention to provide a decorative member having excellent long-term adhesion.
- the decoration treatment is performed by a decorative layer, and the decorative layer, the adhesive layer, the resin layer and the primer layer are provided in the order of the base material, the decorative layer, the adhesive layer, the resin layer and the primer layer.
- the decorative material according to any one of 4. 6.
- 7. A decorative member having the decorative material and the substrate according to any one of 1 to 6 above via an adhesive layer so that the base material of the decorative material and the substrate face each other.
- the adhesive layer is made of a urethane resin-based adhesive.
- the urethane resin adhesive is a moisture-curable adhesive.
- the decorative member according to any one of 7 to 9 above, wherein the substrate is a resin substrate or a metal substrate.
- a decorative material having high initial adhesion strength in the construction process, excellent construction suitability, no peeling even after long-term use, exhibiting excellent long-term adhesion, and a decorative member having excellent long-term adhesion. can be provided.
- the base material is subjected to a decorative treatment, and the moisture permeability measured in accordance with the moisture permeability test method (cup method) of the moisture-proof packaging material specified in JIS Z0208: 1976 is 0. it is characterized in that the 75g / m 2 ⁇ 24h or more 45g / m 2 ⁇ 24h or less.
- the decorative material of the present embodiment exhibits high initial adhesion strength in the process of constructing the decorative material by setting the moisture permeability within a specific range. Therefore, the decorative material of the present embodiment can suppress the occurrence of so-called springback, in which the end face of the decorative sheet is peeled off due to insufficient initial adhesion strength during construction, and improves construction suitability. be able to.
- the decorative material and the substrate are used as a decorative member via an adhesive layer, deterioration of the adhesive layer between the decorative material and the substrate can be suppressed, so that peeling due to the deterioration can be suppressed. Will be exhibited, and excellent long-term adhesion will be exhibited without peeling even after long-term use. That is, by setting the moisture permeability of the decorative material of the present invention within a specific range, it is possible to achieve both excellent construction suitability due to high initial adhesion strength in the construction process and long-term adhesion that does not cause peeling even after long-term use. It will be possible.
- Decorative material of the present embodiment is one having the following moisture permeability 0.75g / m 2 ⁇ 24h or more 45g / m 2 ⁇ 24h. The effect obtained by the moisture permeation will be described more specifically. If the moisture permeability is less than 0.75g / m 2 ⁇ 24h, when the decorative member by attaching the substrate through an adhesive layer, adhesion failure due to curing of the adhesive failure to be used in the adhesive layer Since it is likely to occur, excellent initial adhesive strength cannot be obtained, and excellent construction suitability cannot be obtained.
- the decorative material of the present embodiment has excellent construction suitability due to the high initial adhesion strength in the construction process by setting the moisture permeability within a specific range, and peeling does not occur even after long-term use. Both long-term adhesion can be achieved.
- moisture permeability 1.2g / m 2 ⁇ 24h or more, more preferably 1.5g / m 2 ⁇ 24h, more preferably 2.5g / m 2 ⁇ 24h or more , even more preferably at 4.5g / m 2 ⁇ 24h or more, preferably 40g / m 2 ⁇ 24h or less as the upper limit, more preferably 35g / m 2 ⁇ 24h or less, even more preferably not more than 30g / m 2 ⁇ 24h , even more preferably at most 20g / m 2 ⁇ 24h.
- the moisture permeability can be adjusted mainly by the type of the material constituting the base material described later, and when the resin layer is provided, the type of the material constituting the resin layer and the like.
- FIG. 1 is a schematic cross-sectional view showing an example of the layer structure of the decorative material of the present embodiment, and the decorative material 10 of the present embodiment has the base material 1 and the decorative layer 2 as a typical aspect of the decorative treatment. It is shown that Further, FIG. 2 is a schematic cross-sectional view showing one aspect of a preferable layer structure of the decorative material of the present embodiment, and is a base material 1, a decorative layer 2, an adhesive layer 3, a resin layer 4, a primer layer 5, and a surface protective layer. It is shown to have 6.
- each layer constituting the decorative material of the present embodiment will be described in more detail.
- Base material 1 As the material of the base material, as long as the moisture permeability in the state of being composed of the decorative material is within the above-mentioned predetermined range, those usually used as the base material of the decorative material can be adopted without limitation.
- Typical examples of the material of the base material include a base material made of paper, non-woven fabric or woven fabric, resin, wood, metal, non-metal inorganic material, etc. From the viewpoint of improving adhesion, a base material made of resin is preferable.
- the thickness of the base material is not particularly limited as long as the moisture permeability in the state of being composed of the decorative material is within the above-mentioned predetermined range, and a film, sheet, or plate-like material may be appropriately used as desired. Can be used.
- the thickness of the base material is usually about 20 ⁇ m or more and 200 ⁇ m or less as a film or sheet, and about 500 ⁇ m or more and 10 cm or less as a plate, in consideration of the moisture permeability of the decorative material.
- the resin examples include polyolefin resins such as polypropylene resins and polyethylene resins; polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), ethylene glycol-terephthalic acid-isophthalic acid copolymer, and the like.
- Polyester resin such as polyester thermoplastic elastomer; acrylic resin such as polymethyl (meth) acrylate, polybutyl (meth) acrylate, methyl (meth) acrylate-butyl (meth) acrylate copolymer; polyester resin, polycarbonate resin, acrylonitrile-butadiene -Examples include a resin base material made of a thermoplastic resin such as a styrene resin (hereinafter, also referred to as “ABS resin”) and a vinyl chloride resin.
- ABS resin styrene resin
- polyolefin resins and vinyl chloride resins are preferable, and environmental performance is preferable in consideration of versatility, suitability for use as a decorative material, etc., as well as improving the long-term adhesion as well as construction suitability by easily keeping the moisture permeability within the above range.
- a polyolefin resin is preferable.
- the above resins can be used alone or in combination of two or more. When a plurality of types are combined, a base material made of various single resins may be combined, or a plurality of types of resins may be mixed and used as one base material.
- the polyolefin resin includes homopolymers of olefins such as ethylene, propylene and butene; various copolymers such as block copolymers of ethylene-propylene and random copolymers; at least one of ethylene and propylene. And a copolymer with at least one other olefin such as butene, penten, hexene; a copolymer of at least one of ethylene and propylene and at least one other monomer such as vinyl acetate and vinyl alcohol; And so on.
- olefins such as ethylene, propylene and butene
- various copolymers such as block copolymers of ethylene-propylene and random copolymers
- at least one of ethylene and propylene at least one of ethylene and propylene.
- a copolymer with at least one other olefin such as butene, penten, hexene
- polyethylene-based resins containing ethylene as a constituent unit and polypropylene-based resins containing propylene as a constituent unit are preferable, and polypropylene-based resins are preferable, from the viewpoint of easily keeping the moisture permeability within the above range and improving construction suitability and long-term adhesion. preferable.
- the moisture permeation is preferably adjusted because it is easy and more reliable to adjust the thickness of the layer in which the resin such as the base material and the resin layer can be used.
- the thickness of the base material and the resin layer is considered in consideration of the ratio of the thickness to the total thickness of the decorative material in the laminated structure of the decorative material. It is preferable that the temperature is in a predetermined range depending on the type of the material constituting these layers, preferably the resin.
- the thickness of the base material is preferably 40 ⁇ m or more and 200 ⁇ m or less when a polyethylene resin, a polypropylene resin, and a vinyl chloride resin are used. It may be selected from the range in consideration of the laminated structure of the decorative material and the desired moisture permeability.
- the polyethylene-based resin may be a homopolymer of ethylene, that is, polyethylene, or ethylene and other comonomer copolymerizable with ethylene (for example, propylene, 1-butene, 1-). It may be a copolymer with ⁇ -olefin such as hexene and 1-octene, vinyl acetate, vinyl alcohol, etc.).
- polyethylene include high-density polyethylene (HDPE), medium-density polyethylene (MDPE), low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), ultra-low-density polyethylene (VLDPE), and ultra-high-density polyethylene (UHMWPE). ), Crosslinked polyethylene (PEX) and the like. These polyethylene-based resins may be used alone or in combination of two or more.
- the polypropylene-based resin may be a homopolymer of propylene, that is, polypropylene, or propylene and another comonomer copolymerizable with propylene (for example, ethylene, 1-butene, 1-hexene, 1-octene, etc.).
- ⁇ -Olefin; vinyl acetate, vinyl alcohol, etc. may be a copolymer.
- the moisture permeability of the base material can be adjusted by adjusting the crystallinity.
- the higher the crystallinity the lower the moisture permeability of the polypropylene resin.
- the crystallinity is preferably 30% or more, more preferably 40% or more, and the upper limit is preferably 80% or less. It is preferably 70% or less.
- the moisture permeability of the base material can be adjusted by adjusting the mass ratio of the isotactic polypropylene and the atactic polypropylene.
- the moisture permeability of the base material can be reduced by adding the isotactic polypropylene as compared with the case where the ratio of the atactic polypropylene in the polypropylene is 100% by mass.
- the mass ratio of the atactic polypropylene to the isotactic polypropylene is preferably 0/100 or more and 20/80 or less in consideration of the ease of adjusting the moisture permeability.
- the vinyl chloride resin is a copolymer of a homopolymer of a vinyl chloride monomer, that is, polyvinyl chloride or a vinyl chloride monomer, and a monomer copolymerizable with the vinyl chloride monomer.
- the copolymer thus obtained can also be used.
- Examples of monomers copolymerizable with vinyl chloride monomer include vinyl esters such as vinyl acetate and vinyl propionate; acrylic acid esters such as methyl acrylate and butyl acrylate; methacrylate esters such as methyl methacrylate and ethyl methacrylate; butyl malate and Maleic acid esters such as diethyl malate; Fumaric acid esters such as dibutyl fumarate and diethyl fumarate; Vinyl ethers such as vinyl methyl ether, vinyl butyl ether and vinyl octyl ether; Vinyl cyanide such as acrylonitrile and methacrylonitrile Olefins such as ethylene, propylene, butylene and styrene; Dienes such as isoprene and butadiene; Vinylidene halides other than vinyl chloride such as vinylidene chloride and vinyl bromide, vinyl halides; Allyl phthalates such as diallylphthalate , Et
- the average degree of polymerization of the vinyl chloride resin is preferably 500 or more and 4000 or less, more preferably 700 or more and 3900 or less, and 1000 or more and 3800 or less from the viewpoint that the moisture permeability can be easily kept within the above range and the long-term adhesion is improved as well as the workability. Is more preferable.
- the average degree of polymerization is within the above range, excellent mechanical strength and moldability can also be obtained.
- the average degree of polymerization is the average degree of polymerization measured in accordance with JIS K6721.
- a plasticizer when a vinyl chloride resin is used, a plasticizer can be added from the viewpoint of easily keeping the moisture permeability within the above range, improving the long-term adhesion as well as the workability, and improving the workability. preferable.
- the plasticizer is not particularly limited as long as it is compatible with the vinyl chloride resin.
- dibutyl phthalate DBP
- dioctyl phthalate DOP
- diisononyl phthalate DINP
- diisodecyl phthalate Plasticizer
- phthalic acid plasticizers such as diundecyl phthalate (DUP)
- adipic acid plasticizers such as dibutyl adipate
- phosphoric acid plasticizers such as tributyl phosphate, tricredil phosphate, triphenyl phosphate
- trimerits Trimellitic acid-based plasticizers such as tributyl acid and trioctyl trimellitic acid
- various known polyester-based plasticizers such as adipic acid-based polyester
- citrate esters such as acetyltributylcitrate and acetyltrioctylcitrate; and the like can be mentioned.
- phthalic acid-based plasticizers adipic acid-based plasticizers, and polyester-based plasticizers are preferable from the viewpoint of improving the long-term adhesion as well as the workability and the ease of keeping the moisture permeability within the above range.
- Phthalic acid-based plasticizers and polyester-based plasticizers are more preferable.
- these plasticizers may be used alone or in combination of two or more.
- the content of the plasticizer may be appropriately adjusted and used according to the desired moisture permeability, and it cannot be said unconditionally, but usually, the additive of the plasticizer is increased and the moisture permeability of the vinyl chloride resin is increased. Tend to do. In consideration of this point, the amount is preferably 15 parts by mass or more, more preferably 20 parts by mass or more, still more preferably 25 parts by mass or more, and preferably 50 parts by mass as an upper limit with respect to 100 parts by mass of the vinyl chloride resin. Hereinafter, it is more preferably 45 parts by mass or less, still more preferably 35 parts by mass or less.
- the content of the plasticizer By setting the content of the plasticizer within the above range, it becomes easy to adjust the moisture permeability to a desired range, and it is possible to improve the long-term adhesion as well as the construction suitability. Further, when the content of the plasticizer is 20 parts by mass or more, the vinyl chloride resin can be made flexible and the workability can be improved, while when it is 50 parts by mass or less, the bleed-out of the plasticizer is suppressed. However, it becomes easier to stably adjust the moisture permeability to the desired range, and it is possible to improve the long-term adhesion as well as the construction suitability.
- the content thereof is 100 parts by mass of the vinyl chloride resin.
- it is preferably 25 parts by mass or more, more preferably 30 parts by mass or more, further preferably 35 parts by mass or more, and the upper limit is preferably 50 parts by mass or less, more preferably 45 parts by mass or less, still more preferably 40 parts by mass. It is less than a part.
- polyester plasticizer When a polyester plasticizer is used, its content is preferably 15 parts by mass or more, more preferably 18 parts by mass or more, and further preferably 20 parts by mass or more with respect to 100 parts by mass of the vinyl chloride resin.
- the upper limit is preferably 35 parts by mass or less, more preferably 30 parts by mass or less, and further preferably 25 parts by mass or less.
- the paper base material examples include kraft paper, titanium paper, linter paper, sulfate paper, glassine paper, parchment paper, resin impregnated paper, thin paper, Japanese paper and the like.
- the base material of the non-woven fabric or woven fabric is composed of, for example, inorganic fibers such as glass fiber, alumina fiber, silica fiber and carbon fiber, and organic fiber of various synthetic resins such as polyester resin, acrylic resin, polyethylene resin and polypropylene resin. Examples thereof include non-woven fabrics or woven fabrics to be used, and base materials such as composites thereof.
- Examples of the wood include a wood base material made of wood of various tree species such as cedar, cypress, pine, oak, lauan, teak, and rubber tree.
- the wood base material may be in the form of a film or sheet called a veneer, or in the form of a single plate, plywood, laminated wood, particle board, fiberboard or the like.
- Examples of the metal include iron, aluminum, copper, tin, titanium, and a metal base material made of an alloy containing at least one of these metals (for example, carbon steel, stainless steel, duralumin, brass, bronze, etc.).
- Examples of non-metallic inorganic materials include cement, gypsum, calcium silicate, ceramics, glass, and various ceramics.
- the base material may be colored or uncolored (transparent), and when it is colored, the mode of coloring is not particularly limited and may be transparently colored. It may be opaque coloring (concealed coloring), and these may be arbitrarily selected.
- the colorants include, for example, inorganic pigments such as titanium white, antimony white, iron black, yellow lead, titanium yellow, petal pattern, cadmium red, ultramarine blue, and cobalt blue; Organic pigments or dyes such as isoindolinone yellow, phthalocyanine blue, nickel-azo complex, azomethine azo black pigment, perylene black pigment; metal pigment consisting of scaly foil pieces such as aluminum and brass; titanium dioxide coated mica, basic Examples thereof include colorants such as pearl luster (pearl) pigments composed of scaly foil pieces such as lead carbonate.
- inorganic pigments such as titanium white, antimony white, iron black, yellow lead, titanium yellow, petal pattern, cadmium red, ultramarine blue, and cobalt blue
- Organic pigments or dyes such as isoindolinone yellow, phthalocyanine blue, nickel-azo complex, azomethine azo black pigment, perylene black pigment
- metal pigment consisting of scaly foil pieces such
- any means such as addition to the resin (kneading, kneading) or formation by applying a coating film of a paint containing the resin and a colorant can be adopted.
- coloring the base material of paper, non-woven fabric, or woven fabric it can be carried out by any means such as mixed extraction with pulp or fiber material, formation of a coating film, or a combination thereof.
- Additives may be added to the base material, if necessary.
- the additive include an inorganic filler such as calcium carbonate and clay, a flame retardant such as magnesium hydroxide, an antioxidant, a lubricant, a foaming agent, an antioxidant, an ultraviolet absorber, a light stabilizer and the like.
- the blending amount of the additive is not particularly limited as long as it does not impair the processing characteristics and the like, and can be appropriately set according to the required characteristics and the like.
- a weather resistant agent such as an ultraviolet absorber and a light stabilizer among the above additives.
- an ultraviolet absorber generally used for cosmetic materials can be used without particular limitation, and either an organic substance or an inorganic substance can be used.
- the organic substance-based ultraviolet absorber include a benzotriazole-based ultraviolet absorber, a benzophenone-based ultraviolet absorber, a triazine-based ultraviolet absorber, a hydroxyphenyltriazine-based ultraviolet absorber, and the like.
- a light stabilizer generally used for cosmetic materials can be used without particular limitation, and examples thereof include hindered amine-based light stabilizers such as piperidinyl sebacate-based light stabilizers. Further, these ultraviolet absorbers and light stabilizers may have a reactive functional group having an ethylenic double bond such as a (meth) acryloyl group, a vinyl group or an allyl group in the molecule.
- the inorganic ultraviolet absorber include titanium dioxide, ferric oxide, zinc oxide, cerium oxide, zirconium oxide and the like having an average particle size of 380 nm or less, preferably 100 nm or less, which is the shortest wavelength of visible light. ..
- These ultraviolet absorbers, weathering agents such as light stabilizers, and various other additives can be used alone or in combination of two or more.
- the shape of the base material is not particularly limited and may be appropriately selected as desired.
- a flat plate shape, a curved surface shape, or a non-flat plate shape having corners or the like may be used. It may be.
- the decorative material in the form of a flat plate also referred to as “sheet-like” is shown in FIGS. 1 and 2, the shape of the decorative material of the present invention is not limited to this. Considering the ease of manufacturing, use, processing, etc. of the decorative material, the flat plate shape is preferable.
- the thickness of the base material is preferably 20 ⁇ m or more, more preferably 30 ⁇ m or more, still more preferably 40 ⁇ m or more, in consideration of surface characteristics such as abrasion resistance, weather resistance, and scratch resistance, processing characteristics, and ease of handling.
- the upper limit is preferably 500 ⁇ m or less, more preferably 300 ⁇ m or less, and even more preferably 150 ⁇ m or less.
- the base material is physically surface-treated on one side or both sides by an oxidation method, an unevenness method, etc. in order to improve the interlayer adhesion between the base material and the other layers and to strengthen the adhesiveness with various base materials.
- an oxidation method such as chemical surface treatment can be applied.
- the oxidation method include corona discharge treatment, chromium oxidation treatment, flame treatment, hot air treatment, ozone-ultraviolet treatment method and the like
- the unevenness method include sandblasting method and solvent treatment method.
- a primer layer (“easy-adhesion layer” described later) is applied to at least one surface of the base material. It may also be referred to as (also referred to as)).
- the decorative material of the present embodiment is formed by subjecting a base material to a decorative treatment.
- the decorative material of the present embodiment can be used as the decorative material, which imparts a design such as a color, a pattern, or an uneven pattern to the decorative material of the present embodiment to improve the design.
- various known forms can be adopted as the decoration treatment, for example, formation of a decorative layer such as a pattern layer and a colored layer by printing or the like, a metal processing layer by vacuum deposition or the like, or a base material.
- Addition of a colorant to a resin layer or the like, which will be described later, formation of an uneven pattern (molding) by embossing, or the like can be adopted.
- the decoration treatment that is typically used is the formation of a decoration layer.
- the decorative treatment the formation of the decorative layer will be mainly described.
- the decorative layer as a decorative treatment is provided on one surface of the base material and is provided so as to cover the entire surface of the decorative layer 2A (also referred to as a "total solid layer").
- the decorative layer 2A also referred to as a "total solid layer”
- Only, or a layer composed only of the pattern layer 2B provided so as to form a pattern so as to cover a part of the layer, or the entire surface is colored. It may be a layer in which the layer 2A and the pattern layer 2B are combined.
- the decorative layer is preferably a layer composed of a pattern layer and a fully colored layer.
- the decorative material of the present embodiment preferably has a base material, a fully colored layer, and a pattern layer in this order, and the pattern layer may be one layer or two or more layers.
- the pattern given by the decorative layer may be selected as desired without any particular limitation.
- a wood grain pattern or a marble pattern for example, travertin marble
- stone patterns that imitate the surface of rocks such as the open surface of granite plates
- fabric patterns that imitate textures and cloth-like patterns
- leather (skin grain) patterns that express leather grain
- tiled patterns bricks
- patterns include patterns such as pile patterns, hairlines, perforated grooves, satin finish, grain, letters, symbols, geometric patterns, and parquet, patchwork, and block patterns that combine these patterns.
- the wood grain pattern is preferable as the pattern of the decorative material of the present invention because the popularity of the wood grain pattern is deep-rooted.
- the wood grain pattern includes a grain pattern, a plank pattern, a heather pattern, a wood grain pattern, and the like, but any of them may be used.
- an ink or paint is laminated on the entire surface or in a desired pattern by various printing methods, or a pattern layer or a color layer on the entire surface, or aluminum, chromium, gold, silver by vacuum deposition, spatter, plating, etc. , A metal layer formed by laminating various metal layers made of copper, tin, etc. on the entire surface or in a desired pattern can be adopted.
- a form of a decorative layer composed of a particularly general-purpose pattern layer and / or a fully colored layer will be described.
- a resin composition containing at least a binder resin and a coloring agent such as a pigment or a dye is preferably used for forming a decorative layer having the form of a pattern layer or a fully colored layer, and other components used as desired.
- a matting agent, an extender pigment, a stabilizer, an ultraviolet absorber, a light stabilizer, a solvent and the like can be appropriately mixed.
- the decorative layer is a layer containing at least a binder resin and a colorant such as a pigment or a dye, and is a layer that can contain other components that can be used as desired and optionally.
- the binder resin is not particularly limited, and for example, urethane resin, acrylic polyol resin, acrylic resin, polyester resin, alkyd resin, amide resin, butyral resin, styrene resin, urethane-acrylic copolymer, vinyl chloride-vinyl acetate common weight.
- Preferred examples thereof include a coalesced resin, a vinyl chloride-vinyl acetate-acrylic copolymer, a nitrocellulose (nitrated cotton), and a resin such as cellulose acetate.
- a curable resin such as a two-component curable urethane resin containing various polyols such as acrylic polyol as a main agent and various isocyanates as a curing agent may be used. These can be used alone or in combination of two or more.
- Examples of the colorants such as pigments and dyes that can be used in the decorative layer include the same colorants as the pigments and dyes that can be used for the above-mentioned base material, and among these, depending on the desired pattern. It may be selected as appropriate.
- the decorative layer preferably contains a matting agent among the above-mentioned other components used as desired.
- Matters include inorganic fillers such as silica, clay, kaolinite, heavy calcium carbonate, light calcium carbonate, precipitated barium sulfate, calcium silicate, synthetic silicate, and fine powder of silicic acid; acrylic resin, urethane. Examples thereof include organic fillers such as resins, nylon resins, polypropylenes, and urea-based resins.
- the decorative layer contains a matting agent, the decorative layer has a lower gloss, so that it is possible to express a design having a visual unevenness due to the difference in gloss.
- the wood grain pattern exemplified as a preferable pattern includes a lower gloss (matte or low gloss) conduit portion, a higher gloss (glossy or high gloss) spring wood portion, and a higher gloss autumn wood portion (shining portion). ) Etc. exist.
- a plurality of pattern layers such as a pattern layer forming a lower glossy conduit portion, a pattern layer forming a higher glossy spring material portion, and a pattern layer forming a higher gloss autumn material portion are combined. Therefore, it is possible to form a pattern with a high degree of design.
- the entire coloring layer and the pattern layer can be separated from each other. It is also possible to increase the gloss difference and improve the design.
- the volume average particle diameter of these matting agents is preferably 0.5 ⁇ m or more and 25 ⁇ m or less, more preferably 1 ⁇ m or more and 15 ⁇ m or less, and further preferably 3 ⁇ m or more and 10 ⁇ m or less.
- the content of the matting agent in the decorative layer with respect to 100 parts by mass of the binder resin is preferably 0.5 parts by mass or more, more preferably 1 part by mass or more, still more preferably 2 parts by mass or more, and the upper limit is It is usually 100 parts by mass or less, preferably 50 parts by mass or less, more preferably 20 parts by mass or less, and further preferably 10 parts by mass or less.
- the decorative layer can be visually recognized as a lower gloss layer, so that it is possible to improve the visual unevenness due to the gloss difference, and the resin composition.
- the thixotropic property is not extremely high and the coating performance is improved, and as a result, the design property is improved.
- the decorative layer may contain a weather resistant agent such as an ultraviolet absorber and a light stabilizer from the viewpoint of improving the weather resistance.
- a weather resistant agent such as an ultraviolet absorber and a light stabilizer from the viewpoint of improving the weather resistance.
- examples of the ultraviolet absorber and the light stabilizer include those that can be contained in the base material, and the ultraviolet absorber and the light stabilizer may be appropriately selected from these according to the desired performance.
- the thickness of the decorative layer may be appropriately selected according to the desired pattern, preferably 0.5 ⁇ m or more, more preferably 1 ⁇ m or more, still more preferably 2 ⁇ m or more, and the upper limit is preferably 15 ⁇ m or less, more preferably. It is 10 ⁇ m or less, more preferably 8 ⁇ m or less.
- the decorative material of the present embodiment may have a surface protective layer in addition to the above-mentioned base material and decorative layer.
- the surface protective layer is a layer provided on the outermost surface when the decorative material is laminated on various substrates and used for various purposes (for example, interior members of buildings, etc.), that is, on the outermost surface side when used.
- the surface protective layer is a layer that can protect the decorative material of the present embodiment, that is, a layer that can impart surface characteristics such as stain resistance and abrasion resistance to the decorative material of the present embodiment. From such a viewpoint, the surface protective layer is preferably a layer provided over the entire surface of the decorative material of the present embodiment.
- the surface protective layer may be made of either a thermoplastic resin or a curable resin, and from the viewpoint of protecting the decorative material of the present embodiment and obtaining surface properties such as better stain resistance and abrasion resistance.
- a layer composed of a curable resin more specifically, a layer composed of a cured product of a curable resin is preferable.
- the layer may be composed of a combination of a thermosetting resin and a curable resin, and in the present specification, the cured product of the curable resin also includes a cured product of a resin composition containing the curable resin. Is done.
- thermoplastic resin examples include acrylic resin, polyester resin, unsaturated polyester resin, vinyl chloride-vinyl acetate copolymer, polyester urethane resin, and thermoplastic (non-crosslinked) urethane resin.
- a curable resin such as a thermosetting resin, a two-component curable resin, or an ionizing radiation curable resin can be used, and the surface of the decorative material of the present embodiment has stain resistance, abrasion resistance, and the like. From the viewpoint of improving the characteristics, an ionizing thermosetting resin is preferable.
- thermosetting resin examples include acrylic resin, urethane resin, phenol resin, urea melamine resin, epoxy resin, unsaturated polyester resin, and silicone resin.
- a curing agent is added to the thermosetting resin as needed.
- the two-component curable resin includes a two-component curable urethane resin containing a polyol compound as a main agent and an isocyanate compound as a curing agent, a two-component curable epoxy resin using amine and the like as a curing agent, a two-component curable urethane-modified acrylic resin, and two. Examples include liquid-curable polyester resins.
- the ionizing radiation curable resin is a resin that is crosslinked and cured by irradiation with ionizing radiation, and has an ionizing radiation curable functional group.
- the ionizing radiation curable functional group is a group that is crosslinked and cured by irradiation with ionizing radiation, and a functional group having an ethylenic double bond such as a (meth) acryloyl group, a vinyl group, or an allyl group is preferably mentioned. Be done.
- ionizing radiation means an electromagnetic wave or a charged particle beam having an energy quantum capable of polymerizing or cross-linking a molecule, and usually, ultraviolet rays (UV) or electron beams (EB) are used.
- Electromagnetic waves such as X-rays and ⁇ -rays, and charged particle beams such as ⁇ -rays and ion rays are also included.
- the ionizing radiation curable resin can be appropriately selected and used from the polymerizable monomers and polymerizable oligomers conventionally used as ionizing radiation curable resins.
- a (meth) acrylate-based monomer having a radically polymerizable unsaturated group in the molecule is preferable, and a polyfunctional (meth) acrylate monomer is particularly preferable.
- “(meth) acrylate” means "acrylate or methacrylate”.
- the polyfunctional (meth) acrylate monomer include a (meth) acrylate monomer having two or more ionizing radiation curable functional groups in the molecule and having at least a (meth) acryloyl group as the functional group.
- An acrylate monomer having an acryloyl group is preferable from the viewpoint of protecting the decorative material and further improving surface properties such as stain resistance and abrasion resistance.
- the number of functional groups is preferably 2 or more, and the upper limit is preferably 8 or less, more preferably 6 or less, still more preferably 4 or less, and particularly preferably 3 or less.
- These polyfunctional (meth) acrylates may be used alone or in combination of two or more.
- polymerizable monomers examples include bifunctional (meth) acrylates such as ethylene glycol di (meth) acrylate, bisphenol A tetraethoxydiacrylate, bisphenol A tetrapropoxydiacrylate, and 1,6-hexanediol diacrylate; trimethylol.
- bifunctional (meth) acrylates such as ethylene glycol di (meth) acrylate, bisphenol A tetraethoxydiacrylate, bisphenol A tetrapropoxydiacrylate, and 1,6-hexanediol diacrylate; trimethylol.
- the polymerizable oligomer examples include a (meth) acrylate oligomer having two or more ionizing radiation curable functional groups in the molecule and having at least a (meth) acryloyl group as the functional group.
- urethane (meth) acrylate oligomer epoxy (meth) acrylate oligomer, polyester (meth) acrylate oligomer, polyether (meth) acrylate oligomer, polycarbonate (meth) acrylate oligomer, acrylic (meth) acrylate oligomer, polycaprolactone urethane (meth).
- Acrylate oligomer polycaprolactone diol urethane (meth) acrylate and the like.
- the number of functional groups of these polymerizable oligomers is preferably 2 or more, and the upper limit is preferably 8 or less. It is preferably 6 or less, more preferably 4 or less, and particularly preferably 3 or less. From the same viewpoint as this, the weight average molecular weight is preferably 500 or more, more preferably 1,000 or more, and the upper limit is preferably 80,000 or less, more preferably 50,000 or less. As used herein, the weight average molecular weight is the average molecular weight measured by GPC analysis and converted to standard polystyrene.
- the surface protective layer may contain, if desired, a weathering agent such as an ultraviolet absorber or a light stabilizer, an ultraviolet shielding agent, an abrasion resistance improver, a polymerization inhibitor, or a cross-linking agent, as long as the object of the present invention is not impaired.
- a weathering agent such as an ultraviolet absorber or a light stabilizer, an ultraviolet shielding agent, an abrasion resistance improver, a polymerization inhibitor, or a cross-linking agent, as long as the object of the present invention is not impaired.
- Infrared absorbers, antistatic agents, adhesive improvers, leveling agents, thixophilic imparting agents, coupling agents, plasticizers, defoaming agents, fillers, blocking inhibitors, lubricants, solvents, etc. can be added. ..
- a weather resistant agent such as an ultraviolet absorber and a light stabilizer.
- the ultraviolet absorber and the light stabilizer those listed as the ultraviolet absorber and the light stabilizer that can be used
- the thickness of the surface protective layer is preferably 2 ⁇ m or more, more preferably 3 ⁇ m or more, still more preferably 4 ⁇ m or more, from the viewpoint of protecting the decorative material of the present embodiment and obtaining better weather resistance.
- the upper limit is preferably 15 ⁇ m or less, more preferably 10 ⁇ m or less, and even more preferably 8 ⁇ m or less.
- the decorative material of the present embodiment may further have at least one layer selected from an adhesive layer, a resin layer and a primer layer, and preferably has an adhesive layer, a resin layer and a primer layer, depending on the desired performance.
- the stacking order of these layers is not particularly limited and may be provided in an appropriate order according to desired performance and the like, but in the present embodiment, it is usually the side of the decorative layer on which the base material is provided. Is provided in order on the opposite side, and as shown in FIG. 2, it is preferable that the base material, the decorative layer, the adhesive layer, the resin layer, and the primer layer are provided in this order.
- the surface protective layer it is preferable that the base material, the decorative layer, the adhesive layer, the resin layer, the primer layer and the surface protective layer are provided in this order as shown in FIG.
- the resin layer is a layer provided for improving surface characteristics such as stain resistance and abrasion resistance of the decorative material of the present embodiment and for protecting the decorative layer. Therefore, in the decorative material of the present embodiment, it is preferable that the resin layer is provided on the side opposite to the side on which the base material of the decorative layer is provided.
- Examples of the resin constituting the resin layer include resins exemplified as materials constituting the above-mentioned base material, polyolefin resins such as polypropylene and polyethylene, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), and ethylene.
- polyolefin resins such as polypropylene and polyethylene
- PET polyethylene terephthalate
- PBT polybutylene terephthalate
- PEN polyethylene naphthalate
- ethylene ethylene naphthalate
- polyester resin such as polyester thermoplastic elastomer, acrylic such as polymethyl (meth) acrylate, polybutyl (meth) acrylate, methyl (meth) acrylate-butyl (meth) acrylate copolymer
- resin base material made of a thermoplastic resin such as a resin, a polyester resin, a polycarbonate resin, an acrylonitrile-butadiene-styrene resin (hereinafter, also referred to as “ABS resin”), and a vinyl chloride resin.
- the polyolefin resin As the resin constituting the resin layer, among the above, the polyolefin resin, from the viewpoint of easily keeping the moisture permeability within the above range, improving the long-term adhesion as well as the workability, improving the surface characteristics, and protecting the decorative layer, among the above.
- a vinyl chloride resin is preferable, and a polyolefin resin is more preferable.
- These polyolefin resins and vinyl chloride resins can be selected and used from the polyolefin resins and vinyl chloride resins described above as those that can be used as the base material.
- the thickness of the resin layer is preferably determined according to the type of resin constituting the resin layer.
- the thickness of the resin layer is preferably 40 ⁇ m or more and 200 ⁇ m or less when a polyethylene resin, a polypropylene resin, and a vinyl chloride resin are used. It may be selected from the range in consideration of the laminated structure of the decorative material and the desired moisture permeability.
- the resin layer when a polypropylene-based resin is used for the resin layer, it is preferable to appropriately adjust the crystallinity of the polypropylene-based resin and the mass ratio of the isotactic polypropylene to the atactic polypropylene, as in the case of the base material.
- the resin layer is preferably transparent from the viewpoint of making the decorative layer more clearly visible.
- transparent includes not only colorless and transparent but also colored transparent and translucent.
- the colorant preferably includes a colorant exemplified as a colorant that can be used for the above-mentioned decorative layer, and it is preferable to use a colorant having a color similar to that of the decorative layer.
- the resin layer may be blended with additives, if necessary.
- additives those exemplified as additives that can be blended in the above-mentioned base material and surface protective layer, among them, ultraviolet absorbers, light stabilizers and the like. It is preferable to use a weather resistant agent.
- the amount of the additive added is not particularly limited and can be appropriately set according to the required characteristics and the like.
- the ultraviolet absorber and the light stabilizer those listed as the ultraviolet absorber and the light stabilizer that can be used for the base material can be appropriately selected and adopted.
- the thickness of the resin layer is preferably 10 ⁇ m or more and 150 ⁇ m or less, more preferably 30 ⁇ m or more and 120 ⁇ m or less, and further preferably 50 ⁇ m or more and 100 ⁇ m or less from the viewpoint of protecting the decorative layer and improving the surface characteristics. Further, from the viewpoint of protecting the decorative layer and obtaining excellent surface properties, it is preferable to make the decorative layer thicker than the base material.
- the resin layer can be subjected to surface treatment such as physical surface treatment or chemical surface treatment on one side or both sides thereof in order to improve the interlayer adhesion with the other layers. Further, in order to improve the interlayer adhesion between the resin layer and the other layer, a treatment such as forming a primer layer on one side or both sides of the resin layer may be performed. This primer layer will be described later.
- the adhesive layer is preferably provided from the viewpoint of improving the adhesion between the resin layer and the decorative layer when the resin layer is provided.
- the adhesive used for the adhesive layer examples include urethane-based adhesives, acrylic-based adhesives, epoxy-based adhesives, rubber-based adhesives, etc.
- urethane-based adhesives are preferable in terms of adhesive strength.
- an adhesive using a two-component curable urethane resin containing various polyol compounds such as polyether polyol, polyester polyol, and acrylic polyol and a curing agent such as the above-mentioned various isocyanate compounds.
- acrylic-polyester-vinyl acetate resin and the like are also suitable adhesives that easily develop adhesiveness by heating and can maintain adhesive strength even when used at high temperatures.
- the thickness of the adhesive layer is preferably 0.1 ⁇ m or more and 30 ⁇ m or less, more preferably 1 ⁇ m or more and 15 ⁇ m or less, and 2 ⁇ m or more and 10 ⁇ m or less from the viewpoint of efficiently improving the adhesion between the resin layer and the base material or the decorative layer. More preferred.
- the primer layer is a layer mainly provided for improving the interlayer adhesion of each layer constituting the decorative material of the present embodiment, and is also called an easy-adhesion layer. As shown in FIG. 2, for example, by providing the resin layer between the resin layer and the surface protective layer, the interlayer adhesion of these layers can be improved.
- FIG. 2 shows a mode in which the primer layer is provided between the decorative layer and the surface protective layer, but the present invention is not limited to this, and for example, it can be provided between the base material and the decorative layer.
- a primer layer is provided on the surface of the base material opposite to the surface on which the decorative layer is provided, which faces the substrate constituting the decorative member, from the viewpoint of improving adhesion.
- backside primer layer Also referred to as “backside primer layer”.
- a resin composition containing at least a binder resin is preferably used for forming the primer layer, and other components used as desired, such as an extender pigment, a stabilizer, an ultraviolet absorber, a light stabilizer, and a solvent, are appropriately used.
- a mixture can be used. That is, the primer layer is a layer containing at least a binder resin, and is also a layer that can contain the above-mentioned components that can be used as desired.
- binder resin used for forming the primer layer examples include those exemplified as the binder resin used in the resin composition capable of forming the above-mentioned decorative layer, and those exemplified as the curable resin capable of forming the above-mentioned surface protective layer.
- a thermosetting resin and a two-component curable resin can be preferably used.
- a mixture of these curable resins and a thermoplastic resin such as nitric acid cotton exemplified above may be used.
- these resins may be appropriately selected from these resins as desired.
- the thickness of the primer layer is preferably 0.1 ⁇ m or more, more preferably 1 ⁇ m or more, still more preferably 2 ⁇ m or more, and the upper limit is preferably 10 ⁇ m or less, more preferably 8 ⁇ m, from the viewpoint of efficiently improving the interlayer adhesion. Below, it is more preferably 5 ⁇ m or less.
- a decorative layer composed of a base material, a fully colored layer and a pattern layer, as shown in FIG. 2, which is one of the preferred embodiments of the decorative material of the present embodiment.
- a method for producing the decorative material will be described by taking as an example a decorative material having an adhesive layer, a resin layer, a primer layer, and a surface protective layer in this order.
- the decorative material of the present embodiment is, for example, a step of providing a fully colored layer and a pattern layer on a base material to form a decorative layer, a step of forming an adhesive layer, a step of forming a resin layer, and a step of forming a primer layer. , And a step of forming a surface protective layer so as to cover the primer layer can be produced.
- the resin composition used for forming the entire colored layer is applied onto the base material to form the desired overall colored layer, and then the resin composition used for forming the pattern layer is applied.
- the resin composition is applied by a known method such as a gravure printing method, a bar coating method, a roll coating method, a reverse roll coating method, or a comma coating method, preferably a gravure printing method.
- the surface treatment When the surface treatment is applied to the base material, it may be performed before forming the entire colored layer, and when the primer layer is provided, it may be performed before forming the entire colored layer. Further, when the back surface primer layer is provided on the surface (back surface) opposite to the surface on which the decorative layer of the base material is provided, it may be provided before or after the formation of the decorative layer.
- an adhesive may be applied on the decorative layer to form the adhesive layer.
- the coating method is not particularly limited, and for example, it may be appropriately selected from the coating methods that can be adopted when forming the decorative layer.
- the resin composition constituting the resin layer is bonded and pressure-bonded by a method such as extrusion lamination, dry lamination, wet lamination, thermal lamination, etc., and laminated. be able to.
- the resin composition used for forming the primer layer may be applied to the surface of the resin layer to form the primer layer, and the coating method is to apply the decorative layer. It may be appropriately selected and adopted from the method of applying the resin composition to be formed.
- a curable resin composition containing a liquid uncured product of a curable resin which is used for forming the surface protective layer, is applied to the entire surface of the decorative material and cured if necessary.
- a method for applying the uncured resin composition containing the liquid uncured material any of the known methods exemplified as the method for applying the resin composition of the decorative layer may be adopted.
- the curing method of the uncured resin composition containing the liquid uncured product of the curable resin may be selected according to the type of the curable resin contained in the uncured resin composition. For example, when the uncured resin composition is a resin composition containing a liquid uncured product of a thermosetting resin, it may be cured by performing a heat treatment according to the thermosetting resin to be used.
- the uncured resin layer formed by coating the uncured resin composition is irradiated with ionizing radiation such as electron beam and ultraviolet rays. It may be a cured product.
- ionizing radiation such as electron beam and ultraviolet rays.
- the acceleration voltage can be appropriately selected according to the resin to be used and the thickness of the layer, but the uncured resin layer is usually cured at an acceleration voltage of 70 kV or more and 300 kV or less. Is preferable.
- the irradiation dose is preferably an amount at which the crosslink density of the ionizing radiation curable resin is saturated, and is usually selected in the range of 5 kGy or more and 300 kGy or less (0.5 Mrad or more and 30 Mrad or less), preferably 10 kGy or more and 50 kGy or less (1 Mrad or more and 5 Mrad or less).
- the electron beam source is not particularly limited, and for example, a cockloft Walton type, a bandegraft type, a resonance transformer type, an insulated core transformer type, or various electron beam accelerators such as a linear type, a dynamitron type, and a high frequency type are used. be able to.
- ultraviolet rays When ultraviolet rays are used as ionizing radiation, those containing ultraviolet rays having a wavelength of 190 nm or more and 380 nm or less are emitted.
- the ultraviolet source is not particularly limited, and for example, a high-pressure mercury lamp, a low-pressure mercury lamp, a metal halide lamp, a carbon arc lamp, or the like is used.
- the surface protective layer after forming the surface protective layer, it is also possible to impart an uneven shape by heat and pressure molding with an embossed plate, if necessary. By forming the uneven shape, a tactile sensation is imparted, and the design of the decorative material of the present invention is improved. Further, for example, when a wood grain pattern is formed by a decorative layer, it is possible to express an excellent design with a high texture by synchronizing the conduit portion in the wood grain pattern with the concave and convex concave portions.
- the conditions for heat and pressure molding may be appropriately adjusted according to the type of the curable resin used, and are not particularly limited.
- the temperature is usually 100 ° C. or higher and 200 ° C. or lower, and the pressure is 0.1 MPa or higher. It is 8 MPa or less and the time is 10 seconds to 120 minutes.
- the decorative material of the present embodiment As properties of the decorative material of the present embodiment, as described above, it requires that moisture permeability is less than 0.75g / m 2 ⁇ 24h or more 45g / m 2 ⁇ 24h. By having such properties, the decorative material of the present embodiment has both excellent construction suitability due to high initial adhesion strength in the construction process and long-term adhesion that does not cause peeling even after long-term use. The preferred range is also as described above.
- the decorative material of the present embodiment has a floating decorative material that hinders workability and quality of the decorative member at the time of bending, which is often used when the decorative material is laminated on a substrate to form a decorative member.
- the tensile elastic modulus at 60 ° C. is preferably in the following range. That is, the decorative material of the present embodiment has a tensile elastic modulus at 60 ° C. of preferably 80 MPa or more, more preferably 90 MPa or more, further preferably 100 MPa or more, still more preferably 110 MPa or more, and preferably 600 MPa or less as an upper limit. , More preferably 500 MPa or less, still more preferably 420 MPa or less, still more preferably 375 MPa or less.
- the decorative material of the present embodiment has the above tensile elastic modulus, it is easy to keep the moisture permeability within the above range, and it is easy to improve the long-term adhesion as well as the construction suitability.
- a tensile elastic modulus shall be measured by the method of carrying out in the following Example.
- the decorative material of the present embodiment can be used as it is, laminated on a substrate via an adhesive layer, or subjected to a predetermined molding process or the like for various purposes. Since the decorative material of the present embodiment is excellent in construction suitability, it is suitably used for a decorative member obtained by laminating it on a substrate via an adhesive layer.
- the decorative member thus obtained is laminated on, for example, a flat plate of various materials, a plate material such as a curved plate, or a substrate such as a sheet (or film), and is, for example, an interior member of a building such as a wall, a ceiling, or a floor.
- Exterior materials such as outer walls, roofs, eaves ceilings, fences, gates, various doors such as window frames and entrance doors, handrails, skirts, surrounding edges, window frames, door frames, fittings such as moldings, and other building materials. It is suitably used as a surface decorative board for kitchens, furniture or light electrical products, cabinets for OA equipment, vehicle interior members, vehicle exterior members, and the like.
- the decorative member of the present embodiment has the decorative material and the substrate of the present embodiment described above via an adhesive so that the base material of the decorative material and the substrate face each other. That is, the decorative member of the present embodiment has a base material, an adhesive layer, and a decorative material in this order.
- the decorative member 20 of the present embodiment the decorative member 21 in which the substrate 21 and the decorative material 10 shown in FIG. 1 are laminated via the adhesive layer 22, specifically, the decorative material 10.
- the one having the substrate 21 via the adhesive layer 22 is shown on the side of the substrate 1 opposite to the side having the decorative layer 2. That is, FIG. 3 shows a decorative member 20 having a base 21, an adhesive layer 22, a base 1, and a decorative layer 2 in this order.
- a decorative member in which a substrate 21 and a decorative material 10 shown in FIG. 2 are laminated via an adhesive layer 22 can be mentioned. That is, as a preferred embodiment of the decorative member 20 of the present embodiment, the base material 21, the adhesive layer 22, the base material 1, the decorative layer 2, the adhesive layer 3, the resin layer 4, the primer layer 5, and the surface protective layer 6 are provided in this order. Decorative members can be mentioned.
- the base material of the present embodiment is in the form of a sheet (or film), that is, when the decorative material of the present embodiment is in the form of a sheet (or film), the decorative material of the present embodiment is laminated with the base material via an adhesive layer. It is easy to obtain the decorative member of the present embodiment.
- the substrate may be appropriately selected according to the desired member, and is not particularly limited.
- the substrate include wood single boards made of various woods such as cedar, cypress, pine, and lauan, wood plywood, particle boards, wood substrates such as MDF (medium density fiber board); metal substrates such as iron and aluminum; glass.
- Ceramics such as ceramics, non-cement ceramic materials such as plaster, ceramic substrates such as ALC (lightweight cellular concrete) plates; polyolefin resins such as acrylic resin, polyester resin, polystyrene resin, polypropylene, ABS (acrylonitrile-butadiene-styrene) Polymer) Resin, phenol resin, vinyl chloride resin, cellulose resin, resin substrate such as rubber, and the like can be mentioned.
- these substrates can be used alone or in combination of two or more.
- the shape of the substrate may be a flat plate shape or a three-dimensional shape.
- the substrate may be appropriately determined according to the intended use, but the resin substrate and the metal substrate are preferable.
- the adhesive used for the adhesive layer is not particularly limited, and a known adhesive can be used and may be appropriately selected depending on the intended use.
- the adhesive used for the adhesive layer is, for example, a moisture-curable adhesive, an anaerobic curable adhesive, a dry-curable adhesive, a UV-curable adhesive, a heat-sensitive adhesive (for example, a hot melt type adhesive), and a feeling.
- Adhesives such as pressure adhesives are preferred.
- a moisture-curable adhesive and a heat-sensitive adhesive are preferable in consideration of compatibility with the decorative material of the present embodiment having a predetermined water vapor permeability, ease of handling, and the like. Further, a moisture-curable and heat-sensitive adhesive is more preferable.
- the heat-sensitive adhesive is preferable in that the molten liquid adhesive layer is cooled and solidified, and at the same time, the adhesive force rises to a saturated state.
- Decorative material of the present embodiment is moisture permeability 0.75g / m 2 ⁇ 24h or more. Therefore, the moisture-curable adhesive can be exposed to an appropriate amount of moisture in the construction process, and the initial adhesion strength of the adhesive used for the adhesive layer can be easily increased. Further, the decorative material of the present embodiment is less moisture permeability 45g / m 2 ⁇ 24h. For this reason, the moisture-curable adhesive does not come into contact with excessive moisture, and the deterioration of the adhesiveness due to the deterioration of the moisture-curable adhesive due to hydrolysis is suppressed. It becomes easy to obtain long-term adhesion.
- the moisture-curable adhesive is also preferable in terms of ease of handling and the like.
- the resin used for these adhesives examples include acrylic resin, urethane resin, vinyl chloride resin, vinyl acetate resin, vinyl chloride-vinyl acetate copolymer, styrene-acrylic copolymer, polyester resin, and amide resin.
- examples thereof include cyanoacrylate resin and epoxy resin, and these can be used alone or in combination of two or more.
- a two-component curable urethane-based adhesive or an ester-based adhesive using an isocyanate compound or the like as a curing agent can also be applied.
- an adhesive may be used for the adhesive layer.
- acrylic-based, urethane-based, silicone-based, rubber-based and other pressure-sensitive adhesives can be appropriately selected and used.
- a moisture-curable adhesive which is one of the adhesives preferably used in the present embodiment and whose resin system is a urethane resin contains a prepolymer having an isocyanate group at the molecular terminal as an essential component. ..
- the prepolymer is usually a polyisocyanate prepolymer having one or more isocyanate groups at both ends of the molecule, and is in the state of a solid thermoplastic resin at room temperature.
- polyisocyanate prepolymer for example, a solid polyester polyol which is crystalline at room temperature is used as a polyol component, and a polyisocyanate composed of 4,4-diphenylmethane diisocyanate, tolylene diisocyanate, or the like is used as a polyisocyanate component.
- a polyisocyanate composed of 4,4-diphenylmethane diisocyanate, tolylene diisocyanate, or the like is used as a polyisocyanate component.
- the adhesive layer is obtained by applying and drying an adhesive obtained by applying the above resin to a solution or an emulsion or the like in a form that can be applied, by means such as a gravure printing method, a screen printing method, or a reverse coating method using a gravure plate. Can be formed.
- the thickness of the adhesive layer is not particularly limited, but from the viewpoint of obtaining excellent adhesiveness, it is preferably 1 ⁇ m or more and 100 ⁇ m or less, more preferably 5 ⁇ m or more and 50 ⁇ m or less, and further preferably 10 ⁇ m or more and 30 ⁇ m or less.
- the decorative member of the present embodiment can be arbitrarily cut, and the surface and the end of the wood can be arbitrarily decorated by grooving, chamfering, etc. using a cutting machine such as a router or a cutter.
- the decorative member of the present embodiment is, for example, an interior member or an outer wall of a building such as a wall, a ceiling, or a floor; an exterior member such as a roof, an eaves ceiling, a fence, or a gate; a window frame; various doors such as an entrance door; Joinery or building members such as handrails, skirting boards, surrounding edges, window frames, door frames, moldings; kitchens; furniture; light electrical products; cabinets for OA equipment, etc. It can be used as an exterior member or the like.
- Tensilon universal material tester (Tensilon RTC-1250A (product name)", manufactured by Orientec Co., Ltd.) in a temperature environment of 60 ° C, the conditions are a tensile speed of 50 mm / min, a chuck distance of 80 mm, and a width of 25 mm. Then, the sample was pulled to an arbitrary elongation to obtain the tensile elastic modulus of the decorative material.
- the sample was subjected to a Tensilon universal material tester (“Tensilon RTC-1250A (product name)”, manufactured by Orientec Co., Ltd.) under a temperature environment of 25 ° C., tensile strength: 10 mm / min, peeling direction.
- a peeling test was performed under the conditions of 90 ° and a distance between chucks: 30 mm, and the peeling strength was measured as the initial adhesive strength and evaluated according to the following criteria. If the evaluation is B or higher, the evaluation of construction suitability is passed.
- B The peeling strength was 0.5 N / mm or more and less than 1.0 N / mm.
- the peeling strength was less than 0.5 N / mm.
- 2-2. Evaluation of long-term adhesion The sample prepared in the above "2-1. Evaluation of construction suitability" was left in a moist heat environment of 70 ° C. and 90% RH for 6 weeks, and then subjected to a Tencilon universal material test in a temperature environment of 25 ° C. Using a machine ("Tencilon RTC-1250A (product name)", manufactured by Orientec Co., Ltd.), a peeling test was conducted under the conditions of a tensile speed of 50 mm / min and a peeling direction of 90 °, and the peeling strength was measured. Evaluated in.
- the peeling strength was 2.0 N / mm or more.
- Processability When a sample is attached (laminated) in preparation in the above "2-1. Evaluation of construction suitability", the floating of the decorative material at the bent part (bending angle: 1 mmR) is visually confirmed, and the following criteria are used. evaluated. If the evaluation is B or higher, the processing suitability is acceptable. A: No floating was confirmed. B: Floating was hardly confirmed. C: Floating was confirmed and peeling occurred.
- Example 1 Gravure printing using a printing ink using a two-component curable acrylic-urethane resin as a binder resin on one side of a base material (thickness: 80 ⁇ m, polypropylene sheet, polyolefin 1) that has undergone double-sided corona discharge treatment.
- a decorative layer (thickness: 3 ⁇ m) is formed, and a two-component curable urethane-nitrated cotton mixed resin (curing agent: hexamethylene diisocyanate is mixed by 5 parts by mass with respect to 100 parts by mass of the mixed resin) on the other surface of the base material.
- a resin composition containing (containing) was applied to form a back surface primer layer (thickness: 3 ⁇ m).
- a transparent urethane resin adhesive is applied onto the decorative layer to form an adhesive layer (thickness: 3 ⁇ m), and a polypropylene-based resin is heated, melted and extruded onto the adhesive by a T-die extruder to obtain a transparent resin.
- a layer (thickness: 80 ⁇ m) was formed.
- a composition composed of a polycarbonate-based urethane-acrylic copolymer and an acrylic polyol and hexamethylene diisocyanate are mixed on the resin layer at a mass ratio of 100: 5.
- the resin composition was applied and dried to form a primer layer (thickness: 4 ⁇ m).
- the following ionizing radiation curable resin composition is applied onto the primer layer to form an uncured resin layer, and then the uncured resin layer is irradiated with an electron beam (165 keV, 5Mrad (50 kGy)) to be cured.
- a surface protective layer (thickness: 5 ⁇ m) was formed by allowing the material to be formed to prepare a decorative material.
- Ionizing radiation curable resin composition Ionizing radiation curable resin: Urethane acrylate UV absorber 1 (trade name: Adecastab LA-46, hydroxyphenyltriazine UV absorber, manufactured by ADEKA Co., Ltd.): 2 parts by mass UV absorber 2 with respect to 100 parts by mass of the above resin (Product name: Tinuvin 1600, hydroxyphenyltriazine-based ultraviolet absorber, manufactured by BASF): 2 parts by mass with respect to 100 parts by mass of the resin Hindered amine light stabilizer (trade name: Tinuvin 123, manufactured by BASF): 100 parts by mass of the resin 3 parts by mass
- a moisture-curable and hot-melt type urethane resin adhesive is applied to the substrate to form an adhesive layer with a thickness of 5 ⁇ m, which is attached to the obtained decorative material and left in an environment of 90 ° C. for 1 hour. Obtained a decorative member. Separately from this, using the obtained decorative material, a sample was prepared based on the above method and evaluated. The results are shown in Table 1.
- Example 1 the decorative materials and decorative members of Examples 2 to 4 were produced in the same manner as in Example 1 except that the base material and the resin layer were changed to those shown in Table 1. Using the obtained decorative material, a sample was prepared based on the above method and evaluated. The results are shown in Table 1.
- Polyolefin 1 Polypropylene resin sheet (propylene-ethylene random copolymer (ethylene content: 4.5% by mass or less), thickness: 80 ⁇ m, crystallinity: 70%)
- Polyolefin 2 Polypropylene resin sheet (propylene-ethylene random copolymer (ethylene content: 4.5% by mass or less), thickness: 60 ⁇ m, crystallinity: 50%)
- Polyolefin 3 Polypropylene resin sheet (propylene-ethylene random copolymer (ethylene content: 4.5% by mass or less), thickness: 60 ⁇ m, crystallinity: 40%)
- Polyolefin 4 Polypropylene resin sheet (propylene-ethylene random copolymer (ethylene content: 4.5% by mass or less), thickness: 100 ⁇ m, crystallinity: 70%)
- -PVC1 Polyvinyl chloride resin sheet (thickness: 120 ⁇ m) It is produced by extruding a resin composition obtained by extruding a resin composition obtained by extruding a resin
- -PVC2 Polyvinyl chloride resin sheet (thickness: 120 ⁇ m)
- the plasticizer was a polyester-based plasticizer (adipic acid-based polyester), and the content thereof was 33 parts by mass with respect to 100 parts by mass of the polyvinyl chloride resin. It was done.
- -Polyolefin A Polypropylene resin (thickness: 80 ⁇ m)
- -Polyolefin B Polypropylene resin (thickness: 40 ⁇ m)
- -Polyolefin C Polypropylene resin (thickness: 100 ⁇ m)
- the decorative material of the present embodiment has excellent coating suitability by having a predetermined moisture permeability, and the decorative member of the present embodiment using the decorative material has an excellent long-term condition. It was confirmed that it had adhesiveness.
- Comparative Example 1 if the moisture permeability is too large, it deteriorates due to the hydrolysis reaction between the moisture in the atmosphere and the adhesive forming the adhesive layer, and excellent long-term adhesion cannot be obtained. It was confirmed that if the moisture permeability is too small, a good cured state of the adhesive forming the adhesive layer cannot be obtained, the initial adhesion strength becomes small, and excellent construction suitability cannot be obtained.
- the decorative material and decorative member of the present embodiment have excellent construction suitability and long-term adhesion, interior members of buildings such as walls, ceilings, and floors, or outer walls, roofs, eaves ceilings, fences, gates, etc. Exterior materials, window frames, various doors such as entrance doors, handrails, skirting boards, surrounding edges, window frames, door frames, fittings such as moldings, and building materials, as well as cabinets for kitchens, furniture or light electrical products, OA equipment, etc. It is suitably used for surface decorative boards, interior members of vehicles, exterior members, and the like.
- Decorative material 1 Base material 2: Decorative layer 2A: Fully colored layer 2B: Pattern layer 3: Adhesive layer 4: Resin layer 5: Primer layer 6: Surface protective layer 20: Decorative member 21: Base material 22: Adhesive layer
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Abstract
Description
他方、上記の化粧材を基体に貼付けた化粧部材を使用していると、大気中の水分、風雨、更には日射による紫外線の影響により、最表面に設けられる化粧材を構成する基材の劣化、化粧材と基体とを接着させる接着剤の劣化等を要因として、化粧材が基体から剥離するといった問題が生じる場合がある。
2.前記基材が、塩化ビニル系樹脂及びポリオレフィン樹脂から選ばれる少なくとも一種の樹脂により構成される上記1に記載の化粧材。
3.更に、表面保護層を、最表面に有する上記1又は2に記載の化粧材。
4.前記表面保護層が、硬化性樹脂の硬化物で構成される層である上記3に記載の化粧材。
5.前記装飾処理が装飾層によるものであり、前記装飾層、接着層、樹脂層及びプライマー層を、前記基材、前記装飾層、前記接着層、前記樹脂層及び前記プライマー層の順に有する上記1~4のいずれか1に記載の化粧材。
6.60℃における引張弾性率が、80MPa以上600MPa以下である上記1~5のいずれか1に記載の化粧材。
7.上記1~6のいずれか1に記載の化粧材及び基体を、前記化粧材の前記基材と前記基体とが対面するように接着剤層を介して有する化粧部材。
8.前記接着剤層が、ウレタン樹脂系接着剤で構成される上記7に記載の化粧部材。
9.前記ウレタン樹脂系接着剤が、湿気硬化型接着剤である上記8に記載の化粧部材。
10.前記基体が、樹脂基体又は金属基体である上記7~9のいずれか1に記載の化粧部材。
以下、本発明の実施形態(以下、「本実施形態」と称することがある。)について説明する。なお、本明細書中において、数値範囲の「以上」及び「以下」に係る数値は任意に組み合わせできる数値である。また、本明細書中において、実施例の数値は数値範囲の上下限に用い得る数値である。
本実施形態の化粧材は、透湿度を特定の範囲とすることで、当該化粧材の施工過程において高い初期密着強度が発現する。このため、本実施形態の化粧材は、施工の際に、初期密着強度が不足することにより当該化粧シートの端面が剥がれる、いわゆるスプリングバックの発生を抑制することができ、施工適性を良好にすることができる。他方、当該化粧材と基体とを接着剤層を介して化粧部材とした場合、主に当該化粧材と当該基体との間における接着剤層の劣化を抑制することができるので、当該劣化による剥離を抑制し、長期使用しても剥離が生じない、優れた長期密着性を発現することとなる。すなわち、本発明の化粧材の透湿度を特定の範囲とすることで、施工過程における高い初期密着強度による優れた施工適性とともに、長期使用しても剥離が生じない長期密着性を両立することが可能となる。
本実施形態において、透湿度の調整は、主に、後述する基材を構成する材料の種類、樹脂層を有する場合は樹脂層を構成する材料の種類等によって行うことができる。
図1は、本実施形態の化粧材の層構成の一例を示す模式断面図であり、本実施形態の化粧材10が基材1及び装飾処理の代表的な一態様として装飾層2を有していることが示される。
また、図2は、本実施形態の化粧材の好ましい層構成の一態様を示す模式断面図であり、基材1、装飾層2、接着層3、樹脂層4、プライマー層5及び表面保護層6を有することが示される。
以下、本実施形態の化粧材を構成する各層について、より詳細に説明する。
基材の材料としては、化粧材の構成とした状態における透湿度が、上記所定の範囲内となる限りにおいては、通常化粧材の基材として用いられるものを制限なく採用することができる。基材の材料としては、例えば、紙、不織布又は織布、樹脂、木材、金属、非金属無機材料等からなる基材が代表的に挙げられ、透湿度を上記範囲内とし、施工適性とともに長期密着性を向上させる観点から、樹脂からなる基材が好ましい。
基材の厚みも、化粧材の構成とした状態における透湿度が、上記所定の範囲内となる限りにおいては特に制限はなく、フィルム、シート、又は板状の形態のものを所望に応じて適宜用いることができる。基材の厚みは、通常は、フィルム又はシートとして20μm以上200μm以下程度、板としては500μm以上10cm以下程度のものが、化粧材の透湿度を考慮した上で、用いられる。
なお、本願明細書中において、例えば、「(メタ)アクリレート」、「(メタ)アクリル酸」等の表記は、各々「アクリレート又はメタアクリレート(ないしはメタクリレート)」、「アクリル酸又はメタアクリル酸(ないしはメタクリル酸)」等を意味する略称である。
透湿度を上記範囲内としやすく、施工適性とともに長期密着性を向上させる観点から、上記の中でもエチレンを構成単位として含むポリエチレン系樹脂、プロピレンを構成単位として含むポリプロピレン系樹脂が好ましく、ポリプロピレン系樹脂が好ましい。
化粧材の透湿度を上記の所定範囲内としやすくするためには、基材の厚さは、ポリエチレン系樹脂、ポリプロピレン系樹脂、及び塩化ビニル系樹脂を採用する場合、好ましくは40μm以上200μm以下の範囲から、化粧材の積層構成及び所望の透湿度を考慮して選定すればよい。
また、プロピレンの単独重合体(ポリプロピレン)を用いる場合、アイソタクチックポリプロピレンとアタクチックポリプロピレンとの質量比の調節により基材の透湿度を調整することもできる。一般的には、ポリプロピレン中のアタクチックポリプロピレンの割合が100質量%の場合に比べて、アイソタクチックポリプロピレンを添加することで基材の透湿度を低下させることができる。この場合、アタクチックポリプロピレンとアイソタクチックポリプロピレンとの質量比は、透湿度の調整のしやすさを考慮すると、好ましくは0/100以上20/80以下である。
塩化ビニルモノマーと共重合可能なモノマーとしては、酢酸ビニル、プロピオン酸ビニル等のビニルエステル類;メチルアクリレートやブチルアクリレート等のアクリル酸エステル類;メチルメタクリレートやエチルメタクリレート等のメタクリル酸エステル類;ブチルマレートやジエチルマレート等のマレイン酸エステル類;ジブチルフマレートやジエチルフマレート等のフマル酸エステル類;ビニルメチルエーテル、ビニルブチルエーテル及びビニルオクチルエーテル等のビニルエーテル類;アクリロニトリルやメタクリロニトリル等のシアン化ビニル類;エチレン、プロピレン、ブチレン、スチレン等のオレフィン類;イソプレン、ブタジエン等のジエン類;塩化ビニリデン、臭化ビニル等の塩化ビニル以外のハロゲン化ビニリデン、ハロゲン化ビニル類;ジアリルフタレート等のフタル酸アリル類、等が挙げられる。これらのモノマーは、単独で、又は複数種を組み合わせて用いてもよい。
可塑剤としては、塩化ビニル系樹脂と相溶性を有するものであれば特に制限はなく、例えば、フタル酸ジブチル(DBP)、フタル酸ジオクチル(DOP)、フタル酸ジイソノニル(DINP)、フタル酸ジイソデシル(DIDP)、フタル酸ジウンデシル(DUP)等のフタル酸系可塑剤;アジピン酸ジブチル等のアジピン酸系可塑剤;リン酸トリブチル、リン酸トリクレジル、リン酸トリフェニル等のリン酸系可塑剤;トリメリット酸トリブチル、トリメリット酸トリオクチル等のトリメリット酸系可塑剤;アジピン酸系ポリエステルなど公知の各種ポリエステル系可塑剤;アセチルトリブチルシトレート、アセチルトリオクチルシトレート等のクエン酸エステル類;等が挙げられる。中でも、透湿度を上記範囲内としやすく、施工適性とともに長期密着性を向上させる観点から、また加工性を向上させる観点から、フタル酸系可塑剤、アジピン酸系可塑剤、ポリエステル系可塑剤が好ましく、フタル酸系可塑剤、ポリエステル系可塑がより好ましい。また、これらの可塑剤は、単独で、又は複数種を組み合わせて用いてもよい。
金属としては、鉄、アルミニウム、銅、錫、チタニウム、あるいはこれらの金属を少なくとも一種含む合金(例えば、炭素鋼、ステンレス鋼、ジュラルミン、真鍮、青銅等)等からなる金属基材が挙げられる。
また、非金属無機材料としては、セメント、石膏、珪酸カルシウム、陶磁器、硝子、各種セラミックス等が挙げられる。
紫外線吸収剤としては、化粧材に汎用される紫外線吸収剤を特に制限なく用いることができ、有機物系、無機物系の何れも使用することができる。例えば、有機物系の紫外線吸収剤としては、ベンゾトリアゾール系紫外線吸収剤、ベンゾフェノン系紫外線吸収剤、トリアジン系紫外線吸収剤、ヒドロキシフェニルトリアジン系紫外線吸収剤等が挙げられる。光安定剤としても、化粧材に汎用される光安定剤を特に制限なく用いることができ、例えばピペリジニルセバケート系光安定剤等のヒンダードアミン系光安定剤等が挙げられる。また、これらの紫外線吸収剤、光安定剤は、分子中に(メタ)アクリロイル基、ビニル基、アリル基等のエチレン性二重結合を有する反応性官能基を有するものであってもよい。無機物系の紫外線吸収剤としては、平均粒径を可視光線の最短波長である380nm以下、好ましくは100nm以下とした、二酸化チタン、酸化第二鉄、酸化亜鉛、酸化セリウム、酸化ジルコニウム等が挙げられる。
これらの紫外線吸収剤、光安定剤等の耐候剤、その他各種添加剤は、単独で、又は複数種を組み合わせて用いることができる。
基材の厚さは、耐摩耗性、耐候性、耐傷性等の表面特性、加工特性、取扱の容易さ等を考慮すると、20μm以上が好ましく、30μm以上がより好ましく、40μm以上が更に好ましい。上限としては、500μm以下が好ましく、300μm以下がより好ましく、150μm以下が更に好ましい。
酸化法としては、例えばコロナ放電処理、クロム酸化処理、火炎処理、熱風処理、オゾン-紫外線処理法等が挙げられ、凹凸化法としては、例えばサンドブラスト法、溶剤処理法等が挙げられる。これらの表面処理は、基材の種類に応じて適宜選択されるが、一般にはコロナ放電処理法が、表面処理の効果及び操作性等の面から好ましく用いられる。
また、基材と他の層との層間密着性の向上、各種の基体との接着性の強化等のために、基材の少なくとも一方の面に、例えば後述するプライマー層(「易接着層」とも称する。)を形成する等の処理を施してもよい。
本実施形態の化粧材は、基材に装飾処理を施してなる。装飾処理は、本実施形態の化粧材に色、模様、凹凸模様等の意匠を付与し、意匠性を向上させる、本実施形態の化粧材を化粧材とし得るものである。
本実施形態において、装飾処理としては、公知の各種形態を採用することができ、例えば、印刷等による絵柄層及び着色層、また真空蒸着等による金属加工層等の装飾層の形成、また基材、後述する樹脂層等への着色剤の添加、エンボス加工等による凹凸模様の形成(賦型)等の処理を採用できる。これらの中でも、代表的に汎用される装飾処理は、装飾層の形成である。
以下、装飾処理として、装飾層の形成を主体として説明する。
需要者の意匠への要望は流行等により変化するものであるが、木目模様への人気は根強いため、本発明の化粧材の模様としても、木目模様が好ましい。木目模様には、柾目模様、板目模様、杢目模様、木口模様等があるが、いずれであってもよい。
絵柄層、全面着色層の形態を有する装飾層の形成には、少なくともバインダー樹脂、並びに顔料又は染料等の着色剤を含む樹脂組成物が用いられることが好ましく、その他所望に応じて用いられる成分、例えば、艶消し剤、体質顔料、安定剤、紫外線吸収剤、光安定剤、溶剤等を適宜混合したものを用いることができる。すなわち、装飾層は、少なくともバインダー樹脂、及び顔料又は染料等の着色剤を含む層であり、その他、上記の所望に応じて所望に応じて用いられる成分を含み得る層である。
艶消し剤としては、シリカ、クレー、カオリナイト、重質炭酸カルシウム、軽質炭酸カルシウム、沈降性硫酸バリウム、ケイ酸カルシウム、合成ケイ酸塩、及びケイ酸微粉末等の無機フィラー;アクリル樹脂、ウレタン樹脂、ナイロン樹脂、ポリプロピレン、又は尿素系樹脂等の有機フィラー、等が挙げられる。
例えば、好ましい模様として例示した木目模様は、より低光沢(艶消又は低艶)の導管部分、より高光沢(艶有又は高艶)の春材部分、更に高光沢の秋材部分(照り部分)等が存在する。装飾層において、より低光沢な導管部分を形成する絵柄層、より高光沢な春材部分を形成する絵柄層、更に高光沢の秋材部分を形成する絵柄層等の複数の絵柄層を組み合わせることで、意匠性の高い模様を形成することが可能である。また、全面着色層に艶消し剤を含有させないこと、あるいは絵柄層の艶消剤の含有量よりも全面着色層の艶消剤の含有量を少なくすることで、全面着色層と絵柄層との艶差をより大きくして、意匠性を向上させることも可能である。
また、装飾層中のバインダー樹脂100質量部に対する艶消し剤の含有量は、好ましくは0.5質量部以上、より好ましくは1質量部以上、更に好ましくは2質量部以上であり、上限としては通常100質量部以下であり、好ましくは50質量部以下、より好ましくは20質量部以下、更に好ましくは10質量部以下である。艶消し剤の含有量が上記範囲内であると、装飾層はより低光沢な層として視認できるようになるため、艶差による視覚的な凹凸感を向上させることが可能となり、かつ樹脂組成物のチキソトロピック性が極端に高くなることがなく塗布性能が向上するため、結果として意匠性が向上する。
本実施形態の化粧材は、上記基材及び装飾層に加えて、表面保護層を有してもよい。表面保護層は、化粧材を各種基体上に積層して各種用途(例えば、建築物の内装用部材等)に用いる際の最表面、すなわち使用する際の最外面側に設けられる層である。表面保護層は、本実施形態の化粧材を保護し得る層、すなわち本実施形態の化粧材に、耐汚染性及び耐摩耗性等の表面特性を付与し得る層である。このような観点から、表面保護層は、本実施形態の化粧材の最表面に全面にわたって設けられる層であることが好ましい。
二液硬化樹脂としては、ポリオール化合物を主剤としイソシアネート化合物を硬化剤とする二液硬化型ウレタン樹脂、アミン等を硬化剤とする二液硬化型エポキシ樹脂、二液硬化型ウレタン変性アクリル樹脂及び二液硬化型ポリエステル樹脂等が挙げられる。
電離放射線硬化性樹脂としては、具体的には、従来電離放射線硬化性樹脂として慣用されている重合性モノマー、重合性オリゴマーの中から適宜選択して用いることができる。
多官能性(メタ)アクリレートモノマーとしては、分子中に2つ以上の電離放射線硬化性官能基を有し、かつ該官能基として少なくとも(メタ)アクリロイル基を有する(メタ)アクリレートモノマーが挙げられ、化粧材を保護し、更には耐汚染性及び耐摩耗性等の表面特性の向上の観点から、アクリロイル基を有するアクリレートモノマーが好ましい。
また、これと同様の観点から、官能基数は好ましくは2以上であり、上限として好ましくは8以下、より好ましくは6以下、更に好ましくは4以下、特に好ましくは3以下である。これらの多官能性(メタ)アクリレートは、単独で、又は複数種を組み合わせて用いてもよい。
また、これと同様の観点から、重量平均分子量は、500以上が好ましく、より好ましくは1,000以上であり、上限として好ましくは80,000以下、より好ましくは50,000以下である。本明細書において、重量平均分子量は、GPC分析によって測定され、かつ標準ポリスチレンで換算された平均分子量である。
紫外線吸収剤及び光安定剤としては、基材に用いられ得る紫外線吸収剤及び光安定剤として列記したものから適宜選択して採用できる。
これらの層について、説明する。
樹脂層は、本実施形態の化粧材の耐汚染性及び耐摩耗性等の表面特性の向上を図るため、また装飾層を保護するために設けられる層である。よって、本実施形態の化粧材においては、樹脂層は装飾層の基材が設けられる側とは反対側に設けられることが好ましい。
化粧材の透湿度を上記の所定範囲内としやすくするためには、樹脂層の厚さは、ポリエチレン系樹脂、ポリプロピレン系樹脂、及び塩化ビニル系樹脂を採用する場合、好ましくは40μm以上200μm以下の範囲から、化粧材の積層構成及び所望の透湿度を考慮して選定すればよい。
また、樹脂層にポリプロピレン系樹脂を採用する場合も、基材と同様に、ポリプロピレン系樹脂の結晶化度、アイソタクチックポリプロピレンとアタクチックポリプロピレンとの質量比を適宜調整することが好ましい。
紫外線吸収剤及び光安定剤としては、基材に用いられ得る紫外線吸収剤及び光安定剤として列記したものから適宜選択して採用できる。
また、樹脂層と他の層との層間密着性の向上を得る等のために、樹脂層の片面又は両面にプライマー層を形成する等の処理を施してもよい。このプライマー層については、後述する。
接着層は、上記樹脂層を設ける場合に、当該樹脂層と装飾層との密着性を向上する観点から、好ましく設けられる層である。
プライマー層は、主に本実施形態の化粧材を構成する各層の層間密着性を向上させるために設けられる層であり、易接着層とも称される層である。図2に示されるように、例えば樹脂層と表面保護層との間に設けられることで、これらの層の層間密着性を向上させることができる。図2には、プライマー層が装飾層と表面保護層との間に設けられる態様が示されているが、これに限らず、例えば基材と装飾層との間に設けることも可能である。
例えば、また本実施形態の化粧材を化粧部材に用いる場合、基材の装飾層を設ける面とは反対側の、化粧部材を構成する基体と対向する面に、密着性向上の観点からプライマー層(「裏面プライマー層」とも称される。)を設けることもできる。
本実施形態においては、これらの樹脂から所望に応じて適宜選択すればよい。
本実施形態の化粧材を製造する方法について、本実施形態の化粧材として好ましい態様の一つである、図2に示される、基材、全面着色層と絵柄層とにより構成される装飾層、接着層、樹脂層、プライマー層及び表面保護層を順に有する化粧材を例にとって、その製造方法を説明する。
液体状の未硬化物を含む未硬化樹脂組成物の塗布方法としては、上記装飾層の樹脂組成物の塗布の方法として例示した公知の方式のいずれかを採用すればよい。
また、硬化性樹脂の液体状の未硬化物を含む未硬化樹脂組成物の硬化方法は、該未硬化樹脂組成物に含まれる硬化性樹脂の種類に応じて選択すればよい。例えば、未硬化樹脂組成物が熱硬化性樹脂の液体状の未硬化物を含む樹脂組成物である場合、使用する熱硬化性樹脂に応じた熱処理を施して、硬化させればよい。
電子線源としては、特に制限はなく、例えばコックロフトワルトン型、バンデグラフト型、共振変圧器型、絶縁コア変圧器型、あるいは直線型、ダイナミトロン型、高周波型等の各種電子線加速器を用いることができる。
また、電離放射線として紫外線を用いる場合には、波長190nm以上380nm以下の紫外線を含むものを放射する。紫外線源としては特に制限はなく、例えば高圧水銀燈、低圧水銀燈、メタルハライドランプ、カーボンアーク燈等が用いられる。
本実施形態の化粧材の性状として、既述のように、透湿度が0.75g/m2・24h以上45g/m2・24h以下であることを要する。このような性状を有することで、本実施形態の化粧材は、施工過程における高い初期密着強度による優れた施工適性とともに、長期使用しても剥離が生じない長期密着性を両立するものとなる。また、好ましい範囲も既述の通りである。
すなわち、本実施形態の化粧材は、60℃における引張弾性率として、好ましくは80MPa以上、より好ましくは90MPa以上、更に好ましくは100MPa以上、より更に好ましくは110MPa以上であり、上限として好ましくは600MPa以下、より好ましくは500MPa以下、更に好ましくは420MPa以下、より更に好ましくは375MPa以下である。本実施形態の化粧材は、上記引張弾性率を有することで、透湿度を上記範囲内としやすく、施工適性とともに長期密着性を向上させやすくなる。なお、本明細書において、引張弾性率は、下記実施例で実施の方法により測定されるものとする。
本実施形態の化粧材は、そのままで、又は基体に接着剤層を介して積層する、あるいは所定の成形加工等を施して各種用途に用いることができる。本実施形態の化粧材は、施工適性に優れることから、基体に接着剤層を介して積層して得られる化粧部材に好適に用いられる。
このようにして得られる化粧部材は、例えば、各種素材の平板、曲面板等の板材、シート(又はフィルム)等の基体に積層し、例えば壁、天井、床等の建築物の内装用部材又は外壁、屋根、軒天井、柵、門扉等の外装用部材、窓枠、玄関ドア等の各種扉、手すり、幅木、廻り縁、窓枠、扉枠、モール等の建具又は造作部材の他、キッチン、家具又は弱電製品、OA機器等のキャビネットの表面化粧板、車両の内装用部材又は外装用部材等として好適に用いられる。
本実施形態の化粧部材は、上記の本実施形態の化粧材及び基体を、当該化粧材の基材と当該基体とが対面するように接着剤を介して有するものである。すなわち、本実施形態の化粧部材は、基材、接着剤層及び化粧材を順に有するものである。
図3には、本実施形態の化粧部材20として、基体21と、図1に示される化粧材10とが接着剤層22を介して積層された化粧部材、具体的には、化粧材10の基材1の装飾層2を有する側とは反対側に、接着剤層22を介して基体21を有するものが示されている。すなわち、図3には、基体21、接着剤層22、基材1及び装飾層2を順に有する化粧部材20が示されている。
また、本実施形態の化粧部材20の好ましい態様としては、例えば基体21と、図2に示される化粧材10とが接着剤層22を介して積層された化粧部材が挙げられる。すなわち、本実施形態の化粧部材20の好ましい態様としては、基体21、接着剤層22、基材1、装飾層2、接着層3、樹脂層4、プライマー層5及び表面保護層6を順に有する化粧部材が挙げられる。
本実施形態の化粧材は、基材がシート(又はフィルム)状であると、すなわち、本実施形態の化粧材がシート(又はフィルム)状であると、接着剤層を介して基体と積層しやすく、本実施形態の化粧部材が得られやすい。
本実施形態において、基体としては、その用途に応じて適宜決定すればよいが、上記樹脂基体、金属基体が好ましい。
感熱接着剤は、溶融した液状の接着剤層を冷却固化と同時に接着力が飽和状態まで立ち上がる点で好ましい。
本実施形態の化粧材は透湿度が0.75g/m2・24h以上である。このため、湿気硬化型接着剤は、施工過程において、適度な湿気に触れることができ、接着剤層に用いられる接着剤の初期密着強度を高くしやすくできる。また、本実施形態の化粧材は透湿度が45g/m2・24h以下である。このため、湿気硬化型接着剤は、過剰な湿気に触れることがなくなり、湿気硬化型接着剤の加水分解に伴う劣化による密着性の低下が抑制されることから、結果としてより優れた施工適性とともに長期密着性が得られやすくなる。また、湿気硬化型接着剤は、扱いやすさ等の点でも好ましい。
また、接着剤層には、粘着剤を用いることもできる。粘着剤としては、アクリル系、ウレタン系、シリコーン系、ゴム系等の粘着剤を適宜選択して用いることができる。
接着剤層の厚さは特に制限はないが、優れた接着性を得る観点から、1μm以上100μm以下が好ましく、5μm以上50μm以下がより好ましく、10μm以上30μm以下が更に好ましい。
1-1.透湿度の測定
実施例及び比較例で得られた化粧材について、JIS Z0208:1976に規定される防湿包装材料の透湿度試験方法(カップ法)に準拠して、透湿度を測定した。
1-2.引張弾性率の測定
実施例及び比較例で得られた化粧材について、JIS K6732:2006に準拠したダンベル型試験片に打ち抜いたシートをサンプルとして用意した。60℃の温度環境下にて、テンシロン万能材料試験機(「テンシロンRTC-1250A(品名)」、オリエンテック(株)製)を用い、引張速度50mm/分、チャック間距離80mm、幅25mmの条件で、前記サンプルを任意の伸度まで引っ張り、化粧材の引張弾性率を得た。
2-1.施工適性の評価
実施例及び比較例で得られた化粧材と、幅25mmの平板上の基体(材質:ポリ塩化ビニル(PVC))とを、湿気硬化型かつホットメルト型ウレタン樹脂系接着剤(分子中にイソシアネート基を有するポリウレタン系プレポリマー、「1308.20(品名)」、TAKA社製)を120℃で溶融してなる厚さ50μmの接着剤層を介して貼着し、室温23℃にて該接着剤層を冷却し、固化させて、1時間90℃の環境下に放置して試料を作製した。前記試料に対して、25℃の温度環境下にて、テンシロン万能材料試験機(「テンシロンRTC-1250A(品名)」、オリエンテック(株)製)を用い、引張速度:10mm/分、剥離方向90°、チャック間距離:30mmの条件でピーリング試験を行い、ピーリング強度を初期接着強度として測定し、以下の基準で評価した。B評価以上であれば、施工適性の評価は合格である。
A:ピーリング強度が1.0N/mm以上であった。
B:ピーリング強度が0.5N/mm以上1.0N/mm未満であった。
C:ピーリング強度が0.5N/mm未満であった。
2-2.長期密着性の評価
上記「2-1.施工適性の評価」で作製した試料を、70℃90%RHの湿熱環境に6週間放置した後、25℃の温度環境下にて、テンシロン万能材料試験機(「テンシロンRTC-1250A(品名)」、オリエンテック(株)製)を用い、引張速度:50mm/分、剥離方向90°の条件でピーリング試験を行い、ピーリング強度を測定し、以下の基準で評価した。B評価以上であれば、長期密着性の評価は合格である。
A:ピーリング強度が2.0N/mm以上であった。
B:ピーリング強度が1.0N/mm以上2.0N/mm未満であった。
C:ピーリング強度が1.0N/mm未満であった。
2-3.加工適性
上記「2-1.施工適性の評価」で試料を作製において貼着(ラミネート)する際、曲げ部分(曲げ角度:1mmR)における化粧材の浮きを目視にて確認し、以下の基準で評価した。B評価以上であれば、加工適性は合格である。
A:浮きは全く確認されなかった。
B:浮きはほとんど確認されなかった。
C:浮きが確認され、剥離が生じた。
両面コロナ放電処理を施した基材(厚さ:80μm、ポリプロピレンシート、ポリオレフィン1)の一方の面に、2液硬化型のアクリル-ウレタン樹脂をバインダー樹脂とする印刷インキを用いてグラビア印刷にて装飾層(厚さ:3μm)を形成し、前記基材の他方の面に、2液硬化型ウレタン-硝化綿混合樹脂(硬化剤:ヘキサメチレンジイソシアネートを混合樹脂100質量部に対して5質量部含有)を含む樹脂組成物を塗布して裏面プライマー層(厚さ:3μm)を形成した。次いで、装飾層上に、透明ウレタン樹脂接着剤を塗布して接着層(厚さ:3μm)を形成し、当該接着剤上に、ポリプロピレン系樹脂をTダイ押出し機により加熱溶融押出し、透明な樹脂層(厚さ:80μm)を形成した。
次いで、プライマー層上に、下記の電離放射線硬化性樹脂組成物を塗布して未硬化樹脂層を形成した後、当該未硬化樹脂層に電子線(165keV、5Mrad(50kGy))を照射して硬化させることにより、表面保護層(厚さ:5μm)を形成して化粧材を作製した。
(電離放射線硬化性樹脂組成物)
電離放射線硬化性樹脂:ウレタンアクリレート
紫外線吸収剤1(商品名:アデカスタブLA-46、ヒドロキシフェニルトリアジン系紫外線吸収剤、株式会社ADEKA製):上記樹脂100質量部に対して2質量部
紫外線吸収剤2(商品名:Tinuvin1600、ヒドロキシフェニルトリアジン系紫外線吸収剤、BASF社製):上記樹脂100質量部に対して2質量部
ヒンダードアミン光安定剤(商品名:Tinuvin123、BASF社製):上記樹脂100質量部に対して3質量部
また、これとは別に、得られた化粧材を用いて、上記方法に基づき試料を作製し、評価を行った。その結果を第1表に示す。
実施例1において、基材及び樹脂層を第1表に示されるものにかえた以外は、実施例1と同様にして実施例2~4の化粧材、化粧部材を作製した。得られた化粧材を用いて、上記方法に基づき試料を作製し、評価を行った。その結果を第1表に示す。
・ポリオレフィン1:ポリプロピレン系樹脂シート(プロピレン-エチレンランダム共重合体(エチレン含有量:4.5質量%以下)、厚さ:80μm、結晶化度:70%)
・ポリオレフィン2:ポリプロピレン系樹脂シート(プロピレン-エチレンランダム共重合体(エチレン含有量:4.5質量%以下)、厚さ:60μm、結晶化度:50%)
・ポリオレフィン3:ポリプロピレン系樹脂シート(プロピレン-エチレンランダム共重合体(エチレン含有量:4.5質量%以下)、厚さ:60μm、結晶化度:40%)
・ポリオレフィン4:ポリプロピレン系樹脂シート(プロピレン-エチレンランダム共重合体(エチレン含有量:4.5質量%以下)、厚さ:100μm、結晶化度:70%)
・PVC1:ポリ塩化ビニル樹脂シート(厚さ:120μm)
ポリ塩化ビニル樹脂100質量部に対して、可塑剤としてフタル酸エステル系可塑剤(フタル酸ウンデシル(DUP))を38質量部加えた樹脂組成物を押出し成形して作製したものである。
・PVC2:ポリ塩化ビニル樹脂シート(厚さ:120μm)
上記PVC1において、可塑剤を、ポリエステル系可塑剤(アジピン酸系ポリエステル)とし、その含有量を、ポリ塩化ビニル樹脂100質量部に対して、33質量部としたこと以外はPVC1と同様にして作製したものである。
・ポリオレフィンA:ポリプロピレン系樹脂(厚さ:80μm)
・ポリオレフィンB:ポリプロピレン系樹脂(厚さ:40μm)
・ポリオレフィンC:ポリプロピレン系樹脂(厚さ:100μm)
一方、比較例1より、透湿度が大きすぎると大気中の水分と接着剤層を形成する接着剤との加水分解反応により劣化し、優れた長期密着性が得られず、また比較例2より、透湿度が小さすぎると接着剤層を形成する接着剤の良好な硬化状態が得られず、初期密着強度が小さくなり、優れた施工適性が得られないことが確認された。
1:基材
2:装飾層
2A:全面着色層
2B:絵柄層
3:接着層
4:樹脂層
5:プライマー層
6:表面保護層
20:化粧部材
21:基体
22:接着剤層
Claims (10)
- 基材に装飾処理を施してなり、JIS Z0208:1976に規定される防湿包装材料の透湿度試験方法(カップ法)に準拠して測定された透湿度が0.75g/m2・24h以上45g/m2・24h以下である化粧材。
- 前記基材が、塩化ビニル系樹脂及びポリオレフィン樹脂から選ばれる少なくとも一種の樹脂により構成される請求項1に記載の化粧材。
- 更に、表面保護層を、最表面に有する請求項1又は2に記載の化粧材。
- 前記表面保護層が、硬化性樹脂の硬化物で構成される層である請求項3に記載の化粧材。
- 前記装飾処理が装飾層によるものであり、前記装飾層、接着層、樹脂層及びプライマー層を、前記基材、前記装飾層、前記接着層、前記樹脂層及び前記プライマー層の順に有する請求項1~4のいずれか1項に記載の化粧材。
- 60℃における引張弾性率が、80MPa以上600MPa以下である請求項1~5のいずれか1項に記載の化粧材。
- 請求項1~6のいずれか1項に記載の化粧材及び基体を、前記化粧材の前記基材と前記基体とが対面するように接着剤層を介して有する化粧部材。
- 前記接着剤層が、ウレタン系接着剤で構成される請求項7に記載の化粧部材。
- 前記ウレタン系接着剤が、湿気硬化型接着剤である請求項8に記載の化粧部材。
- 前記基体が、樹脂基体又は金属基体である請求項7~9のいずれか1項に記載の化粧部材。
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JP5699378B2 (ja) * | 2013-01-23 | 2015-04-08 | 大日本印刷株式会社 | 防湿化粧シートを用いた化粧板 |
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2020
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JP2010234763A (ja) * | 2009-03-31 | 2010-10-21 | Dainippon Printing Co Ltd | 化粧シート及び該化粧シートを用いた化粧板 |
JP2015052090A (ja) * | 2013-09-09 | 2015-03-19 | 積水フーラー株式会社 | 湿気硬化型ホットメルト接着剤 |
WO2016125907A1 (ja) * | 2015-02-06 | 2016-08-11 | 大日本印刷株式会社 | 化粧シート及び該化粧シートを備える化粧部材 |
JP2018171884A (ja) * | 2017-03-31 | 2018-11-08 | 大日本印刷株式会社 | 化粧シート及びこれを用いた化粧材 |
JP2018171920A (ja) * | 2017-03-31 | 2018-11-08 | 大日本印刷株式会社 | 熱接着加工用化粧シート |
JP2018187877A (ja) * | 2017-05-10 | 2018-11-29 | 凸版印刷株式会社 | 化粧シート |
WO2020067469A1 (ja) * | 2018-09-28 | 2020-04-02 | 大日本印刷株式会社 | 化粧シート及びこれを用いた化粧材 |
WO2020067569A1 (ja) * | 2018-09-28 | 2020-04-02 | 大日本印刷株式会社 | 化粧シート及びこれを用いた化粧材 |
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CN114423836A (zh) | 2022-04-29 |
AU2020346581A1 (en) | 2022-03-31 |
EP4029692A4 (en) | 2023-09-27 |
JP2022050482A (ja) | 2022-03-30 |
JPWO2021049611A1 (ja) | 2021-09-27 |
EP4029692A1 (en) | 2022-07-20 |
JP7001196B2 (ja) | 2022-01-19 |
US20220324209A1 (en) | 2022-10-13 |
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