WO2021065620A1 - 化粧シート及びこれを用いた化粧材 - Google Patents
化粧シート及びこれを用いた化粧材 Download PDFInfo
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- WO2021065620A1 WO2021065620A1 PCT/JP2020/035790 JP2020035790W WO2021065620A1 WO 2021065620 A1 WO2021065620 A1 WO 2021065620A1 JP 2020035790 W JP2020035790 W JP 2020035790W WO 2021065620 A1 WO2021065620 A1 WO 2021065620A1
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- decorative sheet
- radical scavenger
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- TWCBCCIODCKPGX-UHFFFAOYSA-N octyl 2-[4-[4,6-bis(4-phenylphenyl)-1,3,5-triazin-2-yl]-3-hydroxyphenoxy]propanoate Chemical compound OC1=CC(OC(C)C(=O)OCCCCCCCC)=CC=C1C1=NC(C=2C=CC(=CC=2)C=2C=CC=CC=2)=NC(C=2C=CC(=CC=2)C=2C=CC=CC=2)=N1 TWCBCCIODCKPGX-UHFFFAOYSA-N 0.000 description 1
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- 125000000913 palmityl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- FZUGPQWGEGAKET-UHFFFAOYSA-N parbenate Chemical compound CCOC(=O)C1=CC=C(N(C)C)C=C1 FZUGPQWGEGAKET-UHFFFAOYSA-N 0.000 description 1
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- 125000004817 pentamethylene group Chemical group [H]C([H])([*:2])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[*:1] 0.000 description 1
- YWAKXRMUMFPDSH-UHFFFAOYSA-N pentene Chemical compound CCCC=C YWAKXRMUMFPDSH-UHFFFAOYSA-N 0.000 description 1
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- 125000004079 stearyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 229920001909 styrene-acrylic polymer Polymers 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
- 125000000999 tert-butyl group Chemical group [H]C([H])([H])C(*)(C([H])([H])[H])C([H])([H])[H] 0.000 description 1
- 125000005063 tetradecenyl group Chemical group C(=CCCCCCCCCCCCC)* 0.000 description 1
- WUPCFMITFBVJMS-UHFFFAOYSA-N tetrakis(1,2,2,6,6-pentamethylpiperidin-4-yl) butane-1,2,3,4-tetracarboxylate Chemical compound C1C(C)(C)N(C)C(C)(C)CC1OC(=O)CC(C(=O)OC1CC(C)(C)N(C)C(C)(C)C1)C(C(=O)OC1CC(C)(C)N(C)C(C)(C)C1)CC(=O)OC1CC(C)(C)N(C)C(C)(C)C1 WUPCFMITFBVJMS-UHFFFAOYSA-N 0.000 description 1
- 125000000383 tetramethylene group Chemical group [H]C([H])([*:1])C([H])([H])C([H])([H])C([H])([H])[*:2] 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- DVKJHBMWWAPEIU-UHFFFAOYSA-N toluene 2,4-diisocyanate Chemical compound CC1=CC=C(N=C=O)C=C1N=C=O DVKJHBMWWAPEIU-UHFFFAOYSA-N 0.000 description 1
- 125000003944 tolyl group Chemical group 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- STCOOQWBFONSKY-UHFFFAOYSA-N tributyl phosphate Chemical compound CCCCOP(=O)(OCCCC)OCCCC STCOOQWBFONSKY-UHFFFAOYSA-N 0.000 description 1
- 125000005040 tridecenyl group Chemical group C(=CCCCCCCCCCCC)* 0.000 description 1
- 125000002889 tridecyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- XZZNDPSIHUTMOC-UHFFFAOYSA-N triphenyl phosphate Chemical compound C=1C=CC=CC=1OP(OC=1C=CC=CC=1)(=O)OC1=CC=CC=C1 XZZNDPSIHUTMOC-UHFFFAOYSA-N 0.000 description 1
- 229920000785 ultra high molecular weight polyethylene Polymers 0.000 description 1
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- 235000013799 ultramarine blue Nutrition 0.000 description 1
- 238000002211 ultraviolet spectrum Methods 0.000 description 1
- 125000005065 undecenyl group Chemical group C(=CCCCCCCCCC)* 0.000 description 1
- 125000002948 undecyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- 238000007666 vacuum forming Methods 0.000 description 1
- 229920001866 very low density polyethylene Polymers 0.000 description 1
- 229920001567 vinyl ester resin Polymers 0.000 description 1
- 210000002268 wool Anatomy 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
- 239000001052 yellow pigment Substances 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
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Images
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- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
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Definitions
- the present invention relates to a decorative sheet and a decorative material using the same.
- decorative sheets have been used to decorate and protect the surfaces of interior and exterior members of buildings, interior and exterior members of vehicles such as automobiles, furniture, building members, and home appliances. ing.
- the decorative sheet has, for example, a configuration having a surface protective layer on a base material.
- the radical scavenger has a problem that it easily bleeds out from the surface protective layer over time. “Bleed out” may also be referred to as “bleed out” or “transition”.
- bleed out may also be referred to as “bleed out” or “transition”.
- the decorative sheet of Patent Document 1 has been proposed.
- the decorative material used for the members for the above purposes for example, a plastic product using a decorative sheet using a polyvinyl chloride sheet as a base material and, if necessary, providing a decorative layer as a decorative treatment, a surface protective layer, and the like. Etc. are also used (for example, Patent Document 2).
- the hindered amine-based light stabilizer (radical scavenger) in the surface protective layer has a reactive functional group, the hindered amine-based light stabilizer is fixed in the surface protective layer and bleed-out is suppressed. Is to be done.
- the decorative sheet of Patent Document 1 can suppress the bleed-out of the hindered amine-based light stabilizer, it cannot sufficiently capture the radicals generated by the irradiation of ultraviolet rays, so that the decorative sheet deteriorates over time and has sufficient weather resistance. It was not something that could be said. Further, the decorative sheet of Patent Document 1 has a problem that the scratch resistance of the surface protective layer is lowered because the crosslink density of the ionizing radiation curable resin composition is lowered.
- the present invention is excellent in that it can improve weather resistance, suppress deterioration of scratch resistance of the surface protective layer, have high initial adhesion strength in the construction process, are excellent in construction suitability, and do not cause peeling even after long-term use.
- An object of the present invention is to provide a decorative sheet and a decorative material that exhibit long-term adhesion.
- the radical scavenger has a radical scavenger i having an ethylenic double bond that can be polymerized with the ionizing radiation curable resin composition and an ethylenic double bond that can be polymerized with the ionizing radiation curable resin composition.
- the content of the radical scavenger in the composition A is 0.5 parts by mass or more and less than 10.0 parts by mass with respect to 100 parts by mass of the ionizing radiation curable resin composition.
- the decorative sheet of JIS Z0208 1976 in moistureproof packaging material moisture permeability test method (cup method) measured according the moisture permeability of 0.75g / m 2 ⁇ 24h or more 45 g / m 2 ⁇ of defined A decorative sheet that is 24 hours or less.
- the weather resistance can be improved, the deterioration of the scratch resistance of the surface protective layer can be suppressed, the initial adhesion strength in the construction process is high, the construction suitability is excellent, and peeling does not occur even after long-term use. It is possible to provide a decorative sheet and a decorative material that exhibit excellent long-term adhesion.
- the decorative sheet of the present invention is a decorative sheet having a surface protective layer on a substrate, and the surface protective layer is obtained by cross-linking and curing a composition A containing an ionizing radiation curable resin composition and a radical scavenger.
- the layer, the radical scavenger is a radical scavenger i having an ethylenic double bond polymerizable with the ionizing radiation curable resin composition and an ethylenic double layer polymerizable with the ionizing radiation curable resin composition.
- the content of the radical scavenger in the composition A containing the radical scavenger ii having no bond is 0.5 parts by mass or more and 10.0 parts by mass with respect to 100 parts by mass of the ionizing radiation curable resin composition. less than parts by weight, the decorative sheet of JIS Z0208: 1976 to defined the moisture permeability test method of dry packing material (cup method) in moisture permeability was measured according the 0.75g / m 2 ⁇ 24h or more 45g / m is 2 ⁇ 24h not more than.
- Decorative sheet of the present invention JIS Z0208: 1976 to defined the moisture permeability test method of dry packing material (cup method) in moisture permeability was measured according the 0.75g / m 2 ⁇ 24h or more 45 g / m 2 -It is characterized by being 24 hours or less.
- the decorative sheet of the present invention exhibits high initial adhesion strength in the process of constructing the decorative sheet by setting the moisture permeability within a specific range. Therefore, the decorative sheet of the present invention 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, so that the construction efficiency can be improved.
- Decorative sheet of the present invention are those having the following moisture permeability 0.75g / m 2 ⁇ 24h or more 45g / m 2 ⁇ 24h. If the moisture permeability is less than 0.75g / m 2 ⁇ 24h, through the adhesive layer when the decorative material by attaching the adherend, adhesion by curing failure of the adhesive used in the adhesive layer Since defects are likely to occur, excellent initial adhesive strength cannot be obtained, and excellent construction suitability cannot be obtained.
- the decorative sheet of the present invention has excellent construction suitability due to high initial adhesion strength in the construction process by setting the moisture permeability within a specific range, and long-term use does not cause peeling. Achieves both adhesion and adhesion.
- moisture permeability 1.2g / m 2 ⁇ 24h or more, more preferably 1.5g / m 2 ⁇ 24h or more, 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 having the transparent resin layer, the type of the material constituting the transparent resin layer and the like.
- FIG. 1 is a cross-sectional view showing a typical embodiment of the decorative sheet 100 of the present invention.
- the decorative sheet 100 of FIG. 1 has a surface protective layer 10 on the base material 50. Further, the decorative sheet 100 of FIG. 1 has a primer layer 20 in contact with the surface of the surface protective layer 10 on the base material 50 side. Further, the decorative sheet 100 of FIG. 1 has a transparent resin layer 30 and a decorative layer 40 between the base material 50 and the surface protective layer 10.
- each layer constituting the decorative sheet of the present invention will be described in more detail.
- the base material examples include films, sheets, and boards made of various papers, plastics, metals, woven fabrics or non-woven fabrics, wood, ceramic materials, and the like.
- a flat base material having a predetermined thickness is referred to as a film, a sheet, and a plate in ascending order of thickness.
- these differences in designation are treated as if there is no particular essential difference even if they are replaced with each other as appropriate.
- the difference in the names does not cause a difference in the interpretation of the claims of the present invention.
- plastic has insufficient weather resistance
- the surface protective layer described later can improve the weather resistance of the decorative sheet as a whole.
- resins constituting plastics include polyolefin resins such as polyethylene and polypropylene, vinyl chloride resins, vinylidene chloride resins, polyvinyl alcohols, vinyl resins such as ethylene-vinyl alcohol copolymers, polyethylene terephthalates, and polybutylene terephthalates.
- polyolefin resins such as polyethylene and polypropylene
- vinyl chloride resins vinylidene chloride resins
- polyvinyl alcohols vinyl resins such as ethylene-vinyl alcohol copolymers
- polyethylene terephthalates polybutylene terephthalates
- polyester resin polymethyl methacrylate, methyl polyacrylate
- acrylic resin such as polyethyl methacrylate, polystyrene, acrylonitrile-butadiene-styrene copolymer (ABS resin), cellulose triacetate, polycarbonate and the like
- ABS resin acrylonitrile-butadiene-styrene cop
- the polyolefin resin and chloride are easily kept in the above range for the moisture permeability of the decorative sheet of the present invention, and in consideration of versatility, suitability for use as a decorative material, etc., while improving construction suitability and long-term adhesion.
- Vinyl-based resins are more preferable, and polyolefin resins are even more preferable in consideration of environmental performance.
- 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 in order to easily keep the moisture permeability within the above range and improve the long-term adhesion as well as the construction suitability. Resin is preferred.
- the thickness of the layer in which the resin such as the base material and the transparent resin layer can be used is easy and more reliable.
- the ratio of the thickness to the total thickness of the decorative sheet is taken into consideration in the laminated structure of the decorative sheet, and the base material and the transparent resin layer
- the thickness is preferably 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 sheet and the desired moisture permeability.
- the polyethylene-based resin may be a homopolymer of ethylene, that is, polyethylene, or ethylene and another 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 to 20/80 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 in order to easily keep the moisture permeability within the above range and improve the long-term adhesion as well as the workability. Is more preferable. When the average degree of polymerization is within the above range, excellent mechanical strength and moldability can also be obtained. In the present specification, the average degree of polymerization is the average degree of polymerization measured in accordance with JIS K6721.
- a plasticizer may be added in order to easily keep the moisture permeability within the above range, improve the long-term adhesion as well as the workability, and further improve the workability.
- 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, and phthalic acid-based plasticizers are preferable, in order to easily keep the moisture permeability within the above range, improve long-term adhesion as well as construction suitability, and improve workability. Acid-based plasticizers and polyester-based plasticizers are more preferable. In addition, 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.
- the content of the plasticizer is preferably 15 parts by mass or more, more preferably 20 parts by mass or more, and further preferably 25 parts by mass or more with respect to 100 parts by mass of the vinyl chloride resin.
- the upper limit is preferably 50 parts by mass or less, more preferably 45 parts by mass or less, and further 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, by setting the content of the plasticizer to 20 parts by mass or more, the vinyl chloride resin can be made flexible and the processability can be improved. On the other hand, when it is 50 parts by mass or less, the bleed-out of the plasticizer is suppressed, the moisture permeability can be stably adjusted to a desired range, and the long-term adhesion can be improved as well as the workability.
- 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 base material may be colorless and transparent, or may be colored in order to improve the design.
- a colorant such as a dye or a pigment can be added to the base material.
- pigments that easily suppress fading are preferable.
- white pigments such as zinc flower, lead white, lithopon, titanium dioxide (titanium white), precipitated barium sulfate and barite; black pigments such as carbon black, aometinazo black pigment, perylene black pigment; lead tan, Red pigments such as iron oxide red, quinacridone red, polyazo red; yellow pigments such as yellow lead, zinc yellow (1 zinc yellow, 2 zinc yellow), isoindolinone yellow, nickel-azo complex; ultramarine blue, prussian blue Blue pigments such as (ferroic iron potassium); etc. Titanium dioxide is preferable as a pigment to be added to a base material because it has a high hiding power and is not easily affected by the color of the adherend.
- titanium dioxide generates radicals by irradiation with light including an ultraviolet spectrum, and the weather resistance of the decorative sheet is lowered.
- the generation of radicals can be suppressed, but more radicals are still generated than when titanium dioxide is not contained.
- the weather resistance can be improved for a long period of time. ..
- the base material and the surface protective layer are in contact with each other (when a primer layer is provided, the base material and the primer layer are preferably in contact with each other).
- the thickness of the base material is not particularly limited, but when the base material is a plastic film or sheet, it is preferably 20 ⁇ m or more, and the upper limit is 3200 ⁇ m or less, so that the moisture permeability of the decorative sheet can be easily adjusted within the above-mentioned predetermined range. As described above, 40 ⁇ m or more is more preferable, 200 ⁇ m or less is more preferable as an upper limit, and 100 ⁇ m or less is further preferable.
- the basis weight is usually preferably 20 g / m 2 or more and 150 g / m 2 or less, and more preferably 30 g / m 2 or more and 100 g / m 2 or less.
- the shape of the base material is not limited to a flat plate shape, and may be a special shape such as a three-dimensional shape.
- On the base material in order to improve the adhesion to the layer provided on the base material, one side or both sides may be subjected to an easy adhesion treatment such as a physical treatment or a chemical surface treatment.
- one or both sides of the base material may be subjected to physical surface treatment such as oxidation method or unevenness method, or chemical surface treatment or the like.
- the surface treatment of the above may be applied, or a primer layer may be formed.
- the surface protective layer of the decorative sheet of the present invention is a layer formed by cross-linking and curing a composition A containing an ionizing radiation curable resin composition and a radical scavenger.
- the surface protective layer contains a crosslinked cured product of an ionizing radiation curable resin composition. Since the surface protective layer contains a crosslinked cured product of the ionizing radiation curable resin composition, the scratch resistance of the decorative sheet can be improved. A part of the crosslinked cured product of the ionizing radiation curable resin composition is polymerized with the radical scavenger i described later. Examples of the ionizing radiation curable resin composition include an electron beam curable resin composition and an ultraviolet curable resin composition. Among these, the reason is that the environmental load is small because it can be applied without a solvent, and a polymerization initiator is not required. Therefore, an electron beam curable resin composition is preferable. Further, when the composition A contains an ultraviolet absorber described later, the electron beam curable resin composition is preferable in that the crosslink density of the surface protective layer can be easily increased.
- the ionizing radiation curable resin composition is a composition containing a compound having an ionizing radiation curable functional group (hereinafter, also referred to as “ionizing radiation curable compound”).
- 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, and an allyl group is preferable.
- a (meth) acryloyl group means an acryloyl group or a metachloroyl group.
- (meth) acrylate means acrylate or methacrylate.
- the ionizing radiation means an electromagnetic wave or a charged particle beam having an energy quantum capable of polymerizing and / or cross-linking a molecule, and usually, an ultraviolet ray (UV) or an electron beam (EB) is 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 compound 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”.
- Examples of 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.
- the number of functional groups of the polyfunctional (meth) acrylate monomer is preferably 2 or more and 8 or less, more preferably 2 or more and 6 or less, and further preferably 2 or more and 4 or less. More preferably 2 or more and 3 or less.
- These polyfunctional (meth) acrylates may be used alone or in combination of two or more.
- 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.
- 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 For example, urethane (meth) acrylate oligomer, epoxy (meth) acrylate oligomer, polyester (meth) acrylate oligomer, polyether (meth) acrylate oligomer, polycarbonate (meth) acrylate oligomer, acrylic (meth) acrylate oligomer and the like can be mentioned.
- a polybutadiene (meth) acrylate-based oligomer having a (meth) acrylate group on the side chain of the polybutadiene oligomer and a silicone (meth) acrylate-based oligomer having a polysiloxane bond on the main chain are also used.
- oligomers and the like having cationically polymerizable functional groups are also used.
- polymerizable oligomers may be used alone or in combination of two or more.
- Acrylic (meth) acrylate oligomers are preferable, urethane (meth) acrylate oligomers and polycarbonate (meth) acrylate oligomers are more preferable, and urethane (meth) acrylate oligomers are even more preferable.
- the number of functional groups of these polymerizable oligomers is preferably 2 or more and 8 or less, more preferably 6 or less, still more preferably 4 or less, in order to improve processing characteristics, scratch resistance and weather resistance. 3 or less is even more preferable.
- the weight average molecular weight of these polymerizable oligomers is preferably 2,500 or more and 7,500 or less, and more preferably 3,000 or more and 7,000 or less, in order to improve processing characteristics, scratch resistance and weather resistance. , 3,500 or more and 6,000 or less are more preferable.
- the weight average molecular weight is an average molecular weight measured by GPC analysis and converted with standard polystyrene.
- a monofunctional (meth) acrylate can be used in combination with the ionizing radiation curable resin composition for the purpose of reducing the viscosity of the ionizing radiation curable resin composition.
- These monofunctional (meth) acrylates may be used alone or in combination of two or more.
- the composition A preferably contains additives such as a photopolymerization initiator and a photopolymerization accelerator.
- a photopolymerization initiator include one or more selected from acetophenone, benzophenone, ⁇ -hydroxyalkylphenone, Michler ketone, benzoin, benzyl dimethyl ketal, benzoyl benzoate, ⁇ -acyl oxime ester, thioxanthones and the like.
- the photopolymerization accelerator can reduce the polymerization inhibition by air at the time of curing and accelerate the curing rate. For example, from p-dimethylaminobenzoic acid isoamyl ester, p-dimethylaminobenzoic acid ethyl ester and the like. One or more selected species can be mentioned.
- a radical scavenger i having an ethylenic double bond that can be polymerized with the ionizing radiation curable resin composition and an ethylenic double bond that can be polymerized with the ionizing radiation curable resin composition. Includes a radical scavenger ii that does not have.
- radical scavengers examples include aromatic radical scavengers, amine radical scavengers, organic acid radical scavengers, catechin radical scavengers and hindered amine radical scavengers. preferable.
- the hindered amine radical scavenger has a structure containing a 2,2,6,6-tetramethylpiperidine skeleton in the molecule.
- radical scavenger i When only the radical scavenger i is used, almost all the radical scavengers in the surface protective layer are in an immobilized state, and there is almost no radical scavenger that can move freely in the surface protective layer, so that the radicals are captured. The performance becomes insufficient, and the weather resistance of the decorative sheet cannot be improved. Further, since the radical trapping agent i polymerizes with the ionizing radiation curable resin composition, when only the radical trapping agent i is used, the crosslink density of the crosslinked product of the ionizing radiation curable resin composition is lowered, and the scratch resistance is improved. It will drop.
- the radical scavenger ii when only the radical scavenger ii is used, the radical scavenger ii bleeds out from the surface protective layer over time, the appearance of the decorative sheet surface is spoiled, and the radical scavenger in the surface protective layer over time The concentration decreases and the weather resistance becomes insufficient.
- the content of the radical scavenger in the composition A is 0.5 parts by mass or more and less than 10.0 parts by mass with respect to 100 parts by mass of the ionizing radiation curable resin composition. If the content of the radical scavenger is less than 0.5 parts by mass with respect to 100 parts by mass of the ionizing radiation curable resin composition, the absolute amount of the radical scavenger is insufficient. Even when used in combination, the weather resistance of the decorative sheet cannot be improved.
- the content of the radical trapping agent exceeds 10.0 parts by mass with respect to 100 parts by mass of the ionizing radiation curable resin composition, the crosslink density of the crosslinked product of the ionizing radiation curable resin composition in the surface protective layer is high. There is a problem that the scratch resistance is lowered due to the decrease, and the bleed-out of the radical trapping agent is likely to occur.
- the content of the radical scavenger in the composition A is preferably 0.8 parts by mass or more and 5.0 parts by mass or less, and 1.0 part by mass or more, with respect to 100 parts by mass of the ionizing radiation curable resin composition. It is more preferably 4.0 parts by mass or less.
- the radical scavenger i has an ethylenic double bond that can be polymerized with the ionizing radiation curable resin composition.
- the group having an ethylenic double bond include a (meth) acryloyl group, a crotonoyl group, a vinyl group and an allyl group, and among these, a (meth) acryloyl group is preferable. That is, the radical scavenger i preferably has a (meth) acryloyl group.
- the number of ethylenic double bonds in the radical scavenger i is not particularly limited, and may be one or two or more. Further, only one type of radical scavenger i may be used, or two or more types may be used.
- radical trapping agent i having one ethylenic double bond examples include 4- (meth) acryloyloxy-2,2,6,6-tetramethylpiperidine and 4- (meth) acryloylamino-2,2,6. 6-Tetramethylpiperidin, 4- (meth) acryloyloxy-1,2,2,6,6-pentamethylpiperidin, 4- (meth) acryloylamino-1,2,2,6,6-pentamethylpiperidin, 4-Cyano-4- (meth) acryloylamino-2,2,6,6-tetramethylpiperidine, 4-crotonoyloxy-2,2,6,6-tetramethylpiperidine and 4-crotonoylamino-2, Examples thereof include 2,6,6-tetramethylpiperidine, pentamethylpiperidinyl (meth) acrylate, the compound of CAS number 1010692-24-6, and the compound of CAS number 1010692-21-3.
- radical trapping agent i having two or more ethylenic double bonds examples include 1- (meth) acryloyl-4- (meth) acryloylamino-2,2,6,6-tetramethylpiperidine and 1- (meth) acryloyl-.
- radical scavenger ii does not have an ethylenic double bond that can be polymerized with the ionizing radiation curable resin composition. Only one type of radical scavenger ii may be used, or two or more types may be used.
- radical trapping agent ii examples include 4-benzoyloxy-2,2,6,6-tetramethylpiperidine, bis (2,2,6,6-tetramethyl-4-piperidyl) sebacate, and bis (1,2,2). , 6,6-Pentamethyl-4-piperidyl) sebacate, bis (1-octyl oshiki-2,2,6,6-tetramethyl-4-piperidinyl) sebacate, bis (1,2,2,6,6-pentamethyl- 4-Piperidinyl) sebacate, methyl (1,2,2,6,6-pentamethyl-4-piperidinyl) sebacate, 2,4-bis [N-butyl-N- (1-cyclohexyloxy-2,2,6) 6-Tetramethyl-4-piperidinyl) amino] -6- (2-hydroxyethylamine) -1,3,5-triazine), tetrakis (1,2,2,6,6-pentamethyl-4-piperidyl) -1 ,
- the radical scavenger ii When the decorative sheet has a primer layer in contact with the surface of the surface protective layer on the substrate side, the radical scavenger ii preferably has a functional group capable of reacting with the functional group of the constituent components of the primer layer.
- the radical scavenger ii existing near the interface between the surface protection layer and the primer layer is immobilized at the interface, bleed-out is suppressed, and bleed-out is suppressed, and at other locations.
- the radical scavenger ii present in is preferable in that it can move freely in the surface protective layer and can maintain the radical scavenging performance.
- the radical scavenger ii and the constituent components of the primer layer react at the interface between the surface protective layer and the primer layer, so that the adhesion of the surface protective layer can be improved.
- Examples of the combination of functional groups satisfying the above conditions are those shown in A to D in Table 1 below. Among these, the following A (the radical scavenger ii has a hydroxyl group and the constituent component of the primer layer has an isocyanate group) is preferable.
- the hindered amine-based radical scavenger suitable as the radical scavenger i and the radical scavenger ii is classified into, for example, an amino ether type and a non-amino ether type.
- the aminoether type hindered amine radical scavenger refers to a 2,2,6,6-tetramethylpiperidine skeleton in which a hydrogen atom bonded to a nitrogen atom is replaced with OR 1 or OCOR 2.
- R 1 and R 2 are an alkyl group and / or a cycloalkyl group, preferably an alkyl group having 5 or more and 12 or less carbon atoms and / or a cycloalkyl group.
- the non-amino ether type hindered amine radical scavenger is a 2,2,6,6-tetramethylpiperidin skeleton in which the hydrogen atom bonded to the nitrogen atom remains a hydrogen atom or the hydrogen atom is replaced with an alkyl group. It means what was done.
- the mixing ratio of the radical scavenger i and the radical scavenger ii based on the mass is preferably 8: 2 to 2: 8, more preferably 7: 3 to 3: 7, and 6: 4 to 4. : 6 is more preferable.
- the weather resistance can be improved and the crosslink density of the crosslinked cured product of the ionizing radiation curable resin composition is lowered. It can be easily suppressed.
- the composition A forming the surface protective layer preferably contains an ultraviolet absorber.
- the ultraviolet absorber include a benzotriazole-based ultraviolet absorber, a benzophenone-based ultraviolet absorber, a triazine-based ultraviolet absorber, and the like, and a triazine-based ultraviolet absorber is preferable.
- the triazine-based ultraviolet absorbers the hydroxyphenyltriazine-based ultraviolet absorber in which at least three organic groups selected from a hydroxyphenyl group, an alkoxyphenyl group and an organic group containing these groups are linked to the triazine ring is used.
- a hydroxyphenyltriazine-based ultraviolet absorber represented by the following general formula (1) is further preferable. Since the hydroxyphenyltriazine-based ultraviolet absorber has a branched structure, it is expected that it will be difficult to bleed out from the surface protective layer, and excellent weather resistance can be obtained in a longer period of time. Further, an ultraviolet absorber having an ethylenic double bond such as a (meth) acryloyl group, a vinyl group, and an allyl group is preferable because it is easy to suppress bleed-out.
- R 11 is a divalent organic group
- R 13 , R 14 and R 15 are independent of each other. It is a monovalent organic group
- n 11 and n 12 are each independently an integer of 1 or more and 5 or less.
- Examples of the divalent organic group of R 11 include an aliphatic hydrocarbon group such as an alkylene group and an alkenylene group, and an alkylene group is preferable in order to improve weather resistance, and the number of carbon atoms thereof is 1 or more and 20 or less. Preferably, 1 or more and 12 or less is more preferable, 1 or more and 8 or less is further preferable, and 1 or more and 4 or less is particularly preferable.
- the alkylene group and the alkenylene group may be linear, branched or cyclic, but linear or branched is preferable.
- alkylene group having 1 or more and 20 or less carbon atoms examples include a methylene group, a 1,1-ethylene group, a 1,2-ethylene group, a 1,3-propylene, a 1,2-propylene and a 2,2-propylene group.
- Various propylene groups (hereinafter, "various” refers to linear, branched, and those containing isomers thereof), various butylene groups, various pentylene groups, various hexylene groups, various heptylene groups, Various octylene groups, various nonylene groups, various decylene groups, various undecylene groups, various dodecylene groups, various tridecylene groups, various tetradecylene groups, various pentadecylene groups, various hexadecylene groups, various heptadecylene groups, various octadecylene groups, various nonadesilene groups, various icosilene groups. The group is mentioned.
- Examples of the monovalent organic group of R 13 and R 14 include an alkyl group, an alkenyl group, a cycloalkyl group, an aryl group, an arylalkyl group and the like, and an aromatic hydrocarbon group such as an aryl group and an arylalkyl group can be used.
- an aryl group is preferred.
- a phenyl group is preferable as the monovalent organic group of R 13 and R 14.
- the aryl group preferably has 6 or more and 20 or less carbon atoms, more preferably 6 or more and 12 or less carbon atoms, and more preferably 6 or more and 10 or less carbon atoms, for example, a phenyl group, various methylphenyl groups, and various ethylphenyl groups. Groups, various dimethylphenyl groups, various propylphenyl groups, various trimethylphenyl groups, various butylphenyl groups, various naphthyl groups and the like can be mentioned.
- the arylalkyl group preferably has 7 or more and 20 or less carbon atoms, more preferably 7 or more and 12 or less carbon atoms, and more preferably 7 or more and 10 or less carbon atoms, for example, a benzyl group, a phenethyl group, and various phenylpropyl groups.
- Groups, various phenylbutyl groups, various methylbenzyl groups, various ethylbenzyl groups, various propylbenzyl groups, various butylbenzyl groups, various hexylbenzyl groups and the like can be mentioned.
- Examples of the monovalent organic group of R 15 include an alkyl group, an alkenyl group, a cycloalkyl group, an aryl group, an arylalkyl group and the like, and an aliphatic hydrocarbon group such as an alkyl group and an alkenyl group is preferable, and an alkyl group is used. Is more preferable. That is, as R 12 , an alkyl ester group and an alkenyl ester group are preferable, and an alkyl ester group is more preferable.
- the alkyl group preferably has 1 or more and 20 or less carbon atoms, more preferably 2 or more and 16 or less, and further preferably 6 or more and 12 or less alkyl groups, for example, a methyl group, an ethyl group, various propyl groups, various butyl groups, and various types.
- Pentyl group various hexyl groups, various octyl groups, various nonyl groups, various decyl groups, various undecyl groups, various dodecyl groups, various tridecyl groups, various tetradecyl groups, various pentadecyl groups, various hexadecyl groups, various heptadecyl groups, various octadecyl groups. , Various nonadesyl groups and various icosyl groups.
- an alkenyl group having preferably 2 or more and 20 or less carbon atoms, more preferably 3 or more and 16 or less, and further preferably 6 or more and 12 or less, such as a vinyl group, various propenyl groups, various butenyl groups, and various pentenyl groups, Various hexenyl groups, various octenyl groups, various nonenyl groups, various decenyl groups, various undecenyl groups, various dodecenyl groups, various tridecenyl groups, various tetradecenyl groups, various pentadecenyl groups, various hexadecenyl groups, various heptadecenyl groups, various octadecenyl groups, various nonadesenyl groups. Examples include groups and various icosenyl groups.
- R 11 is an alkylene group having 1 or more carbon atoms and 20 or less carbon atoms
- R 12 and R 15 are alkyl groups having 1 or more carbon atoms and 20 or less carbon atoms. It is an alkyl ester group which is a group
- R 13 and R 14 are aryl groups having 6 or more and 20 or less carbon atoms
- a hydroxyphenyltriazine compound having n 11 and n 12 of 1 is preferable
- R 11 has 1 or more carbon atoms and 12 carbon atoms.
- R 12 and R 15 are alkyl ester groups having 2 or more and 16 or less carbon atoms
- R 13 and R 14 are aryl groups having 6 or more and 12 or less carbon atoms
- R 11 is an alkyl group having 1 or more and 8 or less carbon atoms
- R 12 is an alkyl ester group having R 15 and 6 or more and 12 or less carbon atoms.
- R 13 and R 14 are aryl groups having 6 or more and 10 or less carbon atoms, hydroxyphenyltriazine compounds having n 11 and n 12 of 1 are more preferable, and R 11 is an alkylene group having 1 or more and 4 or less carbon atoms.
- R 12 and R 15 are ester groups which are alkyl groups having 8 carbon atoms
- R 13 and R 14 are phenyl groups, and hydroxyphenyl triazine compounds having n 11 and n 12 of 1 are particularly preferable.
- the hydroxyphenyltriazine compound represented by the general formula (1) is an ester group represented by the following chemical formula (2) in which R 11 is an ethylene group and R 12 and R 15 are isooctyl groups. , R 13 and R 14 are phenyl groups, and n 11 and n 12 are 1 hydroxyphenyltriazine compounds, ie 2- (2-hydroxy-4- [1-octyloxycarbonylethoxy] phenyl) -4, 6-Bis (4-phenylphenyl) -1,3,5-triazine is preferable, and this hydroxyphenyltriazine compound is available as a commercially available product (“TINUVIN479”, manufactured by BASF), for example.
- TINUVIN479 commercially available product
- the content of the ultraviolet absorber in the composition A is preferably 0.2 parts by mass or more and 10.0 parts by mass or less, and 0.5 parts by mass or more and 5.0 parts by mass with respect to 100 parts by mass of the ionizing radiation curable resin composition. More preferably, it is 1.0 part by mass or more and 4.0 part by mass or less.
- the type of the ultraviolet absorbing agent used may be one type alone, or a plurality of types may be used in combination.
- the composition A forming the surface protective layer preferably contains an antioxidant.
- an antioxidant By including the antioxidant, the weather resistance can be improved more easily.
- the antioxidant include phenol-based, amine-based, sulfur-based, and phosphorus-based antioxidants. Of these, phenolic antioxidants are preferred.
- phenolic antioxidant examples include a hindered phenolic antioxidant, and specific examples thereof include pentaerythritol tetrakis [3- (3,5-di-tert-butyl-4-hydroxyphenyl). Propionate], octadecyl-3- (3,5-di-tert-butyl-4-hydroxyphenyl) propionate, thiodiethylenebis [3- (3,5-di-tert-butyl-4-hydroxyphenyl) propionate], N, N'-hexane-1,6-diylbis [3- (3,5-di-tert-butyl-4-hydroxyphenylpropionamide), 2,4-dimethyl-6- (1-methylpentadecyl) phenol , Diethyl [[3,5-bis (1,1-dimethylethyl) -4-hydroxyphenyl] methyl] phosphate, 3,3', 3'', 5,5', 5'-he
- the thickness of the surface protective layer is preferably 1.5 ⁇ m or more and 20 ⁇ m or less, more preferably 2 ⁇ m or more and 15 ⁇ m or less, and further preferably 3 ⁇ m or more and 10 ⁇ m or less, from the balance of processing characteristics, scratch resistance and weather resistance.
- the decorative sheet preferably has a primer layer in contact with the surface of the surface protective layer on the substrate side.
- the primer layer improves the adhesion between the base material and the surface protective layer, and makes it easy to secure long-term interlayer adhesion (so-called weather resistance) and scratch resistance when exposed outdoors.
- the primer layer is mainly composed of a binder resin, and may contain additives such as an ultraviolet absorber and a light stabilizer, if necessary.
- a binder resin urethane resin, acrylic polyol resin, acrylic resin, ester resin, amide resin, butyral resin, styrene resin, urethane-acrylic copolymer, polycarbonate-based urethane-acrylic copolymer (carbonate bond to the polymer main chain).
- a curing agent such as an isocyanate-based curing agent or an epoxy-based curing agent.
- the binder resin preferably has a functional group capable of reacting with the functional group of the radical scavenger ii.
- the thickness of the primer layer is preferably 1 ⁇ m or more and 10 ⁇ m or less, more preferably 2 ⁇ m or more and 8 ⁇ m or less, and further preferably 3 ⁇ m or more and 6 ⁇ m or less.
- the decorative sheet may have a back surface primer layer on the side opposite to the front surface protective layer of the base material for the purpose of improving the adhesiveness with the adherend.
- the decorative sheet may have a transparent resin layer between the base material and the surface protective layer for the purpose of increasing the strength.
- the transparent resin layer is preferably located between the base material and the primer layer.
- the transparent resin layer is preferably located between the decorative layer and the surface protective layer in order to protect the decorative layer.
- the resin constituting the transparent resin layer examples include polyolefin-based resin, polyester resin, polycarbonate resin, acrylonitrile-butadiene-styrene resin (hereinafter, also referred to as “ABS resin”), acrylic resin, vinyl chloride resin and the like.
- ABS resin acrylonitrile-butadiene-styrene resin
- acrylic resin vinyl chloride resin
- a polyolefin-based resin is preferable in order to improve processability, and a polyolefin-based resin and a vinyl chloride resin are preferable, and a polyolefin-based resin is more preferable, considering the ease of adjusting the moisture permeability.
- two or more kinds of these illustrated various resins may be laminated or mixed and used.
- the content of the polyolefin-based resin in the transparent resin layer is preferably 50% by mass or more, preferably 70% by mass or more, based on the total resin components of the transparent resin layer in order to improve processing suitability. Is more preferable, and 90% by mass or more is further preferable.
- the polyolefin-based resin of the transparent resin layer includes polyethylene (low density, medium density, high density), polypropylene, polymethylpentene, polybutene, ethylene-propylene copolymer, propylene-butene copolymer, and ethylene-vinyl acetate.
- examples thereof include polymers, ethylene-acrylic acid copolymers, and ethylene-propylene-butene copolymers.
- polyethylene (low density, medium density, high density), polypropylene, ethylene-propylene copolymer, and propylene-butene copolymer are preferable, and polypropylene is more preferable.
- the polyolefin-based resin the polyethylene-based resin and the polypropylene-based resin described as specific examples of the resin constituting the plastic of the base material can be preferably used.
- the vinyl chloride resin described as a specific example of the resin constituting the plastic of the base material can be preferably used.
- the transparent resin layer may contain additives such as an ultraviolet absorber, a light stabilizer, and a colorant.
- the thickness of the transparent resin layer is preferably 20 ⁇ m or more and 150 ⁇ m or less, more preferably 40 ⁇ m or more and 120 ⁇ m or less, and 60 ⁇ m or more and 100 ⁇ m from the viewpoint of easy adjustment of moisture permeability, scratch resistance, processing suitability and weather resistance. The following is more preferable.
- the decorative sheet preferably has a decorative layer at any position on the decorative sheet in order to improve the design.
- the portion where the decorative layer is formed is preferably on the side close to the base material in order to improve the weather resistance of the decorative layer.
- the decorative layer is preferably located between the base material and the primer layer.
- the decorative layer is preferably located between the base material and the transparent resin layer.
- the decorative layer may be, for example, a colored layer that covers the entire surface (so-called solid colored layer), or may be a pattern layer formed by printing various patterns using ink and a printing machine.
- the pattern (pattern) of the pattern layer the annual ring on the surface of the wood board, the grain pattern on the conduit groove, etc., the stone grain pattern on the stone board surface such as marble and granite, the cloth pattern on the cloth surface, and the leather grain pattern on the leather surface.
- the ink used for the decorative layer is a binder resin mixed with colorants such as pigments and dyes, extender pigments, solvents, stabilizers, plasticizers, catalysts, curing agents, ultraviolet absorbers, light stabilizers, etc. as appropriate. used.
- the binder resin of the decorative layer is not particularly limited, and for example, urethane resin, acrylic polyol resin, acrylic resin, ester resin, amide resin, butyral resin, styrene resin, urethane-acrylic copolymer, vinyl chloride-vinyl acetate common weight.
- Examples thereof include a coalesced resin, a vinyl chloride-vinyl acetate-acrylic copolymer resin, a chlorinated propylene resin, a nitrocellulose resin, and a cellulose acetate resin. Further, various types of resins such as a one-component curable resin and a two-component curable resin with a curing agent such as an isocyanate compound can be used.
- the colorant a pigment having excellent hiding power and weather resistance is preferable.
- the same pigment as those exemplified for the plastic base material can be used.
- the content of the colorant is preferably 5 parts by mass or more and 90 parts by mass or less, more preferably 15 parts by mass or more and 80 parts by mass or less, and 30 parts by mass or more and 70 parts by mass with respect to 100 parts by mass of the resin constituting the decorative layer. The following is more preferable.
- the decorative layer may contain additives such as an ultraviolet absorber, a light stabilizer, and a colorant.
- the thickness of the decorative layer may be appropriately selected according to the desired pattern, but is preferably 0.5 ⁇ m or more and 20 ⁇ m or less, preferably 1 ⁇ m or more and 10 ⁇ m in order to hide the ground color of the adherend and improve the design. The following is more preferable, and 2 ⁇ m or more and 5 ⁇ m or less is further preferable.
- the decorative sheet has a transparent resin layer
- the positional relationship between the adhesive layer A and the decorative layer is not particularly limited.
- the decorative sheet of the present invention may have a decorative layer, an adhesive layer A, and a transparent resin layer in this order from the side closer to the base material, or the adhesive may be provided from the side closer to the base material layer.
- the layer A, the decorative layer, and the transparent resin layer may be provided in this order.
- the adhesive layer A can be composed of, for example, an adhesive such as a urethane-based adhesive, an acrylic-based adhesive, an epoxy-based adhesive, or a rubber-based adhesive.
- an adhesive such as a urethane-based adhesive, an acrylic-based adhesive, an epoxy-based adhesive, or a rubber-based adhesive.
- urethane-based adhesives are preferable in terms of adhesive strength.
- the urethane-based adhesive include an adhesive using a two-component curable urethane resin containing various polyol compounds such as a polyether polyol, a polyester polyol, and an acrylic polyol, and a curing agent such as an isocyanate compound.
- the thickness of the adhesive layer A is preferably 0.1 ⁇ m or more and 30 ⁇ m or less, more preferably 1 ⁇ m or more and 15 ⁇ m or less, and further preferably 2 ⁇ m or more and 10 ⁇ m or less.
- the above-mentioned decorative layer, adhesive layer A, primer layer and top coat layer are coated with a coating liquid containing a composition forming each layer by a gravure printing method, a bar coating method, a roll coating method, a reverse roll coating method, or a comma coating method. It can be formed by applying it by a known method such as, and if necessary, drying and curing it.
- the decorative sheet may be given a desired uneven shape (also referred to as an uneven pattern) (also referred to as shaping) by embossing or the like.
- embossing for example, the decorative sheet is heated to preferably 80 ° C. or higher and 260 ° C. or lower, more preferably 85 ° C. or higher and 160 ° C. or lower, and further preferably 100 ° C. or higher and 140 ° C. or lower, and the embossing plate is pressed against the decorative sheet. Then, embossing can be performed.
- the portion where the embossed plate is pressed is preferably on the surface protective layer side of the decorative sheet.
- the decorative material of the present invention has an adherend and the above-mentioned decorative sheet of the present invention. Specifically, a surface requiring decoration of the adherend and a surface of the decorative sheet on the base material layer side. Are laminated so as to face each other.
- adherend examples include flat plates of various materials, plate materials such as curved plates, three-dimensional articles such as cylinders and polygonal columns, and sheets (or films).
- adherend examples include flat plates of various materials, plate materials such as curved plates, three-dimensional articles such as cylinders and polygonal columns, and sheets (or films).
- wood single boards made of various kinds of wood such as cedar, cypress, pine, and lauan, wood plywood, laminated wood, particle boards, wood members such as MDF (medium density fiber board); iron, aluminum, copper, and these metals.
- MDF medium density fiber board
- Metal members made of metals such as alloys containing one or more; ceramic members made of ceramics such as glass and ceramics, plaster, cement, ALC (lightweight cellular concrete), ceramic members made of non-ceramic ceramic materials such as calcium silicate; acrylic resin, Examples thereof include polyester resin, polystyrene resin, polyolefin resin such as polypropylene, ABS (acrylonitrile-butadiene-styrene copolymer) resin, phenol resin, vinyl chloride resin, cellulose resin, resin member made of resin such as rubber, and the like. In addition, these members can be used alone or in combination of two or more.
- the adherend may be appropriately selected from the above depending on the application, and is used for interior members of buildings such as walls, ceilings and floors; for exteriors of buildings such as outer walls, roofs, eaves ceilings, fences and gates.
- Members; fittings or building members such as window frames, doors, handrails, skirting boards, peripheral edges and moldings; etc., which consist of at least one member selected from wood members, metal members and resin members.
- the member is composed of at least one member selected from a metal member and a resin member.
- the thickness of the adherend may be appropriately selected depending on the application and material, and is preferably 0.1 mm or more and 100 mm or less, more preferably 0.3 mm or more and 5 mm or less, and further preferably 0.5 mm or more and 3 mm or less.
- ⁇ Adhesive layer B> The adherend and the decorative sheet are preferably bonded together via the adhesive layer B in order to obtain excellent adhesiveness.
- the adhesive used for the adhesive layer B 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 B 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 the like.
- Adhesives such as pressure sensitive adhesives are preferable.
- 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 B 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 B can be easily increased. Further, the decorative material of the present embodiment is less moisture permeability 45g / m 2 ⁇ 24h.
- the moisture-curable adhesive does not come into contact with excessive moisture, and thus the deterioration of the adhesiveness due to the deterioration of the moisture-curable adhesive due to hydrolysis is suppressed, resulting in better construction suitability. At the same time, long-term adhesion can be easily obtained.
- 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 thickness of the adhesive layer B is not particularly limited, but for the purpose 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 material can be manufactured through a process of laminating a decorative sheet and an adherend.
- This step is a step of laminating the adherend and the decorative sheet of the present invention, in which the surface of the adherend that requires decoration and the surface of the decorative sheet on the base material side are opposed to each other and laminated.
- Examples of the method of laminating the adherend and the decorative sheet include a laminating method of laminating the decorative sheet by pressing the decorative sheet on the plate-shaped adherend with a pressure roller via the adhesive layer B.
- the heating temperature is preferably 160 ° C. or higher and 200 ° C. or lower, and 100 for the reactive hot melt adhesive, although it depends on the type of resin constituting the adhesive. °C or more and 130 °C or less are preferable. Further, in the case of vacuum forming, the processing is generally performed while heating, and the heating temperature is preferably 80 ° C. or higher and 130 ° C. or lower, and more preferably 90 ° C. or higher and 120 ° C. or lower.
- the decorative sheet 100 has the laminated structure of the following (1), but as long as the base material has the above-mentioned surface protective layer specific to the present invention, it can be used. , Various types of laminated configurations can be selected according to the required performance and the like. For example, as another specific laminated structure of the decorative sheet of the present invention, the following laminated structures (2) to (7) can be mentioned.
- Base material 50 / decorative layer 40 / transparent resin layer 30 / primer layer 20 / surface protective layer 10 (2) Base material 50 / surface protective layer 10 (3) Base material 50 / primer layer 20 / surface protection layer 10 (4) Base material 50 / transparent resin layer 30 / surface protective layer 10 (5) Base material 50 / decorative layer 40 / surface protective layer 10 (6) Base material 50 / Transparent resin layer 30 / Decorative layer 40 / Surface protective layer 10 (7) Base material 50 / Transparent resin layer 30 / Decorative layer 40 / Primer layer 20 / Surface protective layer 10
- a known adhesive layer can be interposed between the base material and the transparent resin layer and / or the decorative layer, and the base material can also be interposed.
- the surface of the transparent resin layer or the like can be embossed, or other known methods can be used to shape uneven shapes such as wood grain conduit grooves, sand grain, satin finish, hairline, and skin squeezing (kawashibo).
- "/" means the interface of each layer.
- the decorative material obtained as described above 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.
- a cutting machine such as a router or a cutter.
- various uses for example, interior members of buildings such as walls, ceilings and floors; exterior members such as exterior walls, eaves ceilings, roofs, walls and fences; window frames, doors, door frames, handrails, skirts, etc. Fittings or building members such as peripheral edges and moldings; general furniture such as stools, shelves and desks; kitchen furniture such as dining tables and sinks; surface decorative boards such as cabinets for home appliances and OA equipment; vehicle interior and exterior members It can be used for; etc.
- AA Average score is 2.7 or more
- A Average score is 2.5 or more and less than 2.7
- B Average score is 2.0 or more and less than 2.5
- C Average score is 1.5 or more and less than 2.0
- D Average score is less than 1.5
- AA Average score is 2.7 or more
- A Average score is 2.5 or more and less than 2.7
- B Average score is 2.0 or more and less than 2.5
- C Average score is 1.5 or more and less than 2.0
- D Average score is less than 1.5
- the adhesive layer was solidified by cooling at room temperature 23 ° C.
- the decorative sheet and the adherend were attached to each other and left to stand in an environment of 90 ° C. for 1 hour to prepare a sample.
- 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.
- the measurement results were evaluated according to the following criteria.
- Processing aptitude When preparing a sample in the above "1-5. Evaluation of construction aptitude", visually confirm the floating of the decorative material at the bent part (bending angle: 1 mmR) when attaching (laminating), and then visually check the following. It was evaluated according to the criteria of. If the evaluation is B or higher, the processing suitability is acceptable. ⁇ Evaluation criteria for processing suitability> A: No floating was confirmed. B: Floating was hardly confirmed. C: Floating was confirmed and peeling occurred.
- Example 1 Two-component curable acrylic-urethane on one surface of a base material (80 ⁇ m thick titanium oxide-containing polypropylene resin sheet (also referred to as “polypropylene resin sheet PO-1”)) that has undergone double-sided corona discharge treatment.
- An ink for a decorative layer containing a resin and a colorant was applied by a gravure printing method and dried to form a decorative layer having a wood grain pattern having a thickness of 3 ⁇ m.
- an ink for a back surface primer layer containing a two-component curable urethane-nitrocellulose mixed resin was applied to the other surface of the base material and dried to form a back surface primer layer having a thickness of 3 ⁇ m.
- an adhesive layer having a thickness of 3 ⁇ m made of a urethane resin-based adhesive is formed on the decorative layer, and a polypropylene-based resin is further heated, melted and extruded on the adhesive layer by a T-die extruder to have a transparency of 80 ⁇ m.
- a resin layer was formed.
- the surface of the transparent resin layer was subjected to a corona discharge treatment, and then an ink for a primer layer having the following composition was applied onto the transparent resin layer by a gravure printing method and dried to form a primer layer having a thickness of 4 ⁇ m.
- composition A an ink for a surface protective layer having the following composition is applied onto the primer layer by a roll coating method to form an uncured surface protective layer, and then an electron beam (pressurized voltage: 175 KeV, 5Mrad) (pressurized voltage: 175 KeV, 5Mrad).
- the composition A was crosslinked and cured by irradiating with 5 kGy)) to form a surface protective layer having a thickness of 5 ⁇ m.
- embossing was performed on the surface protective layer to form an uneven pattern of a wood grain conduit groove having a recess having a maximum depth of 50 ⁇ m, and a decorative sheet of Example 1 was obtained. The obtained decorative sheet was evaluated and measured based on the above method. The evaluation and measurement results are shown in Table 2.
- ⁇ Ink for primer layer > ⁇ 100 parts by mass of a mixture of polycarbonate-based urethane-acrylic copolymer and acrylic polyol ⁇ 5 parts by mass of hexamethylene diisocyanate ⁇ UV absorber (hydroxyphenyltriazine, trade name “TUNUVIN479” manufactured by BASF) 3 parts by mass ⁇ UV absorber (Hydroxyphenyltriazine, trade name "TUNUVIN400” manufactured by BASF) 12 parts by mass
- Peridinyl methacrylate (non-amino ether type, number of ethylenic double bonds: 1) 1 part by mass, radical trapping agent ii-a that does not have an ethylenic double bond that can be polymerized in an ionized radiation curable resin composition (Bis (1-octyloxy-2,2,6,6-tetramethyl-4-piperidinyl) sebacate) (Amino ether type, does not have a functional group that can react with the functional group of the constituents of the primer layer) 1 part by mass, UV absorber (hydroxyphenyltriazine, TUNUVIN479, manufactured by BASF) 2 parts by mass, hindered phenolic antioxidant 1 part by mass
- Example 2 to 7 [Comparative Examples 1 to 5] Examples 2 to 2 in the same manner as in Example 1 except that the blending amounts of the radical scavenger i and the radical scavenger ii-a with respect to the ionizing radiation curable resin composition in the composition A were changed as shown in Table 1. 7 and the decorative sheets of Comparative Examples 1 to 5 were obtained. The obtained decorative sheet was evaluated and measured based on the above method. The evaluation and measurement results are shown in Table 2.
- Example 8 A cosmetic sheet of Example 8 was obtained in the same manner as in Example 1 except that the radical scavenger ii-a in the composition A was changed to the following radical scavenger ii-b. The obtained decorative sheet was evaluated and measured based on the above method. The evaluation and measurement results are shown in Table 2.
- Example 9 [Comparative Examples 6 to 7]
- decorative sheets of Examples 9 to 11 and Comparative Examples 6 to 7 were prepared in the same manner as in Example 1 except that the base material and the transparent resin layer were replaced with those shown in Table 3.
- the obtained decorative sheet was evaluated and measured based on the above method. The evaluation and measurement results are shown in Table 3.
- -PO-1 Polypropylene resin sheet (propylene-ethylene random copolymer (ethylene content: 4.5% by mass or less), thickness: 80 ⁇ m, crystallinity: 70%)
- -PO-2 Polypropylene resin sheet (propylene-ethylene random copolymer (ethylene content: 4.5% by mass or less), thickness: 60 ⁇ m, crystallinity: 50%)
- -PO-3 Polypropylene resin sheet (propylene-ethylene random copolymer (ethylene content: 4.5% by mass or less), thickness: 60 ⁇ m, crystallinity: 40%)
- -PO-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
- -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.
- -PO-A Polypropylene resin (thickness: 80 ⁇ m)
- -PO-B Polypropylene resin (thickness: 40 ⁇ m)
- PO-C Polypropylene resin (thickness: 100 ⁇ m)
- the decorative sheets of Examples 1 to 8 are excellent in weather resistance and can suppress a decrease in scratch resistance of the surface protective layer. Furthermore, moisture permeability because of the following 0.75g / m 2 ⁇ 24h or more 45g / m 2 ⁇ 24h, construction suitability, to be excellent in long-term adhesion and processing characteristics were confirmed.
- the decorative sheet of Example 9-11 using a predetermined radical scavengers, and permeability because moisture is below 0.75g / m 2 ⁇ 24h or more 45g / m 2 ⁇ 24h, It was confirmed that in addition to weather resistance, scratch resistance, and bleed-out suppressing effect, it was excellent in construction suitability, long-term adhesion, and processing characteristics.
- the decorative sheet of Comparative Example 6 moisture permeability damage greater than 45g / m 2 ⁇ 24h, not obtained excellent construction properties and processing suitability
- also decorative sheet of Comparative Example 7 moisture permeability 0.75g since a / m less than 2 ⁇ 24h, it was confirmed that not be obtained excellent long-term adhesion.
- the decorative sheet of the present invention has excellent weather resistance, can suppress a decrease in scratch resistance of the surface protective layer, has high initial adhesion strength in the construction process, is excellent in construction suitability, and does not peel off even after long-term use. Since it exhibits excellent long-term adhesion, it is suitably used as a decorative sheet for members used in an environment exposed to direct sunlight, such as exterior members such as entrance doors, window frames, and fittings such as doors.
- Decorative sheet 10 Surface protection 20: Primer layer 30: Transparent resin layer 40: Decorative layer 50: Base material
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Abstract
Description
ラジカル捕捉剤のブリードアウトによる問題を解消するために、例えば特許文献1の化粧シートが提案されている。
しかし、特許文献1の化粧シートは、ヒンダードアミン系光安定剤のブリードアウトは抑制し得るものの、紫外線の照射により生じたラジカルを十分に捕捉できないため化粧シートが経時的に劣化し、耐候性が十分とはいえないものであった。また、特許文献1の化粧シートは、電離放射線硬化性樹脂組成物の架橋密度が低下するため、表面保護層の耐擦傷性が低下するという問題があった。
他方、上記の化粧シートを被着材に貼付けた化粧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シートを構成する基材の劣化及び化粧シートと被着材とを接着させる接着剤の劣化等を要因として、化粧シートが被着材から剥離する問題があった。
[1]基材上に表面保護層を有する化粧シートであって、前記表面保護層は、電離放射線硬化性樹脂組成物及びラジカル捕捉剤を含む組成物Aを架橋硬化してなる層であり、前記ラジカル捕捉剤は、前記電離放射線硬化性樹脂組成物と重合可能なエチレン性二重結合を有するラジカル捕捉剤i及び前記電離放射線硬化性樹脂組成物に重合可能なエチレン性二重結合を有さないラジカル捕捉剤iiを含み、前記組成物A中の前記ラジカル捕捉剤の含有量は、前記電離放射線硬化性樹脂組成物100質量部に対して0.5質量部以上10.0質量部未満であり、前記化粧シートの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以下である化粧シート。
[2]被着材と上記[1]に記載の化粧シートとを有する化粧材。
以下、本発明の化粧シートについて説明する。なお、本明細書中において、数値範囲の記載に関する「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り、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。
本発明の化粧シートは、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以下であることを特徴とする。
本発明の化粧シートは、透湿度を特定の範囲とすることによって、当該化粧シート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、本発明の化粧シートは、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できるため、施工効率を向上できる。他方、当該化粧シートと被着材とを接着剤層を介して化粧部材とした場合、主に当該化粧シートと当該被着材との間における接着剤層の劣化を抑制できる。このため、接着剤層の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、優れた長期密着性が発現する。すなわち、本発明の化粧シート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、長期使用しても剥離が生じない長期密着性との両立が可能となる。
本発明において、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、透明性樹脂層を有する場合は該透明性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の化粧シート100は、基材50上に表面保護層10を有している。また、図1の化粧シート100は、表面保護層10の基材50側の面に接してプライマー層20を有している。さらに、図1の化粧シート100は、基材50と表面保護層10との間に、透明性樹脂層30及び装飾層40を有している。
以下、本発明の化粧シートを構成する各層について、より詳細に説明する。
基材としては、各種の紙類、プラスチック、金属、織布または不織布、木材、窯業系等素材から成るフィルム、シート、板が挙げられる。
通常、所定厚みを持つ平面状の基材は厚みの薄い順にフィルム、シート、板と区別して呼称されるが、本発明においては厚みの相違を区別する必要性は特にないため、本明細書中においては、これら呼称の相違は適宜相互に置き換えても特に本質的相違は無いものとして取り扱う。また、これら呼称の相違(厚みの相違)によって、本発明の特許請求の範囲の解釈に相違を生じるものでもない。
これらの中でも、プラスチックは耐候性が十分ではないにも関わらず、後述する表面保護層によって化粧シート全体としての耐候性を良好にできるため好ましい。
透湿度を上記範囲内としやすく、また、施工適性とともに長期密着性を向上させるために、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。
化粧シート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、化粧シート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0/100~20/80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等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、また加工性を向上させるために、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。
基材を着色する場合、基材中には、染料、顔料等の着色剤を添加することができる。これら着色剤の中では、退色を抑制しやすい顔料が好ましい。
顔料としては、亜鉛華、鉛白、リトポン、二酸化チタン(チタン白)、沈降性硫酸バリウムおよびバライト等の白色顔料;カーボンブラック、アオメチンアゾ系黒顔料、ペリレン系黒顔料等の黒色顔料;鉛丹、酸化鉄赤、キナクリドンレッド、ポリアゾレッド等の赤色顔料;黄鉛、亜鉛黄(亜鉛黄1種、亜鉛黄2種)、イソインドリノンイエロー、ニッケル-アゾ錯体等の黄色顔料;ウルトラマリン青、プロシア青(フェロシアン化鉄カリ)等の青色顔料;等が挙げられる。
二酸化チタンは、隠蔽力が高く、被着材の色味の影響を受け難くする点で、基材中に添加する顔料として好ましい。しかし、二酸化チタンは紫外線スペクトルを含む光照射によってラジカルを発生し、化粧シートの耐候性が低下する。ルチル型及びブルッカイト型の酸化チタンを使用した場合、ラジカルの発生は抑制できるが、それでも二酸化チタンを含まない場合よりはラジカルが多く発生する。しかしながら、本発明では、二酸化チタンを含む基材を用いたとしても、表面保護層にラジカル捕捉剤i及びラジカル捕捉剤iiを含有することから、長期に渡って耐候性を良好にすることができる。特に、二酸化チタンを含む基材を用いた場合、基材と表面保護層とが接していることが好ましい(プライマー層を有する場合には、基材とプライマー層とが接していることが好ましい)。
基材上には、基材上に設けられる層との密着性を向上させるために、片面又は両面に、物理的処理又は化学的表面処理等の易接着処理を行ってもよい。
本発明の化粧シートの表面保護層は、電離放射線硬化性樹脂組成物及びラジカル捕捉剤を含む組成物Aを架橋硬化してなる層である。
表面保護層は、電離放射線硬化性樹脂組成物の架橋硬化物を含む。表面保護層が電離放射線硬化性樹脂組成物の架橋硬化物を含むことにより、化粧シートの耐擦傷性を良好にできる。なお、電離放射線硬化性樹脂組成物の架橋硬化物の一部は、後述するラジカル捕捉剤iと重合している。
電離放射線硬化性樹脂組成物は、電子線硬化性樹脂組成物及び紫外線硬化性樹脂組成物が挙げられ、これらの中でも、無溶媒で塗布できるため環境負荷が小さく、重合開始剤が不要等の理由から、電子線硬化性樹脂組成物が好ましい。また、組成物Aが後述する紫外線吸収剤を含有する場合、電子線硬化性樹脂組成物の方が表面保護層の架橋密度を高くしやすい点でも好ましい。
また、電離放射線とは、電磁波又は荷電粒子線のうち、分子を重合及び/又は架橋し得るエネルギー量子を有するものを意味し、通常、紫外線(UV)又は電子線(EB)が用いられるが、その他、X線、γ線等の電磁波、α線、イオン線等の荷電粒子線も含まれる。
電離放射線硬化性化合物は、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る。
加工特性、耐擦傷性及び耐候性を向上させるために、多官能性(メタ)アクリレートモノマーの官能基数は2以上8以下が好ましく、2以上6以下がより好ましく、2以上4以下がさらに好ましく、2以上3以下がよりさらに好ましい。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。
さらに、重合性オリゴマーとしては、他にポリブタジエンオリゴマーの側鎖に(メタ)アクリレート基をもつ疎水性の高いポリブタジエン(メタ)アクリレート系オリゴマー、主鎖にポリシロキサン結合をもつシリコーン(メタ)アクリレート系オリゴマー、小さな分子内に多くの反応性基をもつアミノプラスト樹脂を変性したアミノプラスト樹脂(メタ)アクリレート系オリゴマー、及びノボラック型エポキシ樹脂、ビスフェノール型エポキシ樹脂、脂肪族ビニルエーテル、芳香族ビニルエーテル等の分子中にカチオン重合性官能基を有するオリゴマー等がある。
また、これらの重合性オリゴマーの重量平均分子量は、加工特性、耐擦傷性及び耐候性を向上させるために、2,500以上7,500以下が好ましく、3,000以上7,000以下がより好ましく、3,500以上6,000以下がさらに好ましい。ここで、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。
光重合開始剤としては、アセトフェノン、ベンゾフェノン、α-ヒドロキシアルキルフェノン、ミヒラーケトン、ベンゾイン、ベンジルジメチルケタール、ベンゾイルベンゾエート、α-アシルオキシムエステル、チオキサントン類等から選ばれる1種以上が挙げられる。
また、光重合促進剤は、硬化時の空気による重合阻害を軽減させ硬化速度を速めることができるものであり、例えば、p-ジメチルアミノ安息香酸イソアミルエステル、p-ジメチルアミノ安息香酸エチルエステル等から選ばれる1種以上が挙げられる。
本発明では、ラジカル捕捉剤として、電離放射線硬化性樹脂組成物と重合可能なエチレン性二重結合を有するラジカル捕捉剤i、及び、電離放射線硬化性樹脂組成物に重合可能なエチレン性二重結合を有さないラジカル捕捉剤iiを含む。
一方、ラジカル捕捉剤iiのみを用いた場合、ラジカル捕捉剤iiが表面保護層から経時的にブリードアウトし、化粧シート表面の美観が損なわれるとともに、経時的に表面保護層中のラジカル捕捉剤の濃度が低下して耐候性が不十分になってしまう。
ラジカル捕捉剤の含有量が電離放射線硬化性樹脂組成物100質量部に対して0.5質量部未満の場合、ラジカル捕捉剤の絶対量が不足するため、ラジカル捕捉剤i及びラジカル捕捉剤iiを併用したとしても、化粧シートの耐候性を良好にできない。また、ラジカル捕捉剤の含有量が電離放射線硬化性樹脂組成物100質量部に対して10.0質量部を超える場合、表面保護層中における電離放射線硬化性樹脂組成物の架橋物の架橋密度が低下して耐擦傷性が低下したり、ラジカル捕捉剤のブリードアウトが生じやすくなったりする問題が生じる。
ラジカル捕捉剤iは、電離放射線硬化性樹脂組成物と重合可能なエチレン性二重結合を有するものである。エチレン性二重結合を有する基としては、(メタ)アクリロイル基、クロトノイル基、ビニル基及びアリル基が挙げられ、これらの中でも(メタ)アクリロイル基が好ましい。すなわち、ラジカル捕捉剤iは、(メタ)アクリロイル基を有するものが好ましい。
ラジカル捕捉剤i中のエチレン性二重結合の数は特に限定されず、1つであってもよいし、2以上であってもよい。また、ラジカル捕捉剤iは1種のみを用いてもよいし、2種以上を用いてもよい。
エチレン性二重結合を2以上有するラジカル捕捉剤iとしては、1-(メタ)アクリロイル-4-(メタ)アクリロイルアミノ-2,2,6,6-テトラメチルピペリジン、1-(メタ)アクリロイル-4-シアノ-4-(メタ)アクリロイルアミノ-2,2,6,6-テトラメチルピペリジン、1-クロトノイル-4-クロトイルオキシ-2,2,6,6-テトラメチルピペリジン、CAS番号1954659-42-7の化合物及びCAS番号1010692-23-5の化合物が挙げられる。
ラジカル捕捉剤iiは、電離放射線硬化性樹脂組成物と重合可能なエチレン性二重結合を有さないものである。ラジカル捕捉剤iiは1種のみを用いてもよいし、2種以上を用いてもよい。
上記の条件を満たす官能基の組み合わせは、下記表1のA~Dに示すものが挙げられる。これらの中でも、下記A(ラジカル捕捉剤iiが水酸基を有し、プライマー層の構成成分がイソシアネート基を有する)が好ましい。
アミノエーテル型のヒンダードアミン系ラジカル捕捉剤とは、2,2,6,6-テトラメチルピペリジン骨格における、窒素原子に結合する水素原子が、OR1またはOCOR2に置換されたものをいう。なお、R1及びR2は、アルキル基及び/又はシクロアルキル基であり、好ましくは炭素数5以上12以下のアルキル基及び/又はシクロアルキル基である。
一方、非アミノエーテル型のヒンダードアミン系ラジカル捕捉剤とは、2,2,6,6-テトラメチルピペリジン骨格における、窒素原子に結合する水素原子が水素原子のままか、水素原子がアルキル基に置換されたものをいう。
ラジカル捕捉剤iが8に対して、ラジカル捕捉剤iiを2以上とすることにより、耐候性をより良好にし得るとともに、電離放射線硬化性樹脂組成物の架橋硬化物の架橋密度が低下することを抑制しやすくできる。また、ラジカル捕捉剤iが2に対して、ラジカル捕捉剤iiを8以下とすることにより、ラジカル捕捉剤iiのブリードアウトを抑制できる。
表面保護層を形成する組成物Aは、紫外線吸収剤を含有することが好ましい。
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等が挙げられ、トリアジン系紫外線吸収剤が好ましい。また、トリアジン系紫外線吸収剤の中でも、トリアジン環に、ヒドロキシフェニル基、アルコキシフェニル基及びこれらの基を含む有機基から選ばれる少なくとも一つの有機基が三つ連結したヒドロキシフェニルトリアジン系紫外線吸収剤がより好ましく、下記一般式(1)で示されるヒドロキシフェニルトリアジン系紫外線吸収剤がさらに好ましい。ヒドロキシフェニルトリアジン系紫外線吸収剤は、分岐構造を有するため、表面保護層からブリードアウトしにくくなることが期待され、より長期的に優れた耐候性が得られる。
また、(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紫外線吸収剤は、ブリードアウトを抑制しやすい点で好ましい。
炭素数1以上20以下のアルキレン基としては、例えば、メチレン基、1,1-エチレン基、1,2-エチレン基、1,3-プロピレン、1,2-プロピレン、2,2-プロピレン等の各種プロピレン基(以下、「各種」は、直鎖状、分岐状、及びこれらの異性体のものを含むものを示す。)、各種ブチレン基、各種ペンチレン基、各種ヘキシレン基、各種へプチレン基、各種オクチレン基、各種ノニレン基、各種デシレン基、各種ウンデシレン基、各種ドデシレン基、各種トリデシレン基、各種テトラデシレン基、各種ペンタデシレン基、各種ヘキサデシレン基、各種ヘプタデシレン基、各種オクタデシレン基、各種ノナデシレン基、各種イコシレン基が挙げられる。
アリール基としては、好ましくは炭素数6以上20以下、より好ましくは炭素数6以上12以下、更に好ましくは炭素数6以上10以下のアリール基、例えば、フェニル基、各種メチルフェニル基、各種エチルフェニル基、各種ジメチルフェニル基、各種プロピルフェニル基、各種トリメチルフェニル基、各種ブチルフェニル基、各種ナフチル基等が挙げられる。アリールアルキル基としては、好ましくは炭素数7以上20以下、より好ましくは炭素数7以上12以下、更に好ましくは炭素数7以上10以下のアリールアルキル基、例えば、ベンジル基、フェネチル基、各種フェニルプロピル基、各種フェニルブチル基、各種メチルベンジル基、各種エチルベンジル基、各種プロピルベンジル基、各種ブチルベンジル基、各種ヘキシルベンジル基等が挙げられる。
アルキル基としては、好ましくは炭素数1以上20以下、より好ましくは2以上16以下、更に好ましくは6以上12以下のアルキル基、例えば、メチル基、エチル基、各種プロピル基、各種ブチル基、各種ペンチル基、各種ヘキシル基、各種オクチル基、各種ノニル基、各種デシル基、各種ウンデシル基、各種ドデシル基、各種トリデシル基、各種テトラデシル基、各種ペンタデシル基、各種ヘキサデシル基、各種ヘプタデシル基、各種オクタデシル基、各種ノナデシル基、各種イコシル基が挙げられる。
アルケニル基としては、好ましくは炭素数2以上20以下、より好ましくは3以上16以下、更に好ましくは6以上12以下のアルケニル基、例えば、ビニル基、各種プロペニル基、各種ブテニル基、各種ペンテニル基、各種ヘキセニル基、各種オクテニル基、各種ノネニル基、各種デセニル基、各種ウンデセニル基、各種ドデセニル基、各種トリデセニル基、各種テトラデセニル基、各種ペンタデセニル基、各種ヘキサデセニル基、各種ヘプタデセニル基、各種オクタデセニル基、各種ノナデセニル基、各種イコセニル基が挙げられる。
表面保護層を形成する組成物Aは、酸化防止剤を含有することが好ましい。酸化防止剤を含むことにより、耐候性をより良好にしやすくできる。
酸化防止剤としては、フェノール系、アミン系、硫黄系、リン系の酸化防止剤等が挙げられる。これらの中でもフェノール系酸化防止剤が好ましい。
化粧シートは、表面保護層の基材側の面に接してプライマー層を有することが好ましい。プライマー層によって、基材と表面保護層との密着性が向上し、屋外暴露した際の長期的な層間密着性の確保(いわゆる耐候密着性)及び耐擦傷性を良好にしやすくできる。
バインダー樹脂としては、ウレタン樹脂、アクリルポリオール樹脂、アクリル樹脂、エステル樹脂、アミド樹脂、ブチラール樹脂、スチレン樹脂、ウレタン-アクリル共重合体、ポリカーボネート系ウレタン-アクリル共重合体(ポリマー主鎖にカーボネート結合を有し、末端、側鎖に2個以上の水酸基を有する重合体(ポリカーボネートポリオール)由来のウレタン-アクリル共重合体)、塩化ビニル-酢酸ビニル共重合体樹脂、塩化ビニル-酢酸ビニル-アクリル共重合体樹脂、塩素化プロピレン樹脂、ニトロセルロース樹脂(硝化綿)、酢酸セルロース樹脂等の樹脂が好ましく挙げられ、これらを単独で、又は複数種を組み合わせて用いることができる。また、バインダー樹脂は、これら樹脂に、イソシアネート系硬化剤、エポキシ系硬化剤等の硬化剤を添加し、架橋硬化したものであってもよい。これらの中でも、アクリルポリオール樹脂等のポリオール系樹脂をイソシアネート系硬化剤で架橋硬化したものが好ましく、アクリルポリオール樹脂をイソシアネート系硬化剤で架橋硬化したものがより好ましい。
また、上述したように、バインダー樹脂は、ラジカル捕捉剤iiが有する官能基と反応可能な官能基を有することが好ましい。
化粧シートは、強度を高める等の目的から、基材と表面保護層との間に透明性樹脂層を有していてもよい。化粧シートがプライマー層を有する場合、透明性樹脂層は、基材とプライマー層との間に位置することが好ましい。また、化粧シートが装飾層を有する場合、装飾層の保護のために、透明性樹脂層は、装飾層と表面保護層との間に位置することが好ましい。
透明性樹脂層中のポリオレフィン系樹脂の含有量は、加工適性を向上させるために、透明性樹脂層の全樹脂成分に対して50質量%以上であることが好ましく、70質量%以上であることがより好ましく、90質量%以上であることがさらに好ましい。
透明性樹脂層に塩化ビニル樹脂を採用する場合、上記の基材のプラスチックを構成する樹脂の具体例として説明した塩化ビニル樹脂を好ましく使用できる。
透明性樹脂層の厚みは、透湿度の調整のしやすさ、更には耐擦傷性、加工適正及び耐候性のバランスから、20μm以上150μm以下が好ましく、40μm以上120μm以下がより好ましく、60μm以上100μm以下がさらに好ましい。
化粧シートは、意匠性を向上させるために、化粧シートの任意の箇所に装飾層を有することが好ましい。装飾層を形成する箇所は、装飾層の耐候性を向上させるために、基材に近い側であることが好ましい。例えば、化粧シートがプライマー層を有する場合、装飾層は、基材とプライマー層との間に位置することが好ましい。また、化粧シートが透明性樹脂層を有する場合、装飾層は、基材と透明性樹脂層との間に位置することが好ましい。
装飾層のバインダー樹脂としては特に制限はなく、例えば、ウレタン樹脂、アクリルポリオール樹脂、アクリル樹脂、エステル樹脂、アミド樹脂、ブチラール樹脂、スチレン樹脂、ウレタン-アクリル共重合体、塩化ビニル-酢酸ビニル共重合体樹脂、塩化ビニル-酢酸ビニル-アクリル共重合体樹脂、塩素化プロピレン樹脂、ニトロセルロース樹脂、酢酸セルロース樹脂等の樹脂が挙げられる。また、1液硬化型樹脂、イソシアネート化合物等の硬化剤を伴う2液硬化型樹脂等、種々のタイプの樹脂を用いることができる。
着色剤の含有量は、装飾層を構成する樹脂100質量部に対して、5質量部以上90質量部以下が好ましく、15質量部以上80質量部以下がより好ましく、30質量部以上70質量部以下がさらに好ましい。
装飾層の厚みは、所望の絵柄に応じて適宜選択すればよいが、被着材の地色を隠蔽し、かつ意匠性を向上させるために、0.5μm以上20μm以下が好ましく、1μm以上10μm以下がより好ましく、2μm以上5μm以下がさらに好ましい。
化粧シートが透明性樹脂層を有する場合、基材と透明性樹脂層との間には、両層の密着性を向上するために接着剤層Aを形成することが好ましい。
なお、基材と透明性樹脂層との間に、さらに装飾層を有する場合、接着剤層Aと装飾層との位置関係は特に限定されない。具体的には、本発明の化粧シートは、基材に近い側から装飾層、接着剤層A及び透明性樹脂層をこの順に有していてもよいし、基材層に近い側から接着剤層A、装飾層及び透明性樹脂層をこの順に有していてもよい。
ウレタン系接着剤としては、例えば、ポリエーテルポリオール、ポリエステルポリオール、アクリルポリオール等の各種ポリオール化合物と、イソシアネート化合物等の硬化剤とを含む2液硬化型ウレタン樹脂を利用した接着剤が挙げられる。
エンボス加工を行う場合、例えば、化粧シートを好ましくは80℃以上260℃以下、より好ましくは85℃以上160℃以下、さらに好ましくは100℃以上140℃以下に加熱し、化粧シートにエンボス版を押圧して、エンボス加工を行うことができる。エンボス版を押圧する箇所は、化粧シートの表面保護層側とすることが好ましい。
本発明の化粧材は、被着材と上記の本発明の化粧シートとを有するものであり、具体的には、被着材の装飾を要する面と、化粧シートの基材層側の面とを対向させて積層したものである。
被着材としては、各種素材の平板、曲面板等の板材、円柱、多角柱等の立体形状物品、シート(又はフィルム)等が挙げられる。例えば、杉、檜、松、ラワン等の各種木材から成る木材単板、木材合板、集成材、パーティクルボード、MDF(中密度繊維板)等の木質部材;鉄、アルミニウム、銅、及びこれら金属の1種以上を含む合金等の金属からなる金属部材;ガラス、陶磁器等のセラミックス、石膏、セメント、ALC(軽量気泡コンクリート)、珪酸カルシウム系等の非セラミックス窯業系材料からなる窯業部材;アクリル樹脂、ポリエステル樹脂、ポリスチレン樹脂、ポリプロピレン等のポリオレフィン樹脂、ABS(アクリロニトリル-ブタジエン-スチレン共重合体)樹脂、フェノール樹脂、塩化ビニル樹脂、セルロース樹脂、ゴム等の樹脂から成る樹脂部材等が挙げられる。また、これらの部材は、単独で、又は複数種を組み合わせて使用できる。
被着材と化粧シートとは、優れた接着性を得るため、接着剤層Bを介して貼り合わせられることが好ましい。
感熱接着剤は、溶融した液状の接着剤層B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B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いため、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。
化粧材は、化粧シートと被着材とを積層する工程を経て製造できる。
本工程は、被着材と、本発明の化粧シートとを積層する工程であり、被着材の装飾を要する面と、化粧シートの基材側の面とを対向させて積層する。被着材と化粧シートとを積層する方法としては、例えば、接着剤層Bを介して化粧シートを板状の被着材に加圧ローラーで加圧して積層するラミネート方法等が挙げられる。
(1)基材50/装飾層40/透明性樹脂層30/プライマー層20/表面保護層10
(2)基材50/表面保護層10
(3)基材50/プライマー層20/表面保護層10
(4)基材50/透明性樹脂層30/表面保護層10
(5)基材50/装飾層40/表面保護層10
(6)基材50/透明性樹脂層30/装飾層40/表面保護層10
(7)基材50/透明性樹脂層30/装飾層40/プライマー層20/表面保護層10
なお、上記(1)~(7)において、基材と透明樹脂層及び/又は装飾層との間に公知の接着剤層(前記接着剤層A)を介在させることもできるし、また基材、透明樹脂層等の表面に前記エンボス加工、その他公知の各種手法を用いて木目導管溝、砂目、梨地、ヘアライン、皮絞(カワシボ)等の凹凸形状を賦形することもできる。
なお、本段落において、「/」は各層の界面を意味している。
1.評価及び測定
1-1.耐候性
実施例及び比較例で得られた化粧シートに対して、メタルハライドランプ(MWOM)による促進耐候試験を1000時間実施した後の外観を表面保護層側から目視で観察した。外観変化が確認されないといえるレベルであったものを3点、軽微な艶低下が確認されたものを2点、著しい艶低下又はクラックが確認されたものを1点として、20人の被験者が評価した。20人の評価の平均点を算出し、下記基準によりランク付けした。結果を表2に示す。なお、試験装置及び試験条件は下記のとおりとした。
<耐候性評価基準>
AA:平均点が2.7以上
A:平均点が2.5以上2.7未満
B:平均点が2.0以上2.5未満
C:平均点が1.5以上2.0未満
D:平均点が1.5未満
ダイプラ・ウィンテス社製の商品名「ダイプラ・メタルウェザー」
<照射条件>
照度:65mW/m2、ブラックパネル温度:63℃、槽内湿度:50%RH、時間:20時間
<結露条件>
照度:0mW/m2、槽内湿度:98%RH、時間:4時間
実施例及び比較例で得られた化粧シートの表面に対して、300g/m2の荷重でスチールウール(「ボンスター#0000」、日本スチールウール社製)を5往復させて、ラビング試験を行った。ラビング試験後、化粧シートの表面の状態を目視で観察した。傷付きがなく、艶の変化が確認されないといえるレベルであったものを3点、軽微な傷付き、及び軽微な艶の変化が確認されたものを2点、傷付きが確認され、著しい艶変化が確認されたものを1点として、20人の被験者が評価した。20人の評価の平均点を算出し、下記基準によりランク付けした。結果を表2に示す。
<耐擦傷性評価基準>
A:平均点が2.5以上
B:平均点が2.0以上2.5未満
C:平均点が1.5以上2.0未満
D:平均点が1.5未満
実施例及び比較例で得られた化粧シートを40℃の温水に1週間浸漬した。浸漬後の化粧シートを温水から取り出して乾燥した後、浸漬後の化粧シートの外観を表面保護層側から目視で観察した。外観変化が確認されないといえるレベルであったものを3点、微量なブリードが確認されたが実用上問題ない程度であるものを2点、著しいブリードが確認されたものを1点として、20人の被験者が評価した。20人の評価の平均点を算出し、下記基準によりランク付けした。結果を表2に示す。
<ブリードアウト評価基準>
AA:平均点が2.7以上
A:平均点が2.5以上2.7未満
B:平均点が2.0以上2.5未満
C:平均点が1.5以上2.0未満
D:平均点が1.5未満
実施例及び比較例で得られた化粧シートについて、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。
1-5.施工適性の評価
実施例及び比較例で得られた化粧シートと幅25mmの平板上の被着体(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た後、該接着剤層を室温23℃にて冷却することによって、固化させた。次いで、上記化粧シートと被着体とを貼着したものを、90℃の環境下に1時間放置して、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た。測定結果は、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。
<施工適正の評価基準>
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。
1-6.長期密着性の評価
上記「1-5.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た。測定結果は、以下の基準で評価した。B評価以上であれば、長期密着性は合格である。
<長期密着性の評価基準>
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。
1-7.加工適性
上記「1-5.施工適性の評価」で試料を作製する際、貼着(ラミネート)するときに、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。
<加工適正の評価基準>
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。
[実施例1]
両面コロナ放電処理を施した基材(厚み80μmの酸化チタン含有ポリプロピレン樹脂シート(「ポリプロピレン系樹脂シートPO-1」とも称される。))の一方の面に、2液硬化型のアクリル-ウレタン樹脂及び着色剤を含む装飾層用インキをグラビア印刷法で塗布、乾燥して、厚み3μmの木目模様の装飾層を形成した。
次いで、基材の他方の面に、2液硬化型ウレタン-硝化綿混合樹脂を含む裏面プライマー層用インキを塗布、乾燥して、厚み3μmの裏面プライマー層を形成した。
次いで、装飾層上に、ウレタン樹脂系接着剤からなる厚み3μmの接着剤層を形成し、さらに、接着剤層上に、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、厚み80μmの透明性樹脂層を形成した。
次いで、透明性樹脂層の表面にコロナ放電処理を施した後、透明性樹脂層上に、下記組成のプライマー層用インキをグラビア印刷法で塗布、乾燥し、厚み4μmのプライマー層を形成した。
次いで、プライマー層上に、下記組成の表面保護層用インキ(組成物A)をロールコート法で塗布して未硬化の表面保護層を形成した後、電子線(加圧電圧:175KeV、5Mrad(5kGy))を照射して、組成物Aを架橋硬化して、厚み5μmの表面保護層を形成した。
次いで、表面保護層の上からエンボス加工を施し、最大深さ50μmの凹部を有する木目導管溝の凹凸模様を形成し、実施例1の化粧シートを得た。得られた化粧シートについて、上記方法に基づき評価及び測定を行った。評価及び測定結果を表2に示す。
・ポリカーボネート系ウレタン-アクリル共重合体及びアクリルポリオールの混合物 100質量部
・ヘキサメチレンジイソシアネート 5質量部
・紫外線吸収剤(ヒドロキシフェニルトリアジン、BASF社製の商品名「TUNUVIN479」) 3質量部
・紫外線吸収剤(ヒドロキシフェニルトリアジン、BASF社製の商品名「TUNUVIN400」) 12質量部
・電離放射線硬化性樹脂組成物(重量平均分子量4000の3官能ウレタンアクリレートオリゴマー) 100質量部
・電離放射線硬化性樹脂組成物と重合可能なエチレン性二重結合を有するラジカル捕捉剤i(ペンタメチルピペリジニルメタクリレート)(非アミノエーテル型、エチレン性二重結合の数:1) 1質量部
・電離放射線硬化性樹脂組成物に重合可能なエチレン性二重結合を有さないラジカル捕捉剤ii-a(ビス(1-オクチルオキシ-2,2,6,6-テトラメチル-4-ピペリジニル)セバケート)(アミノエーテル型、プライマー層の構成成分が有する官能基と反応可能な官能基を有さない) 1質量部
・紫外線吸収剤(ヒドロキシフェニルトリアジン、TUNUVIN479、BASF社製) 2質量部
・ヒンダードフェノール系酸化防止剤 1質量部
組成物A中の電離放射線硬化性樹脂組成物に対するラジカル捕捉剤i及びラジカル捕捉剤ii-aの配合量を表1のように変更した以外は、実施例1と同様にして、実施例2~7及び比較例1~5の化粧シートを得た。得られた化粧シートについて、上記方法に基づき評価及び測定を行った。評価及び測定結果を表2に示す。
組成物A中のラジカル捕捉剤ii-aを、下記のラジカル捕捉剤ii-bに変更した以外は、実施例1と同様にして、実施例8の化粧シートを得た。得られた化粧シートについて、上記方法に基づき評価及び測定を行った。評価及び測定結果を表2に示す。
<実施例8のラジカル捕捉剤ii-b>
2,4-ビス[N-ブチル-N-(1-シクロヘキロキシ-2,2,6,6-テトラメチルピペリジン-4-イル)アミノ]-6-(2-ヒドロキシエチルアミン)-1,3,5-トリアジン(アミノエーテル型、プライマー層の構成成分が有する官能基(イソシアネート基)と反応可能な官能基(水酸基)を有する)
実施例1において、基材及び透明性樹脂層を表3に示されるものに代えた以外は、実施例1と同様にして実施例9~11、比較例6~7の化粧シートを作製した。得られた化粧シートについて、上記方法に基づき評価及び測定を行った。評価及び測定結果を表3に示す。
・PO-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%)
・PO-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%)
・PO-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%)
・PO-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。
・PO-A:ポリプロピレン系樹脂(厚さ:80μm)
・PO-B:ポリプロピレン系樹脂(厚さ:40μm)
・PO-C:ポリプロピレン系樹脂(厚さ:100μm)
また表3の結果からも、実施例9~11の化粧シートは、所定のラジカル捕捉剤を用い、かつ透湿度が0.75g/m2・24h以上45g/m2・24h以下にあるため、耐候性、耐擦傷性、ブリードアウトの抑制効果に加えて、施工適性、長期密着性及び加工特性に優れていることが確認された。一方、比較例6の化粧シートは、透湿度が45g/m2・24hより大きいいため、優れた施工特性及び加工適性が得られず、また比較例7の化粧シートは、透湿度が0.75g/m2・24h未満であるため、優れた長期密着性が得られないことが確認された。
10:表面保護
20:プライマー層
30:透明性樹脂層
40:装飾層
50:基材
Claims (14)
- 基材上に表面保護層を有する化粧シートであって、前記表面保護層は、電離放射線硬化性樹脂組成物及びラジカル捕捉剤を含む組成物Aを架橋硬化してなる層であり、前記ラジカル捕捉剤は、前記電離放射線硬化性樹脂組成物と重合可能なエチレン性二重結合を有するラジカル捕捉剤i及び前記電離放射線硬化性樹脂組成物に重合可能なエチレン性二重結合を有さないラジカル捕捉剤iiを含み、前記組成物A中の前記ラジカル捕捉剤の含有量は、前記電離放射線硬化性樹脂組成物100質量部に対して0.5質量部以上10.0質量部未満であり、前記化粧シートの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以下である化粧シート。
- 前記ラジカル捕捉剤iと前記ラジカル捕捉剤iiとの質量基準による配合比が8:2~2:8である、請求項1に記載の化粧シート。
- 前記ラジカル捕捉剤がヒンダードアミン系ラジカル捕捉剤である、請求項1又は2に記載の化粧シート。
- 前記組成物Aがさらに紫外線吸収剤を含む、請求項1~3の何れか1項に記載の化粧シート。
- 前記組成物Aがさらに酸化防止剤を含む、請求項1~4の何れか1項に記載の化粧シート。
- 前記表面保護層の前記基材側の面に接してプライマー層を有する請求項1~5のいずれか1項に記載の化粧シート。
- 前記ラジカル捕捉剤iiが、前記プライマー層の構成成分が有する官能基と反応可能な官能基を有する、請求項5に記載の化粧シート。
- 前記ラジカル捕捉剤iiが水酸基を有し、前記プライマー層の構成成分がイソシアネート基を有する、請求項7に記載の化粧シート。
- 前記基材と前記表面保護層との間に装飾層を有する、請求項1~8の何れか1項に記載の化粧シート。
- 前記基材が二酸化チタンを含む、請求項1~9の何れか1項に記載の化粧シート。
- 被着材と請求項1~10の何れか1項に記載の化粧シートとを有する化粧材。
- 前記化粧シートと前記被着材との間に、ウレタン系接着剤で構成される接着剤層を有する請求項11に記載の化粧材。
- 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12に記載の化粧材。
- 前記被着材が、金属部材又は樹脂部材である請求項11~13のいずれか1項に記載の化粧材。
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