JP2008207535A - Decorative sheet and decorative material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a decorative sheet formed of biomass raw material which can be not only laminated onto a planar base material but also is durable to three-dimensional molding such as wrapping onto a three-dimensional base material or vacuum molding, also superior in physical surface properties such as scratch resistance. <P>SOLUTION: The decorative sheet is formed by laminating at least a picture pattern layer and a transparent thermoplastic polyester-based resin layer in this order, and the transparent thermoplastic polyester-based resin layer contains at least polylactic acid, and has a glass transition temperature of 50-90°C, a tensile elastic modulus of 2-3.5 GPa, and a tensile fracture elongation of 100-200%. Also, the transparent thermoplastic polyester-based resin layer of the decorative sheet is a biaxially drawn sheet. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a decorative sheet and a decorative material for use in interior and exterior materials of buildings such as houses, building materials such as construction materials and fittings, furniture fixtures, surface equipment such as residential equipment and home appliances, etc. More specifically, it is excellent in dimensional stability and surface strength, and is also suitable for three-dimensional molding applications such as wrapping laminates or vacuum molding laminates. The present invention relates to a cosmetic sheet and a cosmetic material that do not generate toxic gas and are friendly to the global environment and the human body.

  As such a resin-based decorative sheet, a decorative sheet having a single-layer configuration in which a pattern is printed on the front surface side or the back surface side of the thermoplastic resin base sheet, and a thermoplastic resin base sheet on the back surface side of the pattern layer. There is a decorative sheet having a multilayer structure sandwiched between the transparent resin layer on the surface side. The former has the advantage that it can be manufactured easily and cheaply because of its simple structure, while the latter is somewhat disadvantageous from the manufacturing and price points, but the pattern is protected from both the front and back sides, so the wear resistance of the pattern It combines surface properties such as solvent resistance and weather resistance, and resistance to the adhesive used when adhering to the substrate to be adhered, and also from the design side, it is highly concealed by coloring the base sheet and transparent There are many advantages in terms of performance, such as being able to achieve both high design by embossing the resin layer. Due to this relationship, both are properly used according to the performance and price required by the application.

  Conventionally, as a thermoplastic resin used for this type of decorative sheet, vinyl chloride resin, polyolefin resin, acrylic copolymer resin, etc. are used as a base sheet of the decorative sheet or a transparent resin layer on the surface of the base sheet. Is done. For example, as a base sheet of a decorative sheet, paper or a thermoplastic resin sheet is used, and a printed sheet obtained by printing on the sheet is used as it is, or the transparent resin layer described above as a surface protective layer and / or a design expression layer. Are used, and are used by being bonded to the surface of a wood-based substrate such as wood plywood, wood fiber board, particle board or the like. In particular, high-strength resin materials having excellent surface strength such as vinyl chloride resin and polyethylene terephthalate resin have been used for floor materials and edge materials that require surface strength.

Conventionally, polyvinyl chloride resin, which is inexpensive and excellent in processability and physical properties, has been used most frequently as a constituent material for the base sheet and transparent resin layer of various resin-based decorative sheets described above. In response to the growing social interest in the problem, decorative sheets using resins other than polyvinyl chloride resins that have little adverse effects on the environment, such as polyolefin-based thermoplastic resins, have been developed and proposed. (See Patent Document 1).

A decorative sheet using the above-mentioned polyolefin-based thermoplastic resin has been conventionally used in terms of flexibility and whitening resistance required for secondary processing such as laminating of a decorative sheet to a substrate to be adhered and V-cut processing. Since the performance almost equivalent to that of polyvinyl chloride resin can be obtained relatively easily, it is currently considered most promising among various alternative materials for polyvinyl chloride resin. On the other hand, however, the thermoplastic polyolefin-based thermoplastic resin has a lower surface hardness than the polyvinyl chloride resin having the same flexibility, and tends to have poor scratch resistance on the surface.

On the other hand, various decorative sheets using a polyester-based thermoplastic resin have been proposed. Polyethylene terephthalate resin, the most common polyester-based thermoplastic resin, has a tensile modulus of around 4 GPa, and is too soft for decorative sheets, so it has poor processability, so it can be softened by adding various copolymer components. For example, it is made of a copolyester having a difference between the cold crystallization temperature and the glass transition temperature of 60 ° C. or less and has a quasicrystal melting peak temperature not lower than the cold crystallization temperature and not higher than the melting point. A decorative sheet using a flexible polyester film having an elastic modulus of 1 to 500 MPa has been proposed (see Patent Document 1, Patent Document 2 and Patent Document 3).

However, although the above-mentioned flexible polyester film has solved the problems such as whitening and breakage caused by bending such as V-cut, it has low surface hardness due to its flexibility and is inferior in scratch resistance. In addition, the base material to which the decorative sheet is attached is not necessarily a flat plate, and base materials having various three-dimensional shapes are increasing in various uses such as for bathroom wall surfaces. When affixing to a shaped substrate by a lapping method, a vacuum forming method, or the like, the above-described flexible polyester film is too soft and has a problem that wrinkles, scratches and the like are likely to occur.

In recent years, polylactic acid resin has attracted a great deal of attention because it is one of the most mass-produced biomass materials on the earth and is a biodegradable polymer. Polylactic acid resin is a biomass material that uses starch produced by photosynthesis from carbon dioxide gas and water as a raw material, and it hydrolyzes naturally in soil and water, and then becomes a biodegradable resin that is harmlessly decomposed by microorganisms. But there is. Furthermore, the amount of heat generated by combustion is small, and the carbon dioxide generated during combustion is carbon dioxide in the atmosphere that was originally absorbed when photosynthesising starch, which is the raw material for polylactic acid resin, and is the most promising biodegradation that is friendly to the environment. It is said to be a biomass biomass resin.

Polylactic acid resin is also known as a biodegradable resin, but laminated sheets made of biodegradable resins have excellent surface strength, but have poor heat resistance and poor durability (biodegradability) Until now, it has not been put to practical use as a decorative sheet because of its poor chemical resistance. On the other hand, a decorative member in which a conventional decorative sheet is bonded to a wooden substrate is difficult to separate the decorative sheet and the wooden substrate at the time of disposal, and the material of the surface decorative sheet cannot be distinguished. Due to problems, it is difficult to recycle raw materials, and incineration processing is also difficult due to the problem of generation of harmful gases, and there is a current problem that a disposal method such as landfill processing must be taken.

As described above, Patent Documents 4 and 5 show examples of using a polylactic acid film, which has started to spread as a non-petroleum polymer, as a decorative sheet due to the recent increase in environmental awareness. However, these documents do not specifically describe the film, and disclosure of a film suitable for processing such as cutting, printing, and lamination has been desired.

Examples of methods for reducing the breaking elongation and breaking strength of biaxially stretched polyester films are found in Patent Documents 6 and 7. However, these examples all relate to a film intended as a packaging material, there is no specific description for a decorative sheet, and it cannot be said to be sufficient for solving the problems of the present invention.
JP-A-6-166159 JP 7-17005 A JP-A-7-137205 JP-A-11-129426 Japanese Patent Laid-Open No. 11-227147 Japanese Patent Laid-Open No. 5-104618 JP 2001-191407 A

  The present invention has been made in order to solve the above-described problems in the prior art, and the object of the present invention is not only to laminate on a planar substrate but also to a three-dimensional substrate. An object of the present invention is to provide a decorative sheet made of a biomass raw material that can withstand three-dimensional molding such as lapping and vacuum forming, and has excellent surface properties such as scratch resistance.

  The invention according to claim 1 is a decorative sheet comprising at least a pattern ink layer and a thermoplastic polyester resin layer laminated in this order, wherein the thermoplastic polyester resin layer contains at least polylactic acid, and A decorative sheet characterized in that a glass transition point of a plastic polyester resin layer is 50 ° C. or higher and 90 ° C. or lower, a tensile elastic modulus is 2 GPa or higher and 3.5 GPa or lower, and a tensile breaking elongation is 100% or higher and 200% or lower. .

  The invention according to claim 2 is a decorative sheet in which at least a pattern ink layer and a transparent thermoplastic polyester resin layer are laminated in this order on a thermoplastic resin sheet substrate, the transparent thermoplastic polyester resin layer is And at least polylactic acid, and the glass transition point of the transparent thermoplastic polyester resin layer is 50 ° C. or higher and 90 ° C. or lower, the tensile elastic modulus is 2 GPa or higher and 3.5 GPa or lower, and the tensile elongation at break is 100% or higher and 200%. The decorative sheet is characterized by the following.

  The invention according to claim 3 is the decorative sheet according to claim 1 or 2, wherein the thermoplastic polyester resin layer or the transparent thermoplastic polyester resin layer is a biaxially stretched sheet. is there.

  The invention according to claim 4 is the decorative sheet according to claim 2 or 3, wherein the thermoplastic resin sheet base material is made of a polyester resin containing at least a polylactic acid resin.

  The invention according to claim 5 is the decorative sheet according to claim 2 or 3, wherein the thermoplastic resin sheet substrate is made of at least a polyolefin-based resin.

  The invention described in claim 6 is a decorative material formed by pasting at least the decorative sheet according to any one of claims 1 to 5.

  The invention described in claim 7 is a decorative material comprising at least the decorative sheet according to any one of claims 1 to 5 bonded to a wooden substrate.

The invention according to claim 1 is a decorative sheet comprising at least a pattern ink layer and a thermoplastic polyester resin layer laminated in this order, wherein the thermoplastic polyester resin layer contains at least polylactic acid, and A decorative sheet characterized in that a glass transition point of a plastic polyester resin layer is 50 ° C. or higher and 90 ° C. or lower, a tensile elastic modulus is 2 GPa or higher and 3.5 GPa or lower, and a tensile breaking elongation is 100% or higher and 200% or lower. . The transparent thermoplastic polyester resin layer is made of at least polylactic acid, has a glass transition point of 50 ° C. or more and 90 ° C. or less, a tensile elastic modulus of 2 GPa or more and 3.5 GPa or less, and a tensile breaking elongation of 100% or more and 200% or less. As a result, sufficient three-dimensional formability at the heating temperature in three-dimensional forming such as normal vacuum forming is obtained, there is little residual internal stress, and it has moderate flexibility and moderate waist and surface hardness, It is possible to obtain a decorative sheet having a sufficient level of surface physical properties such as scratch resistance on the surface without generating wrinkles or drawdown during three-dimensional molding.

The invention according to claim 2 is a decorative sheet in which at least a pattern ink layer and a transparent thermoplastic polyester resin layer are laminated in this order on a thermoplastic resin sheet substrate, the transparent thermoplastic polyester resin layer is And at least polylactic acid, and the glass transition point of the transparent thermoplastic polyester resin layer is 50 ° C. or higher and 90 ° C. or lower, the tensile elastic modulus is 2 GPa or higher and 3.5 GPa or lower, and the tensile elongation at break is 100% or higher and 200%. The decorative sheet is characterized by the following. The transparent thermoplastic polyester resin layer is made of at least polylactic acid, has a glass transition point of 50 ° C. or more and 90 ° C. or less, a tensile elastic modulus of 2 GPa or more and 3.5 GPa or less, and a tensile breaking elongation of 100% or more and 200% or less. As a result, sufficient three-dimensional formability at the heating temperature in three-dimensional forming such as normal vacuum forming is obtained, there is little residual internal stress, and it has moderate flexibility and moderate waist and surface hardness, It is possible to obtain a decorative sheet having a sufficient level of surface physical properties such as scratch resistance on the surface without generating wrinkles or drawdown during three-dimensional molding.

The invention according to claim 3 is the decorative sheet according to claim 1 or 2, wherein the thermoplastic polyester resin layer or the transparent thermoplastic polyester resin layer is a biaxially stretched sheet. is there. By using a sheet in which the thermoplastic polyester resin layer or the transparent thermoplastic polyester resin layer is biaxially stretched, a decorative sheet having a more excellent surface strength can be obtained due to the resin orientation.

The invention according to claim 4 is the decorative sheet according to claim 2 or 3, wherein the thermoplastic resin sheet base material is made of a polyester resin containing at least a polylactic acid resin. By making the thermoplastic resin sheet base material a polyester-based resin containing at least a polylactic acid resin, it is possible to make a decorative sheet with more excellent surface strength in consideration of adaptation to environmental problems. Thus, a decorative sheet suitable for various aspects of appropriate balance between flexibility and strength and suitability for processing such as bending and cutting can be obtained. Moreover, the transparent thermoplastic resin layer and the heat deformation temperature can be brought close to each other, and the moldability by a vacuum forming wrapping method or the like can be improved.

The invention according to claim 5 is the decorative sheet according to claim 2 or 3, wherein the thermoplastic resin sheet substrate is made of at least a polyolefin-based resin. By making the thermoplastic resin sheet base material at least a polyolefin-based resin, it is possible to obtain a decorative sheet suitable for various aspects such as an appropriate balance between flexibility and strength, processability such as bending and cutting, and weather resistance. .

The invention described in claim 6 is a decorative material formed by pasting at least the decorative sheet according to any one of claims 1 to 5. A surface material having sufficient surface properties such as scratch resistance on the surface is obtained, and a cosmetic material excellent in surface design is obtained.

The invention described in claim 7 is a decorative material comprising at least the decorative sheet according to any one of claims 1 to 5 bonded to a wooden substrate. A cosmetic material that has sufficient surface properties such as scratch resistance on the surface, excellent surface design, and is composed of biomass raw materials, so that it does not require separation between the decorative sheet and the wooden substrate at the time of disposal. can get.

  The present invention is described in detail below.

  FIG. 1 is a schematic cross-sectional view showing a laminated structure of an example of the decorative sheet of the present invention. In the example shown in FIG. 1, the decorative sheet of the present invention is configured by sequentially laminating a pattern ink layer 2 and a transparent thermoplastic polyester resin layer 1 on a thermoplastic resin base sheet 3, Particularly in the invention, the transparent thermoplastic polyester resin layer 1 contains at least a polylactic acid resin, has a glass transition point of 50 ° C. or more and 90 ° C. or less, and a tensile modulus of 2 GPa or more and 3.5 GPa or less. The elongation at break is 100% or more and 200% or less. The tensile modulus and tensile breaking elongation are values measured according to JIS K6781.

  The reason for limiting the glass transition point, tensile modulus, and tensile elongation at break of the transparent thermoplastic polyester resin layer 1 to the above numerical ranges is the heating temperature (about 60 to 90 ° C.) in three-dimensional molding such as normal vacuum molding. Sufficient three-dimensional formability is obtained, there is little residual internal stress, and it has moderate flexibility and moderate waist and surface hardness, so there is no wrinkling or drawdown during three-dimensional molding, and the surface This is because surface properties such as scratch resistance can be obtained as a decorative sheet. Polyester resins having a glass transition point of less than 50 ° C are softened too much by molding heat during three-dimensional molding, causing wrinkles, scratches, draw-down, etc. It is sufficient and causes molding defects, residual internal stress, cracking, whitening, and the like. If the tensile elastic modulus is less than 2 GPa, the resin is too soft and the surface is not sufficiently scratch-resistant, causing wrinkles and scratches during laminating, and draw-down during thermoforming. If it exceeds 5 GPa, the flexibility of the resin is inadequate, resulting in poor processability, causing molding defects, residual internal stress, cracking, whitening, and the like. Also, if the tensile elongation at break is less than 100%, it will cause the workability such as wrinkles during laminating to be remarkably lowered. On the other hand, if it exceeds 200%, the warp and distortion of the laminated decorative board will be caused by its high tensile elastic modulus. It will cause imitation.

The “transparent” of the transparent thermoplastic polyester resin layer 1 is not necessarily limited to being transparent in a strict sense, and may be translucent or colored transparent. The present invention is not limited to the decorative sheet having the multilayer structure as described above. For example, the surface of the transparent thermoplastic polyester resin layer 1 does not have the thermoplastic resin base sheet 3 in FIG. Alternatively, it includes a decorative sheet having a single layer structure in which the pattern ink layer 2 is provided on the back surface. When the pattern ink layer 2 is provided on the surface of the transparent thermoplastic polyester resin layer 1, the transparent thermoplastic resin is used. The polyester resin layer 1 may be opaque. In addition, one or more transparent thermoplastic resin layers of the same or different type as the transparent thermoplastic polyester resin layer 1 may be provided between the transparent thermoplastic polyester resin layer 1 and the pattern ink layer 2. In addition, one or more other pattern ink layers may be provided between these layers.

As for the specific chemical composition of the polyester-based thermoplastic resin constituting the transparent thermoplastic polyester-based resin layer 1, if the polylactic acid resin is the main component, the glass transition point and the tensile elastic modulus are particularly within the above numerical ranges. Although there is no limit, it can be used as a single material of polylactic acid resin, but it can also be used as a mixture or alloy of these resins, and the processing required for the conditions under which the decorative sheet is used and the manufacturing process It can be used by mixing so that the necessary physical properties can be obtained.

The resin used as an alloy with the polylactic acid resin includes polyolefin resins such as polyethylene and polypropylene, polycarbonate resin, polyethylene terephthalate resin, polybutylene terephthalate resin, polyethylene succinate, polypropylene succinate, polybutylene succinate, and polypentane. Polysuccinate resins such as succinate, polyhexane succinate, caprolactone-butylene succinate, polybutylene adipate terephthalate, polybutylene succinate adipate modified, polycaprolactone, polybutylene succinate carbonate modified, polyethylene terephthalate succinate, polyethylene succinate Nate and polyhydroxybutyrate.

Biomass materials and biodegradable resins that are mixed to improve the heat resistance of polylactic acid resins include polyhydroxybutyrate, polybutylene succinate, polybutylene succinate, polycaprolactone, cellulose acetate, polyester An amide type, a vinyl acetate type, or a starch type can be appropriately selected, and a single type or a mixture of plural types may be used.

For example, when it is desired to increase the surface strength in order to improve the scratch resistance, dent resistance, etc. as a decorative sheet, the polylactic acid resin can be used alone or as a mixture with a polysuccinate resin or other resins. The amorphous sheet of polylactic acid has a glass transition temperature of about 60 ° C., but at a temperature lower than this, the elastic modulus is very high and the surface strength is excellent. In addition, since the polylactic acid resin is excellent in transparency, the degree of freedom of surface decoration expression is increased, and surface decoration that provides a high gloss feeling is possible.

Moreover, when surface decoration by embossing is calculated | required as a decorative sheet, from the polylactic acid resin containing the polylactic acid resin, the polylactic acid amorphous sheet of the polylactic acid resin has a glass transition temperature of about 60 ° C. It is possible to decorate the surface protective layer and the transparent thermoplastic resin layer with heat embossing from the surface protective layer side, and improve the embossability because the heat distortion temperature of polylactic acid resin is relatively low It is also possible to impart excellent surface decoration.

By making the transparent thermoplastic polyester resin layer into a biaxially stretched sheet, the resin orientation further improves the surface strength and thermal dimensional stability, and the tensile elastic modulus increases, so that it becomes a processing board and a decorative board. A decorative sheet having excellent dimensional stability even in a wet state can be obtained.

In addition, the polyester-based thermoplastic resin may include, for example, an antioxidant, an ultraviolet absorber, a light stabilizer, a heat stabilizer, a plasticizer, a lubricant, an antistatic agent, a difficulty, depending on the intended use of the decorative sheet. One or more conventionally known various additives such as a fuel, a filler, a hydrolysis inhibitor, and a nucleating agent may be added.

Examples of antioxidants include phenol-based, sulfur-based, phosphorus-based, etc., ultraviolet absorbers include, for example, benzophenone-based, benzotriazole-based, salicylate-based, cyanoacrylate-based, formamidine-based, oxanilide-based, etc. Hindered amines, nickel complexes, etc., heat stabilizers such as hindered phenols, sulfurs, hydrazines, etc., plasticizers depending on the type of resin, but phthalates, phosphates, fatty acids, etc. Type, aliphatic dibasic acid ester type, oxybenzoic acid ester type, epoxy type, polyester type, etc., as the lubricant, for example, fatty acid ester type, fatty acid type, metal soap type, fatty acid amide type, higher alcohol type, paraffin type, etc. Antistatic agents include, for example, cationic, anionic, and nonio Examples of flame retardants such as bromine, phosphorus, chlorine, nitrogen, aluminum, antimony, magnesium, boron, and zirconium, and fillers such as calcium carbonate, talc, It can be used in one or a mixture of two or more selected from wax, kaolin and the like.

  There is no restriction | limiting in particular in the thickness of the polyester-type thermoplastic resin layer 1, It can set equivalent to the case of the conventional common decorative sheet. Specifically, when it is used as a transparent resin layer of a decorative sheet having a multilayer structure as shown in FIG. 1, it is often in the range of about 20 to 150 μm. In many cases, the range is about 300 μm.

  The pattern ink layer 2 is provided for the purpose of imparting the desired decorative design of the desired decorative sheet to the target decorative sheet, and the type of the pattern is not particularly limited. For example, the grain pattern or the stone pattern Various patterns similar to those in the case of a conventional decorative sheet, such as an abstract pattern and a plain solid color, can be employed. There are no particular limitations on the constituent material and the formation method of the pattern ink layer 2, and for example, a colorant such as an organic or inorganic dye or pigment is dissolved or dispersed in an appropriate solvent together with an appropriate binder resin. The printing ink or the coating agent can be provided by printing or coating by an appropriate printing method or coating method.

Examples of the colorant include inorganic pigments such as carbon black, titanium white, zinc white, dial, bitumen, cadmium red, azo pigments, lake pigments, anthraquinone pigments, phthalocyanine pigments, isoindolinone pigments, dioxazine pigments, and the like. Metallic pigments such as organic pigments, gold powder, silver powder, copper powder, aluminum powder, bronze powder, pearl luster pigments such as fish scale powder, basic lead carbonate, bismuth oxide oxide, titanium oxide-coated mica, fluorescent pigments, nocturnal pigments, etc. Alternatively, a mixture of two or more selected from these can be used.

  Examples of the binder resin include acrylic resins, styrene resins, polyester resins, urethane resins, polyvinyl resins, alkyd resins, petroleum resins, ketone resins, epoxy resins, and melamine resins. , Various synthetic resins such as fluorine-based resins, silicone-based resins, fiber derivatives, and rubber-based resins, or a mixture or copolymer of two or more thereof can be used.

  Examples of the solvent include petroleum organic solvents such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, methylcyclohexane, ethyl acetate, butyl acetate, 2-methoxyethyl acetate, and 2-ethoxyacetate. Ester-based organic solvents such as ethyl, alcohol-based organic solvents such as methyl alcohol, ethyl alcohol, normal propyl alcohol, isopropyl alcohol, isobutyl alcohol, ethylene glycol, propylene glycol, and ketone-based organics such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclohexanone Solvents, ether-based organic solvents such as diethyl ether, dioxane, and tetrahydrofuran; salts such as dichloromethane, carbon tetrachloride, trichloroethylene, and tetrachloroethylene It can be used various organic solvents such systems an organic solvent, an inorganic solvent such as water, or two or more mixed solvents thereof.

In addition, various additives such as extender pigments, plasticizers, dispersants, surfactants, tackifiers, adhesion aids, drying agents, stabilizers, curing agents, curing accelerators or curing retarders, as necessary. Can also be added as appropriate.

  There is no particular limitation on the method for forming the pattern ink layer 2, and various conventionally known printing methods such as gravure printing, offset printing, screen printing, flexographic printing, electrostatic printing, and inkjet printing are used. can do. In addition, for example, in the case of a solid surface, in addition to the above-described various printing methods, for example, roll coating method, knife coating method, air knife coating method, die coating method, lip coating method, comma coating method, kiss coating method, flow coating method Various coating methods such as a dip coating method can also be used. In addition, for example, a hand-drawn method, ink-sink method, photographic method, laser beam or electron beam drawing method, partial vapor deposition method or etching method of metal or the like, or a combination of these methods can of course be performed.

In the decorative sheet having a multilayer structure as shown in FIG. 1, the pattern ink layer 2 is placed on the polyester thermoplastic resin layer 1 side before the thermoplastic resin base sheet 1 and the polyester thermoplastic resin layer 2 are laminated. However, it may be provided on the thermoplastic resin base sheet 3 side. Further, prior to the formation of the pattern ink layer 2, for example, corona treatment, ozone treatment, plasma treatment, ionizing radiation treatment, heavy ion treatment on the printed surface of the polyester-based thermoplastic resin layer 1 or the thermoplastic resin base sheet 3 is performed. By performing surface treatment such as chromic acid treatment, anchor treatment or primer treatment, the adhesion between the polyester-based thermoplastic resin layer 1 or thermoplastic resin substrate sheet 3 and the pattern ink layer 2 can be improved.

There is no restriction | limiting in particular in the kind of thermoplastic resin which comprises the thermoplastic resin sheet base material 3, The various thermoplastic resins currently used for the base sheet of the decorative sheet which concerns can be used. Specifically, for example, polyolefin resins such as polyethylene, polypropylene, polybutene, and polymethylpentene, polyolefin resins such as ethylene-vinyl acetate copolymer or a saponified product thereof, and ethylene- (meth) acrylic acid (ester) copolymer. Copolymer, Polyethylene terephthalate, Polybutylene terephthalate, Polyethylene naphthalate, Polyarylate, Polyester resin such as polycarbonate, Acrylic resin such as polymethyl methacrylate, 6-Nylon, 6,6-Nylon, 6,10-Nylon Polyamide resin such as polystyrene resin, AS resin, ABS resin, styrene resin such as cellulose acetate, cellulose derivatives such as nitrocellulose, chlorinated resin such as polyvinyl chloride and polyvinylidene chloride, polyvinyl fluoride, poly Fluorine resins such as vinylidene chloride, polytetrafluoroethylene, ethylene-tetrafluoroethylene copolymer, etc., or two or more types of copolymers or mixtures selected from these, mixtures, composites, laminates, etc. are used. be able to.

  However, considering the adaptation to the environmental problems described above, among the above-mentioned various thermoplastic resins, the use of a chlorine-based resin or a fluorine-based resin is not very preferable, and contains a halogen element such as chlorine or fluorine. It is preferable to use a non-halogen thermoplastic resin. Among these, a polyolefin-based thermoplastic resin is preferable in view of various balances such as a balance between appropriate flexibility and strength, processability such as bending, cutting and cutting, and weather resistance. Among these, polylactic acid-containing polyester resins are most preferable from the viewpoint of biomass raw material plastics.

  In addition, the polylactic acid-containing polyester resin can suppress the combustion energy smaller than that of the olefin material, and does not interfere with the flame retardant effect as a decorative board when a flame retardant material is used for the wooden base material. I can also expect that.

  Various homopolymers and copolymers such as those listed above are known as the above-mentioned polyolefin-based thermoplastic resins. Among them, the most suitable as a material for a base sheet for a decorative sheet is a polypropylene-based resin, that is, polypropylene. A single or copolymer as a main component, specifically, for example, a homopolypropylene resin, a random polypropylene resin, a block polypropylene resin, and a polypropylene crystal part, and an α having 2 to 20 carbon atoms other than propylene Examples thereof include propylene-α-olefin copolymers containing 15 mol% or more of an olefin, preferably ethylene, butene-1,4-methylpentene-1, hexene-1 or octene-1. . Further, modifiers such as ethylene-α-olefin copolymer, ethylene-propylene copolymer rubber, ethylene-propylene-nonconjugated diene copolymer rubber, which are usually used for softening polypropylene resins can be added. .

  The thermoplastic resin constituting the thermoplastic resin sheet substrate 3 includes, for example, an antioxidant, an ultraviolet absorber, a light stabilizer, a heat stabilizer, a plasticizer, a lubricant, depending on the intended use of the decorative sheet. One or more conventionally known various additives such as an antistatic agent, a flame retardant, and a filler may be added. Specific examples of these additives include those already exemplified as additives for polyester-based thermoplastic resins.

  In addition to the above, the thermoplastic resin sheet substrate 3 may be colored by adding a colorant such as an appropriate organic or inorganic dye or pigment to the thermoplastic resin constituting the thermoplastic resin sheet substrate 3. it can. In particular, when the decorative sheet needs to be concealed depending on the application, it is preferable to make the thermoplastic resin sheet substrate 3 concealable using a concealing pigment. The concealing pigment is a pigment having a high refractive index as compared with the thermoplastic resin as a dispersion medium. From the viewpoint of high refractive index, weather resistance, chemical resistance, etc., for example, a titanium oxide pigment or an iron oxide pigment. It is preferable to use at least an inorganic pigment such as Of course, instead of making the thermoplastic resin sheet substrate 3 itself concealable, as shown in FIG. 2, a concealing solid layer 4 made of a printing ink or a coating agent containing a concealing pigment or the like may be provided. Both can be used in combination.

  There is no restriction | limiting in particular in the thickness of the thermoplastic resin sheet base material 3, The thing of the same thickness as the base material sheet of the conventional general decorative sheet can be used. Specifically, although it depends on the use of the decorative sheet and the type of resin, it is generally selected from a range of about 50 to 200 μm.

  In the case of three-dimensional molding applications, the thermoplastic resin sheet base material 3 is also generally composed of a thermoplastic resin having a glass transition point or softening point of 85 ° C. or less and a tensile elastic modulus of 3 GPa or less. desirable. However, especially when the thermoplastic resin sheet substrate 3 is thinner than the transparent thermoplastic polyester resin layer 1, the upper limit is not necessarily limited as long as the former can sufficiently follow the latter thermal deformation. It may not be done. The lower limit is not particularly limited as long as it is in a range that does not cause general inconveniences as a base sheet for a decorative sheet, for example, is adhesive.

  In the present invention, the method of laminating the transparent thermoplastic polyester resin layer 1 and the thermoplastic resin sheet substrate 3 is not particularly limited, and any conventionally known method can be appropriately applied. Specifically, for example, the transparent thermoplastic polyester-based resin layer 1 previously formed into a film shape or a sheet shape is appropriately bonded using a dry laminate adhesive, a heat sensitive adhesive, a pressure sensitive adhesive, an ionizing radiation curable adhesive, or the like. A method of adhering to the surface of the thermoplastic resin sheet substrate 3 through the agent 5, a method of directly adhering by means of thermocompression bonding or ultrasonic welding without using an adhesive, or heating a polyester-based thermoplastic resin From various methods known in the art, such as a method of melting and extruding into a film or sheet and simultaneously laminating and adhering to the surface of the thermoplastic resin sheet substrate 3, a method that matches the characteristics of the resin is appropriately selected. Can be used.

In addition, of course, the pattern ink layer 2 and the concealing layer 4 may be applied to the transparent thermoplastic polyester resin layer 1 and / or the thermoplastic resin sheet substrate 3 prior to the lamination, For the purpose of improving adhesiveness, the surface of the transparent thermoplastic polyester resin layer 1 and / or the thermoplastic resin sheet substrate 3 is subjected to appropriate surface activation treatment such as corona treatment or ozone treatment, or appropriate adhesion. Anchor layers 6 and 6 'made of a conductive resin composition can also be applied. In the case of the extrusion laminating method, the adhesiveness can be improved by coextrusion laminating so that the adhesive resin is sandwiched between the polyester-based thermoplastic resin and the thermoplastic resin sheet substrate 3. .

The surface of the transparent thermoplastic polyester-based resin layer 1 can be provided with an emboss 7 having an appropriate pattern as required, as is conventionally known. There is no particular limitation on the type of embossed 7 pattern, and it may be various patterns such as, for example, wood grain (especially a conduit pattern), stone texture, Japanese paper, fabric texture, geometric pattern, or the like. For example, it may be a simple matte shape, a grain shape, a hairline shape, a suede tone or the like. Further, the design can be further improved by synchronizing the pattern of the emboss 7 with the pattern of the pattern ink layer 2, but if it is not necessary, the pattern may be non-synchronized. It is also possible to provide an emboss 7 having a pattern including both a pattern synchronized with the two patterns and a pattern not synchronized.

A method for forming the embossing 7 is not particularly limited, but a mechanical embossing method using a metal embossing plate is the most common. Further, there is no particular limitation on the formation time of the emboss 7, and any time can be selected before, simultaneously with or after the lamination with the thermoplastic resin sheet base material 2. The emboss 7 having the same or different pattern can be applied a plurality of times at a plurality of times. In addition, the concave part of the emboss 7 may be filled with the colorant 8 by a method such as a wiping method, if necessary, whereby a decorative sheet having a color pattern synchronized with the uneven pattern on the surface is excellent. Can be obtained.

Moreover, the topcoat layer 9 can also be provided on the surface of the transparent thermoplastic polyester resin layer 1 for the purpose of imparting more excellent surface properties to the surface of the decorative sheet. As a constituent material of the top coat layer 9, any one selected from various known top coat agents conventionally used as a constituent material of the top coat layer of the decorative sheet can be used. In general, it is necessary to have at least transparency that allows the base to be seen through, and it has surface properties such as abrasion resistance, scratch resistance, solvent resistance, and contamination resistance required for decorative sheet applications. In order to achieve this, it is preferable to use a material mainly composed of a curable resin. However, in the case of three-dimensional molding, it is necessary to consider flexibility in order to follow the elongation of the decorative sheet.

Specific examples of the constituent material of the top coat layer 9 include heat such as melamine resin, phenol resin, urea resin, epoxy resin, aminoalkyd resin, urethane resin, polyester resin, and silicone resin. A curable resin, an ionizing radiation curable resin such as an acrylic resin, or the like can be preferably used. If necessary, various additives such as a gloss adjusting agent, a lubricant, an antistatic agent, an anti-condensation agent, an antibacterial agent, and an antifungal agent can be appropriately added. In addition, the top coat layer 9 is composed of two or more layers having different glosses, and one or more of them are provided in a pattern shape to obtain a decorative sheet having a material feeling and a visual three-dimensional effect due to changes in surface gloss. You can also.

There is no particular limitation on the method for forming the top coat layer 9, for example, gravure coating method, roll coating method, dip coating method, air knife coating method, knife coating method, comma coating method, die coating method, lip coating method, kiss coating method, Any conventionally known coating method such as rod coating method, spray coating method, flow coating method and the like can be appropriately applied.

If the adhesion between the transparent thermoplastic polyester resin layer 1 and the topcoat layer 9 is insufficient, the surface of the transparent thermoplastic polyester resin layer 1 is formed prior to the formation of the topcoat layer 9. For example, adhesion between the transparent thermoplastic polyester resin layer 1 and the topcoat layer 9 is achieved by performing a surface treatment such as corona treatment, ozone treatment, plasma treatment, ionizing radiation treatment, dichromic acid treatment, anchor or primer treatment. Can be improved.

As described above, the decorative sheet of the present invention is similar to the conventional decorative sheet, for example, a woody base material such as plywood or particle board, an inorganic base material such as calcium silicate board or wood wool cement board, FRP ( (Fiber reinforced plastics) and the like are used by being attached to the surface of various base materials such as synthetic resin base materials. Although an adhesive is used, depending on the type of resin constituting the thermoplastic resin sheet substrate 3, the adhesiveness with the general-purpose laminating adhesive may be insufficient. In preparation for such a case, it is preferable to provide a primer layer 10 made of a resin excellent in adhesiveness with the above-described general-purpose adhesive on the back surface of the thermoplastic resin sheet substrate 3.

Various primer agents such as urethane, acrylic, ethylene-vinyl acetate copolymer system, vinyl chloride-vinyl acetate copolymer system, etc. are known as the primer layer 10, and among these, a thermoplastic resin sheet base is used. Select the one that matches the material 3 and use it. In addition, if powders such as silica, alumina, calcium carbonate, and barium sulfate are added to the primer layer 10, for example, the surface of the primer layer 10 can be roughened to prevent blocking when the decorative sheet is wound and stored. In addition, the adhesiveness with the laminating adhesive due to the anchoring effect can be improved.

The decorative sheet of the present invention is not only excellent in three-dimensional formability and scratch resistance on the surface due to the configuration as described above, but also has many advantages in common with decorative sheets using various conventional polyester-based thermoplastic resins. It is equipped with. For example, in the case of using a transparent polyester-based thermoplastic resin, the excellent transparency unique to the polyester-based thermoplastic resin makes it easy to create a decorative sheet with excellent pattern sharpness and high surface gloss. Obtainable.

  A decorative sheet with a woodgrain pattern with the following composition was prepared. As the transparent thermoplastic polyester resin layer 1, gravure printing is performed in advance from the back side of an unstretched transparent polylactic acid resin having a glass transition point of 58 ° C., a tensile elastic modulus of 2.1 GPa, and a tensile breaking elongation of 115% and a thickness of 100 μm. After printing the wood grain pattern and providing the pattern ink layer 2, an ink layer as a concealing layer 4 was further provided. The thermoplastic resin sheet base material 3 is bonded to an unstretched polyester sheet having a thickness of 80 μm mainly composed of a polylactic acid resin preliminarily colored in a wood grain pattern through an adhesive layer 5 by a dry laminating method. did. In addition, a urethane coating agent to which an ultraviolet absorber and a light stabilizer are added as a surface protective layer is applied to the transparent thermoplastic resin side by gravure coating so that the thickness after drying and curing is 9 μm. Created. Furthermore, a decorative sheet was prepared by providing a surface embossing 7 by hot-pressure embossing in the subsequent process.

<The layer structure of the decorative sheet of Example 1>
Top coat layer 9: Urethane coating agent 9 μm
Transparent thermoplastic polyester resin layer 1: Polylactic acid resin (glass transition point 58 ° C.) 100 μm
Dry laminate adhesive layer 5: Urethane two-component curing type 10 μm
Printing inks 2, 4: Urethane two-component curing type 0-2 μm
Thermoplastic resin sheet base material 3: Polylactic acid polyester resin 80 μm

  A decorative sheet with a woodgrain pattern with the following composition was prepared. First, a pattern ink layer 2 having a wood grain pattern was provided by gravure printing on a polypropylene resin sheet having a thickness of 70 μm, which was previously colored in a wood grain base color as the thermoplastic resin sheet substrate 3. After applying the anchor coating agent 6 ′ to the printed sheet by the gravure coating method so as to have a thickness of 1 μm, the glass transition point is obtained as the transparent thermoplastic polyester resin layer 1 through the adhesive layer 5. A biaxially stretched polylactic acid resin having a thickness of 58 μm and a tensile elastic modulus of 3.4 GPa and a tensile elongation at break of 125% was bonded by a dry laminating method. Further, on the transparent thermoplastic polyester resin layer 1, a urethane coating agent to which an ultraviolet absorber and a light stabilizer were added as a top coat layer was applied by gravure coating so that the thickness after drying and curing was 6 μm. . Furthermore, a decorative sheet was prepared by providing a surface embossing 7 by hot-pressure embossing in the subsequent process.

<The layer structure of the decorative sheet of Example 2>
Topcoat layer 9: Urethane coating agent 6 μm
Transparent thermoplastic polyester resin layer 1:
Biaxially stretched polylactic acid resin (glass transition point 58 ° C.) 80 μm
Dry laminate adhesive layer 5: Urethane two-component curing type 10 μm
Printing inks 2, 4: Urethane two-component curing type 0-2 μm
Thermoplastic resin sheet base material: Polypropylene 70 μm

<Comparative Example 1>
As a transparent thermoplastic resin, an unstretched amorphous polyethylene terephthalate resin having a glass transition point of 78 ° C., a tensile elastic modulus of 2 GPa, a tensile elongation at break of 170% and a thickness of 100 μm is used. Example 1 The same decorative sheet was prepared.

<The layer structure of the decorative sheet of Comparative Example 1>
Top coat layer 9: Urethane coating agent 9 μm
Transparent thermoplastic polyester resin layer 1:
Amorphous polyethylene terephthalate resin 100μm
Dry laminate adhesive layer 5: Urethane two-component curing type 10 μm
Printing inks 2, 4: Urethane two-component curing type 0-2 μm
Thermoplastic resin sheet base material 3: Polylactic acid polyester resin 80 μm

<Comparative example 2>
As a transparent thermoplastic resin, a biaxially stretched polyethylene terephthalate resin having a glass transition point of 70 ° C., a tensile elastic modulus of 4 GPa, and a tensile breaking elongation of 150% and a thickness of 80 μm is used. The same decorative sheet was created.

<The layer structure of the decorative sheet of Comparative Example 2>
Topcoat layer 9: Urethane coating agent 6 μm
Transparent thermoplastic polyester resin layer 1:
Biaxially stretched polyethylene terephthalate resin 80μm
Dry laminate adhesive layer 5: Urethane two-component curing type 10 μm
Printing inks 2, 4: Urethane two-component curing type 0-2 μm
Thermoplastic resin sheet base material: Polypropylene 70 μm

<Comparative Example 3>
As the transparent thermoplastic resin, an unstretched polypropylene resin having a glass transition point of 140 ° C., a tensile elastic modulus of 0.8 GPa, and a tensile breaking elongation of 600% and a thickness of 80 μm was used. The same decorative sheet was created.

<The layer structure of the decorative sheet of Comparative Example 3>
Topcoat layer 9: Urethane coating agent 6 μm
Transparent thermoplastic polyester resin layer 1: unstretched polypropylene resin 80 μm
Dry laminate adhesive layer 5: Urethane two-component curing type 10 μm
Printing inks 2, 4: Urethane two-component curing type 0-2 μm
Thermoplastic resin sheet base material: Polypropylene 70 μm

<Evaluation>
The above Example 1 and Comparative Example 1 are in a state of being vacuum-formed and bonded to an MDF base material having a thickness of 9 mm and an end portion subjected to curved surface R processing, and Example 2, Comparative Example 2 and Comparative Example 3 are thick. The decorative sheet was evaluated in the state of a decorative board bonded to a 3 mm thick MDF plate.

<Evaluation method>
Embossability: Emboss transferability of the embossed shape of the embossed decorative sheet was evaluated by visual appearance. If the embossed pattern edge shape was transferred, it was marked as ◯, and if the embossed pattern edge shape was not transferred, it was marked as x.

Formability: For Example 1 and Comparative Example 1, the decorative sheet follows the curved surface R for ease of forming when the end portion is vacuum-formed and bonded to the MDF substrate having the curved surface R processed. If no wrinkles or cracks occurred, it was marked as ◯. If wrinkles occurred on the curved surface R portion or if the decorative sheet was cracked, it was marked as x.

Dimensional stability: The shape change of the decorative sheet after being bonded to the MDF base material or MDF plate was measured. The case in which the shape did not change was evaluated as ◯, and the shape in which warpage or deflection occurred was evaluated as ×.

Surface strength: Comparison was made by pencil hardness. H or higher was evaluated as ◯, B to F as Δ, and less than B as X.

Durability: As an accelerated test, put it in an oven at 60 ° C for 10 days, and check for delamination and discoloration between decorative sheet layers (Yes → No, No → Good)
In addition, the wood resin composition bonded to the decorative sheet was introduced for 1000 hours at the sunshine weather meter (irradiation was on the decorative sheet bonding surface side), and the presence or absence of surface deterioration and internal deterioration (existing → × defective, no → good) Those that were not satisfied with any one of them were evaluated as x-defects.

Biomass degree: As a biomass raw material, the polylactic acid resin described in Example 1 and Example 2 and the polylactic acid resin contained in the polylactic acid-based polyester resin described in Example 1 and Comparative Example 1 are targeted. Other adhesive resins, polypropylene resins, urethane coating agents, etc. are not covered. The weight ratio (%) which biomass plastic occupies with respect to the whole decorative sheet among the materials which comprise a decorative sheet was computed from the thickness and specific gravity of each material. If it was 50% or more, it was rated as ◯, if it was 20% or more and less than 50%, Δ, and if it was less than 20%, it was marked as x.

The results are shown below.

  As described above in detail, the decorative sheet of the present invention has a transparent thermoplastic polyester resin layer having a glass transition point of 50 ° C. or more and 90 ° C. or less, a tensile elastic modulus of 2 GPa or more and 3.5 GPa or less, and a tensile breaking elongation. With a transparent thermoplastic resin layer made of a polylactic acid resin characterized in that the rate is 100% or more and 200% or less, as well as lamination to a flat substrate and V-cut processing, a columnar substrate No problems such as cracking, whitening, wrinkles, drawdown, etc., and excellent surface properties such as scratch resistance, even in wrapping laminates and three-dimensional laminates on three-dimensional uneven substrates It has a remarkable effect of being a thing.

It is a schematic cross section which shows the laminated structure of an example of the decorative sheet of this invention. It is a schematic cross section which shows the laminated structure of an example of the decorative sheet of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Transparent thermoplastic polyester-type resin layer 2 Pattern ink layer 3 Thermoplastic resin sheet base material 4 Concealment layer 5 Adhesive layer 6, 6 'anchor layer 7 Embossing 8 Colorant 9 Topcoat layer 10 Primer layer

Claims (7)

  In a decorative sheet in which at least a pattern ink layer and a thermoplastic polyester resin layer are laminated in this order, the thermoplastic polyester resin layer contains at least polylactic acid, and the glass transition point of the thermoplastic polyester resin layer The decorative sheet is characterized by having a tensile elastic modulus of 2 GPa to 3.5 GPa and a tensile breaking elongation of 100% to 200%.   In a decorative sheet in which at least a pattern ink layer and a transparent thermoplastic polyester resin layer are laminated in this order on a thermoplastic resin sheet substrate, the transparent thermoplastic polyester resin layer contains at least polylactic acid, and The transparent thermoplastic polyester resin layer has a glass transition point of 50 ° C. or more and 90 ° C. or less, a tensile elastic modulus of 2 GPa or more and 3.5 GPa or less, and a tensile elongation at break of 100% or more and 200% or less. Sheet.   The decorative sheet according to claim 1 or 2, wherein the thermoplastic polyester resin layer or the transparent thermoplastic polyester resin layer is a biaxially stretched sheet.   The decorative sheet according to claim 2 or 3, wherein the thermoplastic resin sheet base material is made of a polyester resin containing at least a polylactic acid resin.   The decorative sheet according to claim 2 or 3, wherein the thermoplastic resin sheet substrate contains at least a polyolefin-based resin.   A decorative material comprising at least the decorative sheet according to any one of claims 1 to 5 bonded thereto.   A cosmetic material comprising at least the decorative sheet according to any one of claims 1 to 5 bonded to a wooden substrate.

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