JP2017154389A - Decorative sheet, and method for producing decorative sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorative sheet that exhibits no abrasion of a pattern even at a rotation number of 2,000 in CLASS33-3 abrasion resistance test according to EN16511: 2014 (E) in conformity with European Standard EN13329: 2006+A1: 2008 (E) for abrasion resistance.SOLUTION: In a decorative sheet 10, a primer layer 1, a lower base resin layer 2 with a thickness of 125 μm formed of a polypropylene resin with transparency, a raw fabric layer 3 for printing with a thickness 55 μm formed of a polyethylene resin, a pattern layer 4 printed on the raw fabric layer 3 for printing, an upper base resin layer 5 with a thickness of 150 μm formed of a polypropylene resin with transparency, and a surface protective layer 6 provided with an embossment pattern 7 are layered in turn.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a decorative sheet used for vinyl tiles for floors and the like and a method for producing the same.

  For decorative sheets (decorative materials) used for building interior materials such as floors, walls and ceilings, doors and other furniture, furniture and other surface materials, surface properties such as wear resistance and contamination resistance are usually required. Is done. In particular, a decorative sheet to be applied to the outer surface of a building interior material is strongly required to have scratch resistance and wear resistance. Patent Document 1 discloses a floor decorative material using such a decorative sheet.

JP 2014-051832 A

  However, when the conventional decorative sheet rotates 2000 times in the wear resistance test of CLASS 33-3 of EN 16511: 2014 (E) based on the European standard EN13329: 2006 + A1: 2008 (E) for wear resistance, for example, There is a possibility that the wear (scraping) will occur.

  The present invention has been made in view of the above circumstances, and is a wear resistance test of CLASS 33-3 of EN 16511: 2014 (E) conforming to European standard EN13329: 2006 + A1: 2008 (E). An object of the present invention is to provide a decorative sheet that does not wear a pattern even after 2000 rotations, and a method for manufacturing the decorative sheet.

  In order to solve the above problems, a decorative sheet according to an aspect of the present invention includes a primer layer, a base resin layer formed of a polypropylene resin having transparency, and an original printing layer formed of a polyethylene resin. The pattern layer printed on the printing original fabric layer, the upper resin layer formed of a polypropylene resin having transparency, and the surface protective layer formed with an embossed pattern are sequentially laminated. The thickness of the upper resin layer is 150 μm or more.

  According to one aspect of the present invention, the wear resistance of the picture is maintained even after 2000 revolutions in the wear resistance test of CLASS 33-3 of EN16511: 2014 (E) in accordance with European standard EN13329: 2006 + A1: 2008 (E). A decorative sheet for vinyl tiles for flooring without wear can be obtained.

It is typical sectional drawing showing the decorative sheet which concerns on one Embodiment of this invention.

<Embodiment>
Hereinafter, a decorative sheet according to an embodiment of the present invention will be described with reference to the drawings. Here, the drawings are schematic, and the relationship between the thickness and the planar dimensions, the ratio of the thickness of each layer, and the like are different from the actual ones. Further, the embodiment described below exemplifies a configuration for embodying the technical idea of the present invention, and the technical idea of the present invention is that the material, shape, structure, etc. of the component parts are as follows. It is not something specific. The technical idea of the present invention can be variously modified within the technical scope defined by the claims described in the claims.

(Decorative sheet 10)
As shown in FIG. 1, a decorative sheet 10 according to an embodiment of the present invention includes a primer layer 1, a lower resin layer 2, a printing raw fabric layer 3, a pattern layer 4, and an upper resin layer 5. The surface protective layer 6 is sequentially laminated (in this order). Further, an embossed pattern 7 is formed on the surface protective layer 6 that is the outermost layer in the stacking direction of the decorative sheet according to the present embodiment.

(Primer layer 1)
The primer layer 1 is an anchor coat layer intended to improve the adhesiveness of the resin. Moreover, the function of the primer layer 1 includes surface stabilization after surface treatment, corrosion prevention of the metal surface, imparting tackiness, prevention of deterioration of the adhesive, etc., in addition to improvement of adhesion. As a primer (primer) for forming the primer layer 1, for example, a two-component urethane resin primer can be used. The type of primer varies depending on the adherend and application. As the adherend, for example, there is a plate-like member made of metal or wood. Examples of the metal system include aluminum, steel, stainless steel, and a composite panel. As a composite panel, for example, there is a panel provided with a resin layer serving as a core and metal plates (aluminum, galvalume, stainless steel, etc.) attached to both surfaces of the resin layer. Examples of the wood system include MDF (medium density fiberboard), plywood, and particle board.

  The primer layer 1 is not limited to the surface of the lower base resin layer 2 (the surface opposite to the printing original fabric layer 3), but the lower base resin layer 2, the original printing layer 3, the pattern layer 4, and the upper resin layer. 5 and the surface protective layer 6 may also be formed between the respective layers.

(Lower resin layer 2)
The lower base resin layer 2 is a backer layer for the purpose of shock absorption (buffer) and the like, and is also an adhesive layer for bonding the printing original fabric layer 3 and the adherend. Although there is no limitation in particular as a resin component of the base resin layer 2, For example, the polypropylene resin which has transparency is preferable. The thickness of the lower resin layer 2 is preferably about 125 μm or more and 150 μm or less in consideration of impact resistance, for example.

(Print fabric layer 3)
The printing original fabric layer 3 is a base sheet intended to be printed on the surface. The printing raw fabric layer 3 is made of, for example, a resin film. The resin component of the resin film is not particularly limited, but for example, a polyethylene resin is preferable. The thickness of the printing raw fabric layer 3 is preferably about 55 μm or more and 100 μm or less, for example.

A solid layer for improving the adhesion between the printing original fabric layer 3 and the pattern layer 4 may be formed on the surface of the printing original fabric layer 3. As the solid layer, for example, a resin in which a two-component urethane resin and a vinyl acetate resin are mixed can be used. A pigment is added to the resin for coloring. The solid layer is formed by, for example, applying a solid layer-constituting resin on the printing original fabric layer 3. The basis weight after drying is, for example, 2 g / m ² .

(Picture pattern layer 4)
The pattern layer 4 is a pattern layer for imparting design properties to the decorative sheet 10. The pattern pattern layer 4 can be formed, for example, by printing a pattern pattern. The thickness of the pattern layer 4 is different from the type of the pattern, but generally it is preferably in the range of 0.1 μm or more and 10 μm or less.

Examples of the design pattern include a wood grain pattern, a stone pattern, a grain pattern, a tiled pattern, a brickwork pattern, a cloth pattern, a leather pattern, a geometric figure, a character, a symbol, and an abstract pattern. The pattern can be selected according to the purpose.
Examples of the pattern pattern printing technique include gravure printing, flexographic printing, silk screen printing, and offset printing. As the printing ink, for example, a printing ink containing a colorant, a binder resin, and a solvent can be used. These inks may be known or commercially available.

  As the colorant, for example, a pigment can be appropriately used. As the pigment, both inorganic pigments and organic pigments can be used. Inorganic pigments include, for example, titanium oxide, zinc white, carbon black, black iron oxide, yellow iron oxide, yellow lead, molybdate orange, cadmium yellow, nickel titanium yellow, chrome titanium yellow, iron oxide (valve), and cadmium. Examples thereof include red, ultramarine blue, bitumen, cobalt blue, chromium oxide, cobalt green, aluminum powder, bronze powder, titanium mica, and zinc sulfide. Examples of the organic pigment include aniline black, perylene black, azo (azo lake, insoluble azo, condensed azo), polycyclic (isoindolinone, isoindoline, quinophthalone, perinone, flavantron, anthrapyrimidine, anthraquinone, Quinacridone, perylene, diketopyrrolopyrrole, dibromoanthanthrone, dioxazine, thioindigo, phthalocyanine, indanthrone, halogenated phthalocyanine). The content of the pigment is preferably about 10 to 50 parts by mass, more preferably about 15 to 30 parts by mass with respect to 100 parts by mass of the resin component.

  The binder resin can be set according to the type of the lower layer resin that forms the pattern layer 4. Examples of the binder resin include acrylic resin, styrene resin, polyester resin, urethane resin, chlorinated polyolefin resin, vinyl chloride-vinyl acetate copolymer resin, polyvinyl butyral resin, alkyd resin, petroleum Resin, ketone resin, epoxy resin, melamine resin, fluorine resin, silicone resin, fiber derivative, rubber resin and the like.

  Examples of the solvent (or dispersion medium) include petroleum organic solvents such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, and methylcyclohexane; ethyl acetate, butyl acetate, 2-methoxyethyl acetate, and acetic acid-2 -Ester-based organic solvents such as ethoxyethyl; alcohol-based organic solvents such as methyl alcohol, ethyl alcohol, normal propyl alcohol, isopropyl alcohol, isobutyl alcohol, ethylene glycol, propylene glycol; ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclohexanone Organic solvents; ether organic solvents such as diethyl ether, dioxane, tetrahydrofuran; dichloromethane, carbon tetrachloride, trichloroethylene, tetrachloroethylene Chlorinated organic solvents; water and the like. These solvents (or dispersion media) can be used alone or in the form of a mixture.

(Upper resin layer 5)
The upper resin layer 5 is a backer layer for the purpose of shock absorption (buffering) and the like, and is also an adhesive layer for bonding the pattern layer 4 and the surface protective layer 6. Further, the upper resin layer 5 makes the design pattern clear when forming the design pattern layer 4 and improves the scratch resistance of the design pattern layer 4. Although there is no limitation in particular as a resin component of the upper base resin layer 5, For example, the polypropylene resin which has transparency is preferable. The thickness of the upper resin layer 5 is preferably, for example, about 150 μm or more and 200 μm or less in order to clear the abrasion resistance test (2000 rotations).

(Surface protective layer 6)
The surface protective layer 6 is a top coat layer for the purpose of adjusting the gloss and / or protecting the pattern layer 4. The resin component of the surface protective layer 6 is not particularly limited, but for example, an ultraviolet (UV) curable resin is preferable. Although the thickness of the surface protective layer 6 is not limited, For example, about 0.1 micrometer or more and 15 micrometers or less are preferable.

Note that. If it is the surface protective layer 6 aiming at gloss adjustment, there exists the surface protective layer 6 containing known fillers, such as a silica, for example. As a method for forming the surface protective layer 6, for example, a known method such as gravure printing can be employed. In addition, when the adhesiveness of the pattern pattern layer 4 and the surface protective layer 6 is not fully acquired, the surface protective layer 6 can also be provided after carrying out the adhesion process (primer process) of the surface of the pattern pattern layer 4 easily. .
Further, when the surface protective layer 6 is formed for the purpose of surface strength (scratch resistance, etc.), stain resistance, protection of the pattern layer 4 and the like of the decorative sheet 10, an ionizing radiation curable resin is contained as a resin component. What is to be done is suitable. As the ionizing radiation curable resin, for example, those that undergo radical polymerization (curing) by electron beam irradiation are preferable.

(Embossed pattern 7)
The surface of the surface protective layer 6 that is the outermost layer of the decorative sheet 10 is embossed (unevenness forming using an embossed plate), and the embossed pattern 7 is formed (given) on the surface of the decorative sheet 10. The decorative sheet 10 can be configured to make the three-dimensional effect due to the tactile sensation more felt by the embossed pattern 7 formed on the surface of the surface protective layer 6. In the embossing process, for example, a concave portion having a depth of 15 μm or more is passed between an embossing roll and a rubber back roll having a hardness of 50 degrees or more and less than 90 degrees to give the decorative sheet 10 an uneven shape. good. As a method for measuring hardness, for example, JIS K-6301 A type can be used. Examples of the embossed pattern 7 include a wood grain plate conduit groove, a stone plate surface unevenness, a cloth surface texture, a satin finish, a grain, a hairline, and a multiline groove.

Examples of the present embodiment and comparative examples are shown below. In addition, this embodiment is not limited to the following Example.
Example 1
A printing original fabric layer 3 having a thickness of 55 μm was formed using a polyethylene resin.
Next, the grain pattern is printed on the surface of the printing raw fabric layer 3 using a two-component urethane resin / vinyl chloride-vinyl acetate copolymer resin binder ink at a basis weight of 3 g / m ² after drying. Layer 4 was formed.
Next, a transparent polypropylene resin was extruded at a thickness of 150 μm and laminated on the surface of the pattern layer 4 to form an upper resin layer 5. At this time, a two-component urethane resin primer was applied to the surface of the pattern layer 4 at a basis weight of 1.2 g / m ² after drying, and then a transparent polypropylene resin was applied thereon to a thickness of 150 μm. May be extruded and laminated to form the upper resin layer 5.
Next, an ultraviolet (UV) curable resin was applied to the surface of the upper resin layer 5 at a basis weight of 6 g / m ² to form the surface protective layer 6. At this time, a two-component urethane resin primer was applied to the back surface of the pattern layer 4 at a basis weight of 4 g / m ² after drying, and then an ultraviolet (UV) curable resin was applied thereon with a basis weight of 6 g / m. ^The surface protective layer 6 may be formed by coating ² .
Further, the surface of the surface protective layer 6 was embossed to form an embossed pattern 7 and irradiated with ultraviolet rays to cure the ultraviolet (UV) curable resin of the surface protective layer 6.

Next, the lower base resin layer 2 was formed by extruding and laminating a transparent polypropylene resin with a thickness of 125 μm on the back surface (the surface opposite to the pattern layer 4) of the printing original fabric layer 3. At this time, a two-component urethane resin-based primer is applied to the back surface of the printing raw fabric layer 3 at a basis weight of 1.2 g / m ² after drying, and then a transparent polypropylene resin is laminated thereon. Thus, the lower resin layer 2 may be formed.
Finally, a two-component urethane resin-based primer is applied to the surface of the lower resin layer 2 (the surface opposite to the printing raw fabric layer 3) at a basis weight of 1.2 g / m ² after drying. Layer 1 was formed.

  In this way, the primer layer 1, the base resin layer 2 having a thickness of 125 μm formed of a polypropylene resin having transparency, the original printing layer 3 having a thickness of 55 μm formed of polyethylene resin, and printing A pattern layer 4 printed on the raw fabric layer 3, an upper resin layer 5 having a thickness of 150 μm formed of a transparent polypropylene resin, and a surface protective layer 6 formed with an embossed pattern 7 are sequentially formed. A laminated decorative sheet 10 was prepared.

(Comparative Example 1)
As the upper resin layer 5, a polypropylene resin having transparency was extruded by 130 μm and laminated. Other than that was carried out similarly to Example 1, and produced the decorative sheet of the comparative example.

(Performance evaluation)
With regard to wear resistance, the wear resistance test of CLASS 33-3 of EN 16511: 2014 (E) conforming to European standard EN13329: 2006 + A1: 2008 (E), the width of the wear wheel (wheel) is 12.7 mm and the pressure is increased. After 2,000 rotations under the condition of 5.4 N, external observation was performed, and the one with no pattern wear (scraping) was accepted. The results of performance evaluation are listed in Table 1 below.

Since the decorative sheet 10 of Example 1 has no pattern wear (scraping), the overall evaluation is acceptable.
The decorative sheet of Comparative Example 1 was rejected from the overall evaluation because the pattern was worn (scraped) in an area of 10% of the pattern polishing portion (contact portion of the wear ring).
Thus, it was confirmed that when the upper resin layer 5 was provided on the pattern layer 4 in the decorative sheet and the thickness of the upper resin layer 5 was 150 μm, the pattern was not worn (scraped). Further, it was confirmed that when the thickness of the upper resin layer 5 was 130 μm, the pattern was worn (scraped).
Therefore, in order to prevent the pattern from being worn (scraped), it is preferable that the upper base resin layer 5 is provided on the pattern pattern layer 4 in the decorative sheet and the thickness of the upper base resin layer 5 is set to 150 μm or more. I understood.

(Effect of this embodiment)
After forming the lower base resin layer, the printing raw fabric layer, and the upper base resin layer with the minimum necessary thickness, the EN16511: 2014 (E) conforming to the European standard EN13329: 2006 + A1: 2008 (E) for wear resistance. ), A decorative sheet for vinyl tiles for flooring having no pattern abrasion even after 2,000 rotations was obtained.

  The decorative sheet according to the present embodiment is a decorative sheet for vinyl tiles for floors that does not wear (shave) the pattern even after 2000 rotations in the abrasion resistance test of Class 33-3 of European standard EN 16511: 2014 (E). In addition, it can be used for tiles for PVC floors for the European housing market.

  While the present invention has been described with reference to specific embodiments, it is not intended that the invention be limited by these descriptions. From the description of the invention, other embodiments of the invention will be apparent to persons skilled in the art, along with various variations of the disclosed embodiments. Therefore, it is to be understood that the claims encompass these modifications and embodiments that fall within the scope and spirit of the present invention.

DESCRIPTION OF SYMBOLS 1 ... Primer layer 2 ... Lower base resin layer 3 ... Original fabric layer for printing 4 ... Picture pattern layer 5 ... Upper base resin layer 6 ... Surface protection layer 7 ... Embossed pattern 10 ... Cosmetic sheet

Claims (3)

A primer layer;
A base resin layer formed of a polypropylene resin having transparency;
An original printing layer formed of polyethylene resin;
A pattern layer printed on the printing original fabric layer;
An upper resin layer formed of a polypropylene resin having transparency;
A surface protective layer with an embossed pattern,
Are sequentially stacked,
The decorative sheet is characterized in that the thickness of the upper resin layer is 150 μm or more. The thickness of the lower base resin layer is 125 μm or more and 150 μm or less,
The thickness of the printing original fabric layer is 55 μm or more and 100 μm or less,
The decorative sheet according to claim 1, wherein the thickness of the upper resin layer is 150 µm or more and 200 µm or less. Using a polyethylene resin, a printing raw fabric layer having a thickness of 55 μm or more and 100 μm or less is formed,
On the surface of the printing original fabric layer, a two-component urethane resin / vinyl chloride-vinyl acetate copolymer resin binder ink is used to print a wood grain pattern with a basis weight of 3 g / m ² after drying to form a pattern layer. ,
On the surface of the pattern pattern layer, a transparent polypropylene resin is extruded and laminated at a thickness of 150 μm or more and 200 μm or less to form an upper resin layer,
On the surface of the upper resin layer, an ultraviolet curable resin is applied at a basis weight of 6 g / m ² to form a surface protective layer,
Embossing the surface of the surface protective layer to give an embossed pattern,
Irradiate ultraviolet rays to cure the ultraviolet curable resin of the surface protective layer,
On the back side of the printing fabric layer, a polypropylene resin having transparency is extruded and laminated at a thickness of 125 μm or more and 150 μm or less to form a base resin layer,
A method for producing a decorative sheet, comprising: applying a two-component urethane resin-based primer to a surface of the lower resin layer at a basis weight of 1.2 g / m ² after drying to form a primer layer.

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