JP2005125663A - Decorative material and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To easily obtain a fine decorative material which has a wide variety of colors and patterns, and whose appearance with great depth is not deteriorated even if an edge is trimmed. <P>SOLUTION: A decorative paper sheet for a decorative plate is impregnated with a resin solution which is mainly composed of a thermosetting resin, and a thermosetting resin-impregnated decorative paper sheet obtained by being dried is extruded while being wrapped with a plastic resin. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a decorative material, and more particularly, to a decorative material useful for edges of dwelling units, building material members, and the like.

  Up to now, materials used for edge materials such as decorative panels joints, protruding corners, counters and other dwellings, building materials, etc., are printed with metal such as aluminum or plastic extruded materials such as ABS, wood grain patterns and abstract patterns. A decorative sheet using the decorated decorative paper has been used.

However, metal and plastic ones cannot express patterns like printed paper, which may cause the surface pattern and color tone to be unbalanced and inconsistent. there were.
On the other hand, in order to solve such a problem, a decorative sheet using a lamination technique has been developed. For example, a resin reinforced paper or olefin sheet on which a pattern is printed is laminated with a resin plate such as a transparent or translucent thermoplastic resin (FIG. 3), or a thermoplastic resin as shown in FIG. There are three sides covered with resin-reinforced paper or olefin sheet. The multilayer structure includes a support made of a thermoplastic polymer, an intermediate layer provided thereon, and a thermosetting layer applied to the intermediate layer, and the adhesive of the intermediate layer is a plastic resin. A decorative sheet is disclosed (Patent Document 1).
However, although the thing like FIG. 3 has the depth in an external appearance, there exists a problem that it cannot stick to a different shape and it is hard to adhere | attach on a base material. Further, the one shown in FIG. 4 has a defect that the appearance is not deep and the appearance is deteriorated when the edge is trimmed.
As described above, the conventional decorative sheet is rich in design but uses the conventional lamination technique. Therefore, even if the shape is flat, there is no problem even if the shape is flat. There were many problems in obtaining three-dimensional and irregular shapes such as ones and semicircular ones.

Japanese Patent Laid-Open No. 2001-47565

  The problems to be solved are that, conventionally, it has been difficult to obtain a cosmetic material that has a variety of colors and patterns, has a deep appearance, is beautiful, and does not deteriorate the appearance even after trimming the edges. is there.

The present invention relates to a cosmetic material characterized in that a resin-reinforced fabric and / or a thermoplastic resin sheet is wrapped with the same or different thermoplastic resin.
Next, the present invention relates to a method for producing a cosmetic material, characterized in that a resin-reinforced fabric or a thermoplastic resin sheet is molded while being wrapped with the same or different thermoplastic resin.
Here, in the above method, the molding means includes extrusion molding.
In the above method, it is preferable to use, as the resin-reinforced fabric, a thermosetting resin-containing decorative paper that has been subjected to a drying treatment after the decorative paper contains a resin liquid mainly composed of a thermosetting resin.
The resin-reinforced fabric used in the present invention is preferably a thermosetting resin-containing decorative paper, and the thermoplastic resin sheet is a polyolefin sheet, PVC sheet, ABS sheet, PMMA sheet, and PET. It is preferably at least one thermoplastic decorative sheet selected from the system sheets.
In the present invention, when the thermoplastic resin to be wrapped is composed of an upper surface layer and a lower surface layer, the thermoplastic resin of the upper surface layer is a transparent or translucent acrylic resin, polycarbonate resin, PVC resin, At least one selected from the group of ABS resins, AS resins, PS resins, MAS resins, olefin resins, and PET resins is preferred.
On the other hand, in the present invention, when the thermoplastic resin to be wrapped is composed of an upper surface layer and a lower surface layer, the thermoplastic resin of the lower surface layer includes an acrylic resin, a polycarbonate resin, a PVC resin, an ABS resin, At least one selected from the group of AS resins, PS resins, MAS resins, olefin resins, and PET resins is preferred.

The decorative material of the present invention uses a resin-reinforced decorative paper for a decorative board or a decorative sheet made of a thermoplastic resin, and has a variety of designs such as colors and patterns by wrapping it with a resin. In addition, by changing the shape of the extrusion die, an irregular shape can be manufactured.
Moreover, a soft type thing and a hard type thing can be manufactured by changing the composition of a thermoplastic resin suitably.
Further, the decorative material of the present invention has a deep appearance, is beautiful, and does not deteriorate the appearance even when the edge is trimmed. Therefore, unlike the conventional laminated product, it is not necessary to bend for processing of the exposed cross section of the end portion in the longitudinal direction, and it can be used as an edge material or the like as it is by simply forming.
Furthermore, the decorative material of the present invention can change the surface performance by the resin on the upper and lower surfaces.
A decorative material having such a shape in which decorative paper or the like is encased in a resin has not been obtained in the past and has been made for the first time by the present invention.

Hereinafter, the present invention will be described in detail with reference to the drawings.
FIG. 1A is a cross-sectional view showing an example of a decorative material according to the present invention. A resin-containing decorative paper (2) as a decorative base material is wrapped with an upper surface layer 1 and a lower surface layer 1 ′ made of a thermoplastic resin. ing. FIG.1 (b) is another example of the decorative material of this invention, and is not a plane but an irregular shape. Here, although the decorative base material is divided | segmented, the thing of the form which bent the planar thing like Fig.1 (a) as it is may be sufficient.
The decorative material of the present invention is not limited to these shapes, and any material can be used as long as the thermoplastic resin wraps around the resin-reinforced fabric and / or the thermoplastic resin sheet that exhibits design properties. Good. For example, semi-circular or any shape that can be used as a decorative panel joint, corner, counter, door frame, window frame, baseboard, peripheral edge, CV wall material, etc. But you can.
In FIG. 1, a thermosetting resin-containing decorative paper is used as the resin-reinforced fabric.
The resin-reinforced fabric that is a decorative base is a portion that exhibits design properties in the present invention, and is encased in a transparent or translucent resin. Examples of the fabric as the decorative base material include decorative paper, natural and / or synthetic nonwoven fabric, natural and / or synthetic fiber woven fabric, and the like. As a method of resin reinforcement, the fabric may be impregnated with a resin and then dried, or a synthetic resin such as urethane resin or aminoalkyd may be applied to the surface of the paper or the like, or the resin may be mixed with paper. Specific resin-reinforced fabrics include synthetic fibers such as resin-mixed paper mixed with polyethylene terephthalate, resin-coated paper coated with a synthetic resin such as urethane resin and aminoalkyd on the surface of decorative paper, and surface of resin-impregnated decorative paper And a pre-coated paper having a top coat layer formed of a synthetic resin. These can be used singly or in combination of two or more.
The surface of natural and / or synthetic nonwoven fabric, natural and / or synthetic fiber woven or knitted fabric, and resin mixed paper is printed as necessary. Among these, it is preferable to use a resin-containing decorative paper having excellent paper-to-paper strength.

Examples of the resin-containing decorative paper include those obtained by impregnating a decorative paper for a decorative board with a resin liquid containing a thermoplastic resin or a thermosetting resin as a main component and then drying it.
Here, examples of the thermoplastic resin include acrylic resins and styrene-butadiene resins, and examples of the thermosetting resin include amino-formaldehyde resins, diallyl phthalate resins, unsaturated polyester resins, and mixtures thereof. .
These thermoplastic resins or thermosetting resins are used as a resin solution dissolved or dispersed in a mixed solvent of water and methanol, or an organic solvent. In the resin solution, 70% by weight or more in terms of solid content, preferably Is desirably contained in an amount of 80 to 100% by weight.

  Here, the amino-formaldehyde resin is an etherified product with an amino compound such as melamine, urea, benzoguanamine, acetoguanamine or the like, and an initial condensate obtained by reacting formaldehyde with a lower alcohol such as methyl alcohol or butyl alcohol. A melamine-formaldehyde resin that is modified with a reactive modifier that promotes plasticization, such as p-toluenesulfonamide, and is particularly excellent in durability.

  The unsaturated polyester resin is an unsaturated polyester, a polymerizable monomer such as styrene, orthochlorostyrene, diallyl phthalate or methyl methacrylate, an organic peroxide such as methyl ethyl ketone peroxide or benzoyl peroxide as a curing agent. Polymerization inhibitors such as hydroquinone and catechol, mold release agents such as zinc stearate, organic solvents such as toluene and acetone, and curing accelerators such as cobalt naphthenate, cobalt octenoate, cobalt acetylacetate and dimethylaniline as required In addition, a pigment for coloring may be added, and a filler may be added as necessary.

  Unsaturated polyester is obtained by condensation reaction of divalent alcohol and dibasic acid. Divalent alcohols include ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, 1,3-butylene glycol, neopentyl glycol, etc. Examples of dibasic acids include maleic acid, maleic anhydride, fumaric acid, isophthalic acid, phthalic acid, phthalic anhydride, succinic acid, and adipic acid. What is necessary is just to use what selected 1 type or more suitably and made it react by a conventional method.

By impregnating a resin liquid whose viscosity is adjusted with water, an organic solvent, or the like, the resin-reinforced fabric is strongly bonded to the thermoplastic resin enclosing it. In impregnating the resin as described above, the amount of the resin to be impregnated is preferably such that the impregnation ratio represented by the following formula (1) is 80 to 140% by weight. If it is less than 80% by weight, the interlayer strength becomes weak. On the other hand, if it exceeds 140% by weight, uniform impregnation is impossible.
Impregnation rate (% by weight) = [(resin-containing fabric weight−fabric weight) / fabric weight] × 100
......... Formula (1)

As a method of impregnating or coating these resins with a fabric such as decorative paper, in the case of impregnation, by dipping, or in the case of coating, gravure coat, gravure reverse coat, gravure offset coat, spinner coat , Roll coat, reverse roll coat, knife coat, kiss coat, wheeler coat, dip coat, solid coat by silk screen, wire bar coat, flow coat, comma coat, brush coat, spray coat and the like.
Moreover, what is necessary is just to perform drying with a hot air dryer.

In addition to the resin-reinforced fabric, a thermoplastic resin sheet can be used as the decorative base material.
As the thermoplastic resin sheet, a thermoplastic decorative sheet selected from a polyolefin-based sheet, a PVC-based sheet, an ABS-based sheet, a PMMA-based sheet, and a PET-based sheet may be used alone or in combination of two or more. it can. Such a decorative sheet is preferably a sheet or film having a thickness of 10 to 1,000 μm. More preferably, it is a thing of 50-500 micrometers.
The above sheet may be any sheet that is usually used as a decorative sheet having a surface printed or colored.
Moreover, as a decorative base material, it is possible to use a combination of two or more of the resin-reinforced fabric and the thermoplastic resin sheet.

The present invention is characterized in that the thermoplastic resin is molded so as to enclose a resin-reinforced fabric or a thermoplastic resin sheet as a decorative base material.
In this case, the thermoplastic resin that wraps the resin-reinforced fabric or the thermoplastic resin sheet is preferably composed of two layers, an upper surface layer and a lower surface layer. This is because, in the extrusion molding, when the resin-reinforced fabric wraps the thermoplastic resin sheet, it is more convenient in the extrusion molding to use the thermoplastic resin to wrap and simultaneously extrude the two layers of the upper layer and the lower layer.
Here, the thermoplastic resin used for the upper surface layer may be any transparent or translucent one, such as an acrylic resin such as a (meth) acrylic resin, a polycarbonate resin, or a PVC resin. Styrene resin such as resin, polystyrene resin, ABS resin (acrylonitrile-butadiene-styrene copolymer), AS resin (acrylonitrile-styrene copolymer), MAS [(meth) acrylic acid-acrylonitrile-styrene copolymer] , Olefin resin, PET resin and the like. In particular, an acrylic resin excellent in strength, heat resistance, and transparency is preferable. Examples of the acrylic resin include polymethyl methacrylate, methyl methacrylate-butyl acrylate copolymer, and methyl methacrylate-styrene copolymer.
These thermoplastic resins are used individually by 1 type or in combination of 2 or more types.
Further, the upper surface layer may be formed by using two or more extruders, for example, two-color molding in which both transparent and translucent are mixed. Thus, the degree of freedom of expression can be increased by using two or more types in combination.
The thermoplastic resin used for the lower layer may be any material regardless of whether it is transparent or opaque, and examples thereof include the thermoplastic resin used for the upper surface.
In the cosmetic material of the present invention thus obtained, the thickness of the thermoplastic resin to be wrapped is 100 μm or more, preferably 500 to 3000 μm, for both the upper surface layer and the lower surface layer.

In addition, the thermoplastic resin used for enveloping can manufacture a soft type thing and a hard type thing according to a use by changing the composition suitably.
In addition, this thermoplastic resin contains known plasticizers, softeners, inorganic fillers, colorants, heat stabilizers, antistatic agents, weathering stabilizers, anti-aging agents, antibacterial agents, antifungal agents, etc. It can add in the range which does not impair the effect of invention.
Furthermore, the surface performance of the upper surface layer and the lower surface layer can be changed by using different resins for the upper surface layer and the lower surface layer. For example, only the upper surface, which is the surface, can be made weatherproof, chemical resistant, soft, abrasion resistant, scratch resistant, and glossy.

  A preferable molding method is extrusion molding. In extrusion molding, when extruding a thermoplastic resin from a die, the resin-reinforced fabric or thermoplastic resin sheet as the decorative base material is wrapped and extruded. Extrusion may be performed using an apparatus conventionally used for extrusion molding of plastics. That is, a thermoplastic resin is supplied to a screw type extruder such as a ram type extruder, a single screw type extruder, a vent type extruder, etc., melted, and then extruded from a molding die. In particular, a screw extruder capable of continuous operation is more preferable.

An example of the coextrusion molding method of the present invention is shown in FIG. In the extruder of FIG. 2, 5 and 5 ′ are hoppers for the upper surface layer and the lower surface layer, respectively, and the thermoplastic resin pellets for the upper surface layer and the lower surface layer are put into the hoppers, respectively. 6 'is used to extrude the upper and lower layers simultaneously. In this case, different resins can be put in the respective extruders, and the upper surface and the lower surface can be wrapped as different resins.
At this time, the decorative base material (resin reinforced fabric) (2) wound in a roll shape is inserted into the front portion or the rear portion of the die (7), and the decorative base material is extruded and wrapped so as to be wrapped with resin. . At this time, in order to wrap the decorative base material with the thermoplastic resin, the decorative base material may be made small so as to be equal to or less than the size of the resin outlet shape of the die.
Extrusion conditions vary depending on the type of thermoplastic resin, but generally may be a cylinder temperature of 130 to 260 ° C. and an extrusion speed of about 0.2 to 5 m / min.

  According to the method of the present invention, by changing the shape of the die, it is possible to easily obtain a three-dimensional shape such as an irregular shape such as a protruding corner material or a semicircular shape by extrusion molding. This cannot be obtained by a molding method using a conventional lamination technique. Further, by putting different resins into the two extruders, it is possible to obtain molded products having different resins for the upper layer and the lower layer. As shown in FIG. 1, the decorative material obtained in this way has a portion such as decorative paper, which is a portion that expresses a design, wrapped in resin, and the appearance does not deteriorate even when the edge is trimmed. Therefore, in the conventional laminated decorative material, since the decorative paper or the like is exposed on the cross section of the end portion in the longitudinal direction, it is necessary to bend for processing of this cross section, but the decorative sheet of the present invention is molded. By simply doing, it can be used as a decorative panel joint, a corner, a counter, a door frame, a window frame, a baseboard, a surrounding edge, a dwelling unit such as a CV wall material, and a building material member.

EXAMPLES Hereinafter, although an Example is given and this invention is demonstrated in detail, this invention is not limited to these Examples.
Example 1
Resin liquid mainly composed of melamine-formaldehyde resin on wood grain decorative paper of 80 g / m ² (solution using water / methanol mixed solvent with melamine-formaldehyde resin as solvent, solid content concentration = 60 to 70% by weight) Was impregnated so that the impregnation ratio represented by the above formula 1 was about 80%, and then dried to obtain a melamine resin-impregnated decorative paper (cured paper) having a thickness of about 0.2 mm.
Next, (1) pellets of transparent acrylic resin (Kuraray Co., Ltd. GR-H60) and (2) pellets of acrylic resin (Kuraray Co., Ltd. GR-H24) are used as hoppers 5 and 5 of the extruder shown in FIG. The melamine resin is placed in the ′, using the extruders 6 and 6 ′, at a temperature of 200 ° C. and an extrusion speed of 0.3 m / min, so that (1) becomes the upper surface layer and (2) becomes the lower surface layer. Extruding with a rectangular die while wrapping the impregnated decorative paper, the decorative material of Example 1 was obtained. Here, the thickness of the upper surface layer was 1.5 mm, the thickness of the lower surface layer was 1.0 mm, the total thickness of the decorative material was 2.1 mm, and the width was 40 mm. This decorative material had high adhesion to the decorative paper in both the upper surface layer and the lower surface layer, and could not be removed with a cutter knife. The results are shown in Table 1.

Example 2
A cosmetic material was obtained in the same manner as in Example 1 except that a soft acrylic resin (Kuraray Co., Ltd. SA1000-CW001) was used as the pellet used for the upper surface layer. The results are shown in Table 1.

Example 3
Translucent acrylic resin formed by mixing 90 parts by weight of acrylic resin (Kuraray Co., Ltd., GR-24) as a resin used for the upper surface layer and 10 parts by weight of Mitsubishi Rayon F-410 as a translucent material. A cosmetic material was obtained in the same manner as in Example 1 except that a polypropylene sheet (Dai Nippon Printing Co., Ltd., PPZ3PNS Pure Natural) was used as the decorative base material. The results are shown in Table 1.

Example 4
Surface layer so that the transparent resin used in Example 1 (Kuraray Co., Ltd. GR-H24) and the translucent acrylic resin used in Example 3 were striped with a width of 3 mm using separate single extruders. Formed. Example 1 except that ABS resin (Technopolymer Co., Ltd. ABS-130) is used for the lower layer, and polypropylene sheet (Dai Nippon Printing Co., Ltd. PPZ3PNS Pure Natural) is used as the decorative base material. A cosmetic material was obtained. The results are shown in Table 1.

Example 5
As the upper surface layer, the transparent acrylic resin pellets used in Example 1 were used, and for the lower surface layer, colored acrylic resin pellets (Kuraray Co., Ltd. GR-24, 0.5 parts by weight) were mixed with 100 parts by weight. A cosmetic material was obtained in the same manner as in Example 1 except that pelletized material was used. The results are shown in Table 1.

Comparative Example 1
A cosmetic material was obtained in the same manner as in Example 1 except that the transparent acrylic resin pellets used for the upper surface layer were not used. Since the obtained cosmetic material was not formed with an upper surface layer, the surface appearance and scratch resistance were poor. The results are shown in Table 1.

Comparative Example 2
In Example 1, it implemented similarly except not impregnating the resin liquid which has a melamine formaldehyde resin as a main component. The obtained decorative material had weak adhesion between the methyl methacrylate-styrene copolymer and the decorative paper, and could be peeled off with a cutter knife. The results are shown in Table 1.

The evaluation methods of the evaluation items in Table 1 are as follows.
Surface design
A sample having a visually high-class feeling and a smooth surface was marked with ◎, and a sample with irregularities visually confirmed was marked with Δ.
Scratch resistance
In the pencil hardness test, 1H or more was evaluated as ◎, and less than 1H was evaluated as Δ.
chemical resistance
The chemicals (disinfectant, kitchen detergent) without erosion were marked with ◎, and the presence of erosion was marked with △.
Delamination resistance
Those that could be easily peeled off with a cutter knife were indicated as x, those that could be peeled off with a cutter knife were indicated by Δ, and those that could not be peeled off were indicated as ◎.
water resistant
It was immersed in water for 24 hours, x with peeling, Δ with peeling at the end, and ◎ without peeling.
Workability
◎ means that it can be adhered with an adhesive and does not peel off.
Solvent erosion
It was immersed in an organic solvent (acetone, toluene) for 12 hours.

  According to the method of the present invention, by changing the shape of the die, a three-dimensional shape such as an irregular shape or a semicircular shape can be easily obtained by extrusion molding. The appearance of the cosmetic material obtained in this way does not deteriorate even when the edge is trimmed. Accordingly, it can be used as it is as a decorative panel joint, projecting corner, counter, door frame, window frame, skirting board, peripheral edge, CV wall material, and other building materials, and the like, simply by molding.

It is a section lineblock diagram of an example of the decorative material of the present invention. It is a schematic side view which shows an example of the manufacturing method of the decorative material of this invention. It is a cross-sectional block diagram of an example of the conventional decorative material. It is a cross-sectional block diagram of an example of the conventional decorative material.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Thermoplastic resin upper surface layer 1 'Thermoplastic resin lower surface layer 2 Cosmetic base material (resin impregnated decorative paper)
DESCRIPTION OF SYMBOLS 5 Hopper 5 'Hopper 6 Extruder 6' Extruder 7 Die 9 Cosmetics 10 Reinforced paper or olefin sheet 11 Thermoplastic resin

Claims (7)

  A decorative material comprising a resin-reinforced fabric and / or a thermoplastic resin sheet wrapped with the same or different thermoplastic resin.   The resin-reinforced fabric is a thermosetting resin-containing decorative paper, and the thermoplastic resin sheet is at least one thermoplastic makeup selected from a polyolefin sheet, a PVC sheet, an ABS sheet, a PMMA sheet, and a PET sheet. The cosmetic material according to claim 1, which is a sheet.   The encapsulating thermoplastic resin is composed of an upper surface layer and a lower surface layer, and the thermoplastic resin of the upper surface layer is transparent or translucent, acrylic resin, polycarbonate resin, PVC resin, ABS resin, AS resin, PS The cosmetic material according to claim 1 or 2, which is at least one selected from the group consisting of a resin based on resin, a MAS based resin, an olefin based resin, and a PET based resin.   The encapsulating thermoplastic resin is composed of an upper surface layer and a lower surface layer, and the thermoplastic resin of the lower surface layer is an acrylic resin, polycarbonate resin, PVC resin, ABS resin, AS resin, PS resin, MAS resin. The cosmetic material according to any one of claims 1 to 3, wherein the cosmetic material is at least one selected from the group consisting of olefin-based resins, and PET-based resins.   The method for producing a cosmetic material according to any one of claims 1 to 4, wherein the resin-reinforced fabric or the thermoplastic resin sheet is molded while being wrapped with the same or different thermoplastic resin.   The method for producing a decorative material according to claim 5, wherein the molding means is extrusion molding. The manufacturing method of Claim 5 or 6 which uses the thermosetting resin containing decorative paper which carried out the drying process after containing the resin liquid which has thermosetting resin as a main component in decorative paper as a resin reinforced fabric.

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