JP5648735B2 - Decorative sheet and method for producing decorative plate - Google Patents

Description

  The present invention relates to a decorative sheet and a method for producing a decorative board.

  The decorative sheet is used by sticking it on the surface of a wooden board, a plastic board or the like for the purpose of surface protection, decoration, and the like. And the decorative board obtained by this is used for various building materials, furniture, etc.

  The decorative sheet is required to have, for example, scratch resistance and contamination resistance.

  However, the conventional decorative sheet having scratch resistance and stain resistance generally has a smooth surface. Therefore, when it is used for flooring, flooring, etc., it is slippery when a person walks and there is a risk of falling.

  Then, the flooring which added the thermoplastic polymer and the hard particle | grain to the surface layer is proposed for the purpose of providing surface slip resistance and stain resistance to a decorative sheet (patent documents 1 and 2).

JP 2004-225456 A JP 2001-254504 A

  However, when the flooring materials (decorative materials) of Patent Documents 1 and 2 are used for lightweight objects such as dogs and cats, there is a problem that the slip resistance is poor. Moreover, the above-described flooring material has a problem in that the scratch resistance is inferior.

  Therefore, there is a demand for the development of a cosmetic material that is excellent in slip resistance even when the object is light, and has excellent stain resistance and scratch resistance.

  The main object of the present invention is to provide a decorative sheet that is excellent in slip resistance even when the object is light, and has excellent stain resistance and scratch resistance.

  As a result of intensive studies, the present inventor has found that a decorative sheet having a surface protective layer on the outermost surface, and the above object can be achieved when the surface of the surface protective layer satisfies a specific condition. It came to complete.

That is, the present invention relates to the following decorative sheet and decorative plate.
1. A decorative sheet having a surface protective layer on the outermost surface,
(1) The surface protective layer has irregularities, and the average interval Sm between the irregularities is 180 μm to 400 μm,
(2) The maximum height Rz of the surface protective layer is 20 to 50 μm, and (3) the static friction coefficient of the surface protective layer is 0.37 or more.
A decorative sheet characterized by that.
2. The decorative sheet according to Item 1, wherein the surface protective layer has a ten-point average roughness Rzjis of 10 μm or more.
3. Item 3. The decorative sheet according to Item 1 or 2, wherein the surface protective layer is an ionizing radiation curable resin layer formed by resin crosslinking of an ionizing radiation curable resin.
4). Item 4. The decorative sheet according to any one of Items 1 to 3, wherein the surface protective layer contains a filler.
5. Item 5. The decorative sheet according to any one of Items 1 to 4, which has any one of a pattern layer, a transparent thermoplastic resin layer, and a primer layer on a substrate sheet.
6). 6. A decorative board in which the decorative sheet is laminated on an adherend so that the surface protective layer of the decorative sheet according to any one of Items 1 to 5 becomes an outermost surface layer.

Features of the decorative sheet of the present invention The decorative sheet of the present invention is a decorative sheet having a surface protective layer on the outermost surface,
(1) The surface protective layer has irregularities, and the average interval Sm between the irregularities is 180 μm to 400 μm,
(2) The maximum height Rz of the surface protective layer is 20 to 50 μm, and (3) the static friction coefficient of the surface protective layer is 0.37 or more. Since the decorative sheet of the present invention has the above-described characteristics, the object is excellent in slip resistance even in a light object, and has excellent stain resistance, scratch resistance, weather resistance, and design properties.

  As for the decorative sheet of this invention, the average space | interval (Sm) of the unevenness | corrugation of a surface protective layer is 180 micrometers-400 micrometers. More preferably, it is 250-350 micrometers.

  The Sm is an index indicating the interval between the irregularities of the surface protective layer, and is extracted from the roughness curve of the surface protective layer by a reference length L in the direction of the average line, one peak and one valley adjacent thereto. Is obtained by calculating the sum of the lengths of the average lines corresponding to. When Sm is small, the surface is fine (the unevenness is dense).

  In the decorative sheet of the present invention, the maximum height (Rz) of the surface protective layer is 20 to 50 μm. More preferably, it is 20-30 micrometers.

  Rz is an index indicating the maximum height of the surface protective layer, and is extracted from the roughness curve of the surface protective layer by a reference length L in the direction of the average line, and the highest peak from the average line of the extracted portion. This represents the sum of the height Ha up to and the depth Hb up to the lowest valley bottom (Rz = Ha + Hb).

  In the decorative sheet of the present invention, the ten-point average roughness (Rzjis) of the surface protective layer is preferably 10 μm or more, and more preferably 20 to 30 μm.

  The Rz is an index indicating the roughness of the surface protective layer. From the roughness curve of the surface protective layer, the reference length L is extracted in the direction of the average line, and the highest peak is obtained from the average line of the extracted portion. It is the sum of the average value of the absolute values of the altitude at the top of the mountain from the first to the fifth and the average value of the absolute values of the altitude of the bottom of the valley from the lowest to the fifth.

  The above-mentioned Sm is based on JIS B0601 (1994), and Rz and Rzjis are based on JIS B0601 (2001) surface roughness standards.

  The above-described Sm, Rz, and Rzjis are all obtained by measuring the surface roughness. The surface roughness can be measured using a surface roughness shape measuring instrument, for example, Surfcom 120A (manufactured by Tokyo Seimitsu Co., Ltd.).

  In the decorative sheet of the present invention, the static friction coefficient of the surface protective layer is 0.37 or more. More preferably, it is 0.45-0.55.

  Moreover, it is preferable that the dynamic friction coefficient of a surface protective layer is 0.35 or more, and it is more preferable that it is 0.4-0.5.

  The static friction coefficient and the dynamic friction coefficient can be measured in accordance with JIS K 7125.

  The Sm, Rz, Rzjis, static friction coefficient, and dynamic friction coefficient of the surface protective layer can be appropriately set by containing a filler to be described later, embossing, or the like.

  The thickness of the surface protective layer is not particularly limited as long as it does not interfere with the effects of the present invention, but is preferably 1 to 200 μm, more preferably 1 to 100 μm, and even more preferably 5 to 50 μm.

  In the present specification, the thickness of the surface protective layer refers to the length from the bottom of the resin forming the surface protective layer to the smooth portion where no convex portion is formed by the filler described later. Moreover, in this specification, the thickness of the convex part formed with a filler means the length from the smooth part of the surface protective layer in which the convex part is not formed with the filler to the top part formed with the filler. Each thickness described above is described in detail in FIG.

  In the present invention, Sm, Rz, Rzjis, static friction coefficient, and dynamic friction coefficient of the surface protective layer can be appropriately set by containing a specific filler and / or performing a specific embossing.

Layer structure of the decorative sheet of the present invention The decorative sheet of the present invention only needs to have the surface protective layer on the outermost surface, and the specific structure may be appropriately set according to the use of the decorative sheet. For example, a decorative sheet having any one of a pattern layer, a transparent adhesive layer, a transparent thermoplastic resin layer, and a primer layer on a base sheet is mentioned.

  Hereinafter, regarding the decorative sheet of the present invention, on a base sheet, a decorative sheet having a pattern layer, a transparent adhesive layer, a transparent thermoplastic resin layer, a primer layer and the surface protective layer in this order as a representative example I will explain it.

(Base material sheet)
The substrate sheet has a pattern layer or the like sequentially laminated on its surface (front surface).

  As the base sheet, for example, a sheet (film) formed of a thermoplastic resin is suitable. Specifically, polyvinyl chloride, polyethylene terephthalate, polybutylene terephthalate, polyamide, polyethylene, polypropylene, polycarbonate, polyethylene naphthalate, ethylene / vinyl acetate copolymer, ethylene / acrylic acid copolymer, ethylene / acrylic acid ester copolymer Examples include polymers, ionomers, acrylic esters, and methacrylic esters. The said base material sheet is formed by using these resin individually or in combination of 2 or more types.

The base material sheet may be colored. In this case, a coloring material (pigment or dye) can be added to the above thermoplastic resin for coloring. As the colorant, for example, inorganic pigments such as titanium dioxide, carbon black and iron oxide, organic pigments such as phthalocyanine blue, and various dyes can be used. These are known or commercially available ones
Species or two or more can be selected. Further, the addition amount of the colorant may be appropriately set according to the desired color tone.

  The base sheet contains various additives such as fillers, matting agents, foaming agents, flame retardants, lubricants, antistatic agents, antioxidants, UV absorbers, and light stabilizers as necessary. It may be.

  Although the thickness of a base material sheet can be suitably set with the use of a final product, a usage method, etc., generally 20-300 micrometers is preferable.

  If necessary, the base sheet may be subjected to corona discharge treatment on the surface (front surface) in order to enhance the adhesion of the ink for forming the pattern layer. What is necessary is just to implement the method and conditions of a corona discharge process according to a well-known method. Moreover, you may give a corona discharge process to the back surface of a base material sheet, and may form a back surface primer layer as needed.

  Although not shown, the decorative sheet of the present invention may be formed by laminating a polyester-based backer material on the back primer layer side of the base material sheet with a transparent adhesive layer adhesive described later by a dry lamination method. When the back primer layer is not provided, a hard polyolefin-based backer material may be laminated on the back side of the thermoplastic resin base sheet by an extrusion laminating method or the like, and the back primer layer may be provided on the back side of the backer material.

(Pattern pattern layer)
The design pattern layer imparts a desired design (design) to the decorative sheet, and the type of the design is not limited. For example, a wood grain pattern, a leather pattern, a stone pattern, a grain pattern, a tiled pattern, a brickwork pattern, a cloth pattern, a geometric figure, a character, a symbol, an abstract pattern, and the like can be given.

  The method for forming the pattern layer is not particularly limited. For example, an ink obtained by dissolving (or dispersing) a known colorant (dye or pigment) in a solvent (or dispersion medium) together with a binder resin is used. What is necessary is just to form on the base-material sheet | seat surface by the printing method. As the ink, an aqueous composition can be used from the viewpoint of reducing the VOC of the decorative sheet.

  Examples of the colorant include inorganic pigments such as carbon black, titanium white, zinc white, dial, bitumen, and cadmium red; azo pigments, lake pigments, anthraquinone pigments, quinacridone pigments, phthalocyanine pigments, isoindolinone pigments, dioxazine pigments. Organic pigments such as aluminum powder, metal powder pigments such as bronze powder, pearlescent pigments such as titanium oxide-coated mica and bismuth oxide chloride; fluorescent pigments; These colorants can be used alone or in admixture of two or more. These colorants may be used together with fillers such as silica, extender pigments such as organic beads, neutralizing agents, surfactants and the like.

  As binder resin, in addition to polyester urethane resin treated with hydrophilicity, polyester, polyacrylate, polyvinyl acetate, polybutadiene, polyvinyl chloride, chlorinated polypropylene, polyethylene, polystyrene, polystyrene-acrylate copolymer, rosin derivative Alcohol adducts of styrene-maleic anhydride copolymers, cellulose resins, and the like can also be used in combination. More specifically, for example, polyacrylamide resins, poly (meth) acrylic resins, polyethylene oxide resins, poly N-vinyl pyrrolidone resins, water-soluble polyester resins, water-soluble polyamide resins, water-soluble amino acids. Also usable are water-based resins, water-soluble phenolic resins, other water-soluble synthetic resins; water-soluble natural polymers such as polynucleotides, polypeptides, polysaccharides, and the like. Also, for example, natural rubber, synthetic rubber, polyvinyl acetate resin, (meth) acrylic resin, polyvinyl chloride resin, polyurethane-polyacrylic resin, etc. modified or a mixture of the above natural rubber, etc. Resin can also be used. The binder resin can be used alone or in combination of two or more.

  The pattern layer may be formed by a known printing method such as a gravure printing method, an offset printing method, a screen printing method, a flexographic printing method, an electrostatic printing method, or an ink jet printing method.

  The thickness of the pattern layer is not particularly limited and can be set as appropriate according to product characteristics. The layer thickness at the time of coating is about 1 to 15 μm, and the layer thickness after drying is about 0.1 to 10 μm.

(Colored hiding layer)
In the decorative sheet of the present invention, a colored concealing layer may be further formed between the base sheet and the pattern layer.

  The colored concealment layer only needs to conceal the ground color of the adherend when the decorative sheet and the adherend are joined, and is usually formed so as to cover the base sheet.

  The known printing method can be used for forming the colored concealing layer. Moreover, the ink used for formation of the said pattern pattern layer can be used as it is.

  The known printing method can be used for forming the colored concealing layer.

The coating amount is desirably in the range of ^{2 to} 30 g / m2.

  The thickness of the colored masking layer is usually about 0.1 to 20 μm, preferably about 1 to 10 μm.

(Transparent adhesive layer)
In order to improve the adhesion between the transparent thermoplastic resin layer and the pattern layer described later, a transparent adhesive layer may be formed. The transparent adhesive layer is not particularly limited as long as it does not impair the design properties, and includes any of colorless and transparent, colored and transparent, translucent and the like.

  It does not specifically limit as an adhesive agent, A well-known adhesive agent can be used in the field of a decorative sheet.

  Examples of known adhesives in the field of decorative sheets include thermoplastic resins such as polyamide resins, acrylic resins and vinyl acetate resins, and thermosetting resins such as urethane resins. These colorants are used alone or in combination of two or more. Further, a two-component curable polyurethane resin or polyester resin using isocyanate as a curing agent can also be applied.

  The known printing method can be used for forming the transparent adhesive layer.

  Although the thickness of a transparent adhesive bond layer is not specifically limited, The thickness after drying is about 0.1-30 micrometers, Preferably it is about 1-20 micrometers.

(Transparent thermoplastic resin layer)
A transparent thermoplastic resin layer is formed on the transparent adhesive layer.

The transparent thermoplastic resin layer is not particularly limited as long as it is transparent, and includes any of colorless and transparent, colored and transparent, and translucent. Examples of the resin constituting the transparent thermoplastic resin layer include polyethylene terephthalate, polybutylene terephthalate, polyamide, polyethylene, polypropylene, ethylene / vinyl acetate copolymer, ethylene / acrylic acid copolymer, and ethylene / acrylic acid ester. Examples include copolymers, ionomers, polymethylpentene, acrylic acid esters, methacrylic acid esters, polycarbonates, and cellulose triacetates. These resins are used alone or in combination of two or more.

  Preferably, a polyolefin resin typified by polypropylene resin is used. Therefore, when using polyolefin-type resin as a transparent thermoplastic resin layer, the various polyolefin-type resin quoted as what comprises a base material sheet can be used.

  The transparent thermoplastic resin layer may be colored as long as it has transparency, but it is desirable not to add a colorant.

  The method for forming the transparent thermoplastic resin layer is not limited, for example, a method in which a preformed sheet or film is laminated to an adjacent layer, a resin composition that can form a transparent thermoplastic resin layer is melt-extruded, and the adjacent layer is adjacent There is a method of laminating together with the layer to be performed. Examples of the laminating method include a laminating method by a dry laminating method.

  The thickness of the transparent thermoplastic resin layer is usually about 20 to 200 μm, but may exceed the above range depending on the use of the decorative sheet.

(Surface protective layer)
The surface protective layer is preferably transparent when a pattern layer is formed in the lower layer.

  The surface protective layer is preferably an ionizing radiation curable resin layer formed by resin crosslinking of an ionizing radiation curable resin from the viewpoint of scratch resistance and the like. The ionizing radiation curable resin refers to a resin that crosslinks and cures when irradiated with ultraviolet rays, electron beams, or the like.

  As the ionizing radiation curable resin, a known or commercially available product can be used. Specifically, a composition containing at least one of a prepolymer, an oligomer and a monomer having a polymerizable unsaturated bond or an epoxy group in the molecule is used.

Examples of the prepolymer or oligomer include polyester methacrylate, polyether methacrylate, urethane methacrylate, polyol methacrylate, methacrylates such as melamine methacrylate, polyester acrylate, polyether acrylate, urethane acrylate, polyol acrylate, There are acrylates such as melamine acrylate. As the urethane (meth) acrylate, for example, a urethane acrylate oligomer according to Japanese Patent Application Laid-Open No. 2007-118596 may be used.

  Monomers include styrene monomers such as styrene and α-methylstyrene, acrylic acid such as methyl acrylate, 2-ethylhexyl acrylate, methoxyethyl acrylate, butoxyethyl acrylate, butyl acrylate, and phenyl acrylate. Examples include esters, methyl methacrylate, ethyl methacrylate, propyl methacrylate, ethoxymethyl methacrylate, phenyl methacrylate, and lauryl methacrylate.

  As substituted amino alcohol esters of unsaturated acids, acrylic acid-2- (N, N-diethylamino) ethyl, methacrylic acid-2- (N, N-diethylamino) ethyl, acrylic acid-2- (N, N -Substituted amino alcohol esters of unsaturated acids such as -dibenzylamino) methyl and acrylic acid-2- (N, N-diethylamino) propyl.

  In addition, unsaturated carboxylic acid amides such as acrylamide and methacrylamide, ethylene glycol diacrylate, propylene glycol diacrylate, neobenzyl glycol diacrylate, 1,6-hexanediol diacrylate, ethyl carbitol acrylate, diethylene glycol diacrylate, Multifunctional materials such as triethylene glycol diacrylate, dipropylene glycol diacrylate, ethylene glycol acrylate, diethylene glycol dimethacrylate, polyethylene glycol diacrylate, trimethylolpropane triacrylate, pentaerythritol hexaacrylate, dipentaerythritol hexamethacrylate; Trimethylolpropane trithioglycolate, Trime Trimethylolpropane tri thio propiolate, there is a polythiol compound having two or more thiol groups in the molecule, such as dipentaerythritol tetra thioglycolic.

  About the resin of the said illustration, 1 type (s) or 2 or more types can be used together.

(Filler)
Examples of the filler contained in the surface protective layer include inorganic particles such as silica and silicone resin (powder, beads); acrylic, crosslinked alkyl, crosslinked styrene, inzoguanamine resin, urea-formaldehyde resin, phenol resin, polyethylene, nylon Examples thereof include organic material powders and beads. The filler is preferably at least one selected from the group consisting of silica and acrylic beads. In addition, the said filler can be used 1 type, or 2 or more types.

  The average particle diameter of the filler is at least equal to or greater than the thickness of the surface protective layer, and is preferably less than “thickness of the surface protective layer + 40 μm” in order to maintain scratch resistance, which will be described later, The following is more preferable. When the average particle diameter of the filler is equal to the thickness of the surface protective layer, the surface protective layer has no convex portion formed by the filler (that is, the thickness of the convex portion formed by the filler is 0 μm). In addition, there may be a convex portion formed by the filler.

  About the average particle diameter of a filler, it can measure by well-known methods, such as a laser diffraction method, a Coulter counter method, and a sedimentation method. The average particle diameter means a particle diameter (D50) corresponding to a cumulative frequency of 50%.

  The filler content in the surface protective layer is preferably 3 to 50 parts by weight and more preferably 5 to 30 parts by weight with respect to 100 parts by weight of the resin component forming the surface protective layer. preferable.

  In the decorative sheet of the present invention, the filler described above is preferably present inside the surface protective layer as long as the effects of the present invention are not hindered. The smaller the proportion of the filler protruding from the surface of the surface protective layer, the better the surface performance such as scratch resistance.

  In addition to the fillers described above, the surface protective layer has an organic resin such as inorganic particles such as α-alumina, chromium oxide, iron oxide and diamond, and synthetic resin beads such as crosslinked acrylic for the purpose of further improving the scratch resistance. Powders such as particles may be added. Various particle shapes of these powders are used. In particular, when a spherical shape or a shape similar to the spherical shape is used, the scratch resistance is good. The average particle diameter of the powder is preferably equal to or less than the coating thickness (surface protective layer thickness), and the addition amount is preferably 1 to 30 parts by weight with respect to 100 parts by weight of the resin component. One or two or more of the powders described above can be used.

In addition to the above powder, the surface protective layer may use a matting material for the purpose of further enhancing the matting effect (matting) of the surface.

  Matte materials include silica, calcium silicate, aluminum silicate, magnesium silicate, kaolin, mica, talc, and other inorganic pigments; titanium dioxide, calcium carbonate, barium carbonate, and other inorganic pigments; polyurethane, polystyrene, polyamide, poly And organic pigments such as vinyl chloride and acrylic fine polymer particles. Among these, silica is preferable from the viewpoint that the matting effect per weight of the matting material is high. In addition, the said mat | matte material can be used 1 type, or 2 or more types.

  The average particle size of the matte material is at least less than the thickness of the surface protective layer.

And the matting material, when adding the filler simultaneously in the surface protective layer, the average particle size of the filler (d _f), the average particle diameter of the matting material (d _m), and the thickness of the coating film (surface protection relationship layer thickness (D)) is _{0 <d m <D ≦ d} f.

  Here, the preferable specific aspect regarding the average particle diameter of a filler, the average particle diameter of a matting material, and the thickness of a surface protective layer (coating film) is shown below. For example, when the thickness of the surface protective layer is 5 μm, the average particle size of the filler is preferably 6 to 10 μm, and when the matte material is also contained, the average particle size of the matte material is preferably 1 to 4 μm. When the thickness of the surface protective layer is 15 μm, the average particle size of the filler is preferably 16 to 54 μm, and when the matte material is also contained, the average particle size of the matte material is preferably 1 to 14 μm. When the thickness of the surface protective layer is 50 μm, the average particle size of the filler is preferably 51 to 89 μm, and when the matte material is also contained, the average particle size of the matte material is preferably 1 to 49 μm.

The specific surface area of the matting material is usually ^{50 m} 2 / g or more, 50~350m ² / g are preferred.

  The addition amount of the matting material is usually 20 parts by weight or less, preferably 1 to 20 parts by weight, and more preferably 5 to 15 parts by weight with respect to 100 parts by weight of the resin component.

  Further, in order to improve the weather resistance, it is preferable to add a UV absorber such as benzotriazole, benzophenone, salicylate or triazine to the surface protective layer. When adding an ultraviolet absorber, the protective layer is cured by irradiating an electron beam. Further, when the resin layer is cured by irradiating with ultraviolet rays, as photopolymerization initiators, acetophenones, benzophenones, Michler benzoylbenzoate, α-amino oxime ester, tetramethylthiuram monosulfide, thioxanthones, aromatic As photopolymerization accelerators (sensitizers) such as diazonium salts, aromatic sulfonium salts, metallocenes, n-butylamine, triethylamine, tri-n-butylphosphine and the like are used.

  In addition, an antibacterial agent may be added to the surface protective layer in order to impart antibacterial properties. Antibacterial agents include inorganic antibacterial agents and organic antibacterial agents. In particular, inorganic antibacterial agents are desirable because they are generally safer than organic antibacterial agents and are excellent in durability and heat resistance. Inorganic antibacterial agents are those in which antibacterial metals such as silver, copper and zinc are supported on various inorganic carriers. The addition amount of the antibacterial agent is preferably 0.1 to 10 parts by weight with respect to 100 parts by weight of the resin component.

  In addition, the surface protective layer may contain various additives such as colorants such as solvents, dyes and pigments, fillers such as gloss adjusters and extenders, antifoaming agents, leveling agents, and thixotropy imparting agents as necessary. Can be added.

About the formation method of the surface protection layer by ionizing radiation curable resin, a well-known method may be followed. For example, a composition (coating material) containing an ionizing radiation curable resin may be prepared and applied by a known coating method such as a gravure coating method or a roll coating method. The coating amount of the composition in this case is not particularly limited, and may be set as appropriate so that the thickness of the surface protective layer falls within the above range.

  After application, the formed coating film is irradiated with ionizing radiation. Ionizing radiation means an electromagnetic wave or charged particle beam having an energy quantum capable of polymerizing and crosslinking molecules, such as visible light, ultraviolet light (near ultraviolet light, vacuum ultraviolet light, etc.), X-ray, electron beam, ion beam, etc. There is. In particular, ultraviolet rays, electron beams, and the like can be used as ionizing radiation. In particular, the surface protective layer is preferably a layer formed by irradiating the coating film containing the ionizing radiation curable resin with an electron beam. By irradiating the electron beam, a surface protective layer uniformly crosslinked with resin can be obtained with certainty. Moreover, when the resin is crosslinked by electron beam irradiation, the resin can be stably crosslinked and cured without using a photopolymerization initiator, and unlike the resin crosslinking by UV irradiation, the curing reaction rate is influenced by temperature. This is advantageous in that it does not receive much.

  As the ultraviolet light source, a light source such as an ultra-high pressure mercury lamp, a high pressure mercury lamp, a low pressure mercury lamp, a carbon arc lamp, a black light fluorescent lamp, a metal halide lamp can be used. As the wavelength of the ultraviolet light, a wavelength range of about 190 to 380 nm can be used.

  As the electron beam source, various electron beam accelerators such as a cockcroft-wald type, a bandegraft type, a resonant transformer type, an insulating core transformer type, a linear type, a dynamitron type, and a high frequency type can be used. The acceleration voltage of the electron beam is generally about 100 to 1000 keV, preferably about 100 to 300 keV. The irradiation amount of the electron beam is usually about 2 to 15 Mrad.

(Primer layer)
By providing the primer layer, the surface protective layer can be easily formed. The primer layer is not particularly limited as long as it is transparent, and includes any of colorless and transparent, colored and translucent.

  The primer layer can be formed by applying a known or commercially available primer agent on the transparent thermoplastic resin layer. In particular, the primer layer is preferably a layer formed by crosslinking a resin. Examples of the primer agent for forming such a layer include a urethane resin primer agent made of an acrylic-modified urethane resin (acrylic urethane resin), a resin primer agent made of an acrylic and urethane block copolymer, and the like. Is mentioned. These primer agents are used alone or in combination of two or more.

The primer layer may contain silica as a matting agent. The content of silica in the primer agent is preferably 0.1 to 50 parts by weight with respect to 100 parts by weight of the resin component,
10-40 weight part is more preferable.

  Furthermore, you may make a primer agent contain a well-known additive as needed. For example, the adhesion between the transparent thermoplastic resin layer and the surface protective layer can be further improved by adding a hexamethylene diisocyanate curing agent to the primer agent.

  For the formation of the primer layer, the above known methods can be used. For example, a method similar to the method of forming the surface protective layer using the ionizing radiation curable resin can be employed.

The thickness of the primer layer is not particularly limited, but is usually about 0.1 to 100 μm, preferably about 0.5 to 15 μm.

  Moreover, you may add various weathering agents, such as a ultraviolet absorber and a light stabilizer, to a primer layer.

Manufacturing method of decorative sheet The decorative sheet of the present invention is obtained by having at least the above-mentioned surface protective layer on the outermost surface. For example, it is obtained by laminating a pattern layer, a transparent adhesive layer, a transparent thermoplastic resin layer, and a primer layer on a base sheet, and then forming a surface protective layer on the outermost surface.

  Moreover, when embossing of a decorative sheet is given, it may be after forming a surface protective layer, and may be before forming a surface protective layer. For example, as specific embodiments, 1) a pattern layer, a transparent resin layer, and a primer layer may be sequentially formed on a base sheet, and then a surface protective layer may be formed and finally embossed. Further, as another specific embodiment, 2) a pattern layer, a transparent resin layer, and a primer layer may be sequentially formed on the substrate sheet, followed by embossing, and finally a surface protective layer may be formed. In addition, as another specific embodiment, 3) a pattern layer and a transparent resin layer are formed on the base sheet in this order, followed by embossing, then a primer layer is provided, and finally a surface protective layer is formed. May be. When adjusting the Sm, Rz, Rzjis, static friction coefficient and dynamic friction coefficient of the surface protective layer by embossing, it is preferable to perform embossing after forming the surface protective layer.

For the embossing, a known embossed plate is used, and for example, the uneven pattern may be transferred to the pattern printing surface side of the decorative sheet at a sheet temperature of 120 to 160 ° C. and a pressure of 10 to 40 kg / cm ² .

  When performing wiping processing, as described in Japanese Patent Publication No. 58-14312, etc., after applying colored ink on the concavo-convex pattern, wiping is performed, and the concave portion of the concavo-convex pattern is filled with the colored ink. By doing.

  In addition, the said synthetic resin backer material can be formed by extruding molten resin with respect to the base material sheet back surface of the decorative sheet in which the surface protective layer was formed.

Decorative plate The decorative plate of the present invention is formed by laminating the decorative sheet on an adherend such that the surface protective layer of the decorative sheet is the outermost surface layer.

  The adherend is not limited, and the same materials as known decorative sheets can be used. For example, a wood material, a metal, ceramics, plastics, glass, etc. are mentioned. In particular, the decorative sheet of the present invention can be suitably used for a wood material. Specifically, wood materials include veneer, wood veneer, wood plywood, particle board, medium density fiberboard (MDF) made from various materials such as cedar, firewood, firewood, pine, lawan, teak, and melapie. ) And the like.

  The lamination method is not limited. For example, a method of sticking a decorative sheet to an adherend with an adhesive or the like can be employed. What is necessary is just to select an adhesive agent suitably from well-known adhesive agents according to the kind etc. of to-be-adhered material. Examples thereof include polyvinyl acetate, polyvinyl chloride, vinyl chloride / vinyl acetate copolymer, ethylene / acrylic acid copolymer, ionomer, butadiene / acrylonitrile rubber, neoprene rubber, natural rubber and the like. These adhesives are used alone or in combination of two or more.

The decorative board manufactured in this way is, for example, interior decoration materials for buildings such as walls, ceilings and floors, surface decorative boards for furniture such as window frames, doors and handrails, furniture or light electrical appliances, cabinets such as OA equipment. It can be used for a surface decorative board. In particular, the decorative board of the present invention can be suitably used as a floor decorative material.

  The decorative sheet of the present invention is excellent in slip resistance even when the object is light, and has excellent stain resistance, scratch resistance, weather resistance and design. Therefore, the decorative board laminated with the decorative sheet of the present invention can be used for various building materials, furniture and the like. In particular, the decorative board of the present invention can be suitably used as a decorative material for floors because of its excellent scratch resistance, anti-slip property and stain resistance.

FIG. 1 is a cross-sectional view of the decorative sheet of the present invention. FIG. 2 is a conceptual diagram (cross-sectional view) of a layer structure of a decorative sheet produced in the example. FIG. 3 shows the measurement results of the surface roughness of the decorative sheet produced in Example 2. Vertical scale: 20 μm / 10 mm, Horizontal scale: 500 μm / 10 mm FIG. 4 shows the measurement results of the surface roughness of the decorative sheet produced in Example 4. Vertical scale: 20 μm / 10 mm, Horizontal scale: 500 μm / 10 mm FIG. 5 shows the measurement results of the surface roughness of the decorative sheet produced in Example 5. Vertical scale: 20 μm / 10 mm, Horizontal scale: 500 μm / 10 mm FIG. 6 shows the measurement results of the surface roughness of the decorative sheet produced in Example 6. Vertical scale: 20 μm / 10 mm, Horizontal scale: 500 μm / 10 mm FIG. 7 shows the measurement results of the surface roughness of the decorative sheet produced in Example 7. Vertical scale: 20 μm / 10 mm, Horizontal scale: 500 μm / 10 mm FIG. 8 shows the measurement results of the surface roughness of the decorative sheet produced in Comparative Example 1. Vertical scale: 20 μm / 10 mm, Horizontal scale: 500 μm / 10 mm FIG. 9 shows the results of measuring the surface roughness of the decorative sheet produced in Comparative Example 2. Vertical scale: 20 μm / 10 mm, Horizontal scale: 500 μm / 10 mm FIG. 10 shows the measurement results of the surface roughness of the decorative sheet produced in Comparative Example 3. Vertical scale: 20 μm / 10 mm, Horizontal scale: 500 μm / 10 mm FIG. 11 shows the measurement results of the surface roughness of the decorative sheet produced in Comparative Example 4. Vertical scale: 20 μm / 10 mm, Horizontal scale: 500 μm / 10 mm

  Hereinafter, the present invention will be described in more detail with reference to examples and comparative examples. However, the present invention is not limited to the examples.

Example 1
A decorative sheet having the structure shown in FIG. 2 was produced by the following method.

  After performing corona discharge treatment on the front and back surfaces of the base sheet made of a colored polypropylene film having a thickness of 60 μm, a gravure printing method using a colored ink having an acrylic resin as a binder resin on the base sheet, A 4 μm thick grain pattern layer was formed. Also, a thickness of 2 μm is obtained by a gravure printing method using a resin obtained by adding 5 parts by weight of hexamethylene diisocyanate to 100 parts by weight of acrylic urethane resin and nitrified cotton resin on the surface opposite to the pattern layer of the base sheet. The back surface primer layer was formed.

  Next, a sheet of polypropylene resin was laminated on the pattern layer by extrusion lamination to form a transparent thermoplastic resin layer having a thickness of 80 μm.

On the surface of the transparent thermoplastic resin layer, acrylic urethane resin, silica (30 parts by weight with respect to 100 parts by weight of acrylic urethane resin), and hexamethylene diisocyanate curing agent (with respect to 100 parts by weight of acrylic urethane resin) A primer layer having a thickness of 1 μm was formed by a gravure printing method using a resin composition comprising 20 parts by weight).

The embossing of the decorative sheet formed a fine grained embossed shape under the conditions of a sheet temperature of 120 ° C. to 160 ° C. and a pressure of 10 to 40 kg / cm ² .

  Furthermore, on the primer layer, a resin composition comprising a urethane acrylate oligomer (ionizing radiation curable resin) and silica having an average particle size of 40 μm (5 parts by weight with respect to 100 parts by weight of the urethane acrylate oligomer) is applied and dried. Thus, an uncured coating film was formed.

  Thereafter, in an environment having an oxygen concentration of 200 ppm or less, the uncured resin layer was irradiated with an electron beam under conditions of an acceleration voltage of 125 KeV and 5 Mrad to cure the resin, thereby forming a surface protective layer (layer thickness: 15 μm).

Example 2
A decorative sheet was prepared in the same manner as in Example 1 except that silica having an average particle diameter of 20 μm was used as the silica in the surface protective layer.

Example 3
A decorative sheet was produced in the same manner as in Example 2 except that the content of silica in the surface protective layer was 30 parts by weight with respect to 100 parts by weight of the urethane acrylate oligomer.

Example 4
A decorative sheet was prepared in the same manner as in Example 1 except that acrylic beads (average particle size of 40 μm) were used as the filler in the surface protective layer instead of silica.

Example 5
First, by the same method as in Example 1, a laminate in which a back primer, a base sheet, a pattern layer, a transparent thermoplastic resin layer, and a primer layer were sequentially laminated was formed. Thereafter, on the primer layer, a urethane acrylate oligomer (ionizing radiation curable resin) and silica having an average particle diameter of 11 μm and a specific surface area of 300 g / cm ² (10 parts by weight with respect to 100 parts by weight of the urethane acrylate oligomer) are formed. The resin composition was applied and dried to form an uncured coating film.

  Thereafter, in an environment having an oxygen concentration of 200 ppm or less, the uncured resin layer was irradiated with an electron beam under conditions of an acceleration voltage of 125 KeV and 5 Mrad to cure the resin, thereby forming a surface protective layer (layer thickness: 15 μm).

Furthermore, the decorative sheet of the present invention was produced by embossing the sheet on which the surface protective layer was formed. The embossed shape is coarser than the fine grained tone formed in Examples 1 to 4, and finer than the coarse grained tone formed in Comparative Example 1 described later, and has a medium roughness. Grained. Moreover, the embossing was performed from the surface protective layer side, and the sheet temperature was 120 to 160 ° C. and the pressure was 10 to 40 kg / cm ² .

Example 6
Except for containing silica having an average particle diameter of 11 μm and a specific surface area of 300 g / cm ^{2 in} the resin for forming the surface protective layer so as to be 10 parts by weight with respect to 100 parts by weight of the urethane acrylate oligomer, the same as in Example 2. A decorative sheet was prepared by the method described above.

Example 7
A decorative sheet was produced in the same manner as in Example 6 except that the embossed shape was changed to a coarse grained tone instead of a fine grained tone.

Comparative Example 1
A decorative sheet was produced in the same manner as in Example 1 except that the embossed shape was rough and the filler in the surface protective layer was not used.

Comparative Example 2
A decorative sheet was prepared in the same manner as in Example 1 except that the filler in the surface protective layer was not used.

Comparative Example 3
A decorative sheet was prepared in the same manner as in Example 1 except that acrylic beads (average particle diameter of 50 μm) were used as the filler in the surface protective layer instead of silica.

Comparative Example 4
A decorative sheet was prepared in the same manner as in Example 2 except that the content of silica in the surface protective layer was 2 parts by weight with respect to 100 parts by weight of the urethane acrylate oligomer.

Comparative Example 5
Comparative Example 2 except that silica having an average particle size of 11 μm and a specific surface area of 300 g / cm ² is contained in the resin for forming the surface protective layer so as to be 10 parts by weight with respect to 100 parts by weight of the urethane acrylate oligomer. A decorative sheet was prepared by the method described above.

Measuring method 1 (Rz, Rzjis, Sm)
Rz, Rzjis, and Sm values are obtained by measuring the surface roughness of the decorative sheet. The surface roughness was measured according to JIS B0601. As an example, the surface roughness measurement results of the decorative sheets prepared in Examples 2 and 4 to 7 and Comparative Examples 1 to 4 are shown in FIGS. The surface roughness was measured using a surface roughness shape measuring instrument (Surfcom 120A manufactured by Tokyo Seimitsu Co., Ltd.).

Measurement method 2 (Static friction coefficient, Dynamic friction coefficient)
The static friction coefficient and the dynamic friction coefficient of the decorative sheets prepared in Examples 1 to 7 and Comparative Examples 1 to 4 were measured. The measurement was performed according to JIS K 7125.

<Evaluation Test Example 1 (Non-slip Human)>
The slip resistance (human) of the decorative sheets produced in Examples 1 to 7 and Comparative Examples 1 to 4 was confirmed.

  Specifically, each decorative sheet is processed into a floor, and for 15 adult men and women in their 20s to 40s, 1) wearing socks, 2) wearing stockings, and / or 3) walking on the floor with bare feet And he was allowed to walk. The same walk was performed on general-purpose wood floors (general veneer painted floors on the market).

  More than 10 adult men and women rated it as less slippery than a general-purpose wooden floor, and more than 8 adult men and women felt less slippery as ○. Moreover, when there were 7 or less adult men and women who felt that it was hard to slip, it was evaluated as x.

<Evaluation Test Example 2 (Anti-slip dog)>
The slip resistance (dog) of the decorative sheets produced in Examples 1 to 7 and Comparative Examples 1 to 4 was confirmed.

  Specifically, each decorative sheet was floor processed, and small dogs and medium-sized dogs were allowed to walk, normally run, jump, and repeat. The same behavior was applied to general-purpose wood floors.

  Compared with general-purpose wooden floors, small dogs and medium-sized dogs with no foot wobbling / sliding were evaluated as “◯”, and those with wobbling / sliding under the foot were evaluated as “X”.

<Evaluation Test Example 3 (Contamination Resistance)>
The flaw resistance of the decorative sheets prepared in Examples 1 to 7 and Comparative Examples 1 to 4 was confirmed using a Hoffman scratch tester (BYK-Gardnar).

  Specifically, a scratch blade (a cylindrical edge portion having a diameter of 7 mm) is set so as to contact the surface protective layer of the decorative sheet at an angle of 45 degrees, and the surface is moved by pulling the scratch blade. Rubbed. At that time, it was confirmed whether or not the surface protective layer was damaged by changing the load applied to the scratch blade by 100 g in the range of 300 to 700 g.

  A case where no continuous flaw was observed at 500 g load, a case where a continuous flaw was observed at 500 g load, and a case where a continuous flaw was clearly noticeable at 500 g load were evaluated as x.

<Evaluation Test Example 4 (Contamination Resistance)>
The stain resistance of the decorative sheets prepared in Examples 1 to 7 and Comparative Examples 1 to 4 was confirmed.

  Specifically, it was performed in accordance with the regulations of the JAS contamination A test.

  The case where there was no remarkable change in appearance was evaluated as ◯, the case where the change in appearance was slight was evaluated as Δ, and the case where the change in appearance was clearly conspicuous was evaluated as ×.

<Evaluation Test Example 5 (Weather resistance)>
The weather resistance of the decorative sheets prepared in Examples 1 to 7 and Comparative Examples 1 to 4 was confirmed.

  Specifically, the design surface was irradiated with sunshine carbon arc light for 1000 hours using a sunshine weather meter WEL-300 (manufactured by Suga Test Instruments Co., Ltd.).

<Evaluation Test Example 6 (Designability)>
The design property of the decorative sheet produced in Examples 1-7 and Comparative Examples 1-4 was confirmed.

  Specifically, adult men and women in their 20s to 40s evaluated 1) haze feeling and 2) bottom light feeling visually, and 3) evaluated the wood texture with the hand. The same evaluation was performed on general-purpose seat floors (general seat floors on the market).

  Compared to the general-purpose seat floor, three points have been improved, ◎ two points have been improved, ○ one point has been improved, △ all three points have not been evaluated as x. did.

  10 or more adult men and women who felt that all three points were improved compared to the general-purpose seat floor were evaluated as ◎, and 8 or more adult men and women scored 3 points as good. Moreover, it was evaluated as x when the number of adult men and women who felt that 3 points had improved was 7 or less.

  The results are shown in Tables 1-4.

Claims (8)

A method for producing a decorative sheet having a surface protective layer on the outermost surface on a transparent thermoplastic resin layer, wherein the decorative sheet comprises the following (1) to (6):
(1) The surface protective layer contains silica,
(2) The average particle diameter of the silica is not less than the thickness of the surface protective layer,
(3) The surface protective layer has irregularities formed by silica and embossing,
(4) The average interval Sm of the unevenness is 180 μm to 400 μm,
(5) The maximum height Rz of the surface protective layer is 20 to 50 μm, and (6) the static friction coefficient of the surface protective layer is 0.37 or more.
Meet that,
(i) Step 1 of forming a transparent thermoplastic resin layer,
(ii) forming a surface protective layer on the transparent thermoplastic resin layer 2, and
(iii) Step 3 of embossing from the surface protective layer,
A method for producing a decorative sheet, comprising: A method for producing a decorative sheet having a surface protective layer on the outermost surface on a transparent thermoplastic resin layer, wherein the decorative sheet comprises the following (1) to (6):
(1) The surface protective layer contains silica,
(2) The average particle diameter of the silica is not less than the thickness of the surface protective layer,
(3) The surface protective layer has irregularities formed by silica and embossing,
(4) The average interval Sm of the unevenness is 180 μm to 400 μm,
(5) The maximum height Rz of the surface protective layer is 20 to 50 μm, and (6) the static friction coefficient of the surface protective layer is 0.37 or more.
Meet that,
(i) Step 1 of forming a transparent thermoplastic resin layer,
(iii ′) Step 2 of embossing from the transparent thermoplastic resin layer, and
(ii) Step 3 of forming a surface protective layer on the transparent thermoplastic resin layer,
A method for producing a decorative sheet, comprising:   The method for producing a decorative sheet according to claim 1 or 2, comprising a step of forming a primer layer on the transparent thermoplastic resin layer prior to the step 2 or the step 3.   The step (ii) of forming the surface protective layer is a resin composition for forming the surface protective layer, and includes the step of applying the resin composition containing silica. A method for producing a decorative sheet according to claim 1. (Ii) forming the surface protective layer includes irradiating the coating film obtained by applying the resin composition with ionizing radiation;
The manufacturing method according to claim 4, wherein the surface protective layer is an ionizing radiation curable resin layer formed by resin crosslinking of an ionizing radiation curable resin.   The method for producing a decorative sheet according to any one of claims 1 to 5, wherein the surface protective layer has a ten-point average roughness Rzjis of 10 µm or more.   The manufacturing method of the decorative sheet in any one of Claims 1-6 which has a design pattern layer on a base material sheet.   Production of a decorative board for laminating the decorative sheet on the adherend so that the surface protective layer of the decorative sheet obtained by the method for producing a decorative sheet according to any one of claims 1 to 7 is the outermost surface layer. Method.

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