JPH04128041A - Decorative sheet and manufacture thereof - Google Patents

Abstract

PURPOSE:To obtain a decorative sheet rich in a three-dimensional feeling and having variegated design effect by providing an uneven embossed pattern to the single surface of a colored theremoplastic resin film and laminating a transparent or translucent resin film having hot pressing resistance and a transparent or translucent thermoplastic resin film to the embossed surface thereof in this roder. CONSTITUTION:After an uneven embossed pattern 5a is provided to the single surface of a colored thermoplastic film 2 using a proper embossing plate or roll, a transparent or translucent hot pressing-resistant resin layer 3 is laminated to the embossed surface of the film 2 by coating so as to fill at least the uneveness of the film 3 and a transparent or translucent thermoplastic resin film 1 is laminated thereon. As the transparent or translucent thermoplastic resin film 1, a film with thickness of about 20-500mum composed of, for example, polyolefinic resin such as polyethylene or polypropylene or a polycarbonate resin is used. If necessary, a pattern layer may be provided to the upper or lower side of the transparent or translucent thermoplastic resin film. By this method, a sheet having an embossed pattern provided to the inside of the surface 2 thereof and a three-dimensional feeling can be obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a decorative material sheet having a rich three-dimensional effect and having an uneven embossed pattern therein, and a method for manufacturing the decorative material sheet.

[Conventional technology] In order to obtain a decorative material sheet with a three-dimensional effect, a decorative material sheet with an embossed pattern formed on its surface is used. A decorative sheet is used.

[Problem to be solved by the invention]

However, although the decorative material sheet whose surface is given a concavo-convex pattern by the conventional embossing roll has a certain degree of three-dimensional effect, it does not have a three-dimensional effect that can be satisfied overall. For example, when comparing a decorative material sheet printed with a wood grain pattern with a decorative material made of natural wood, it has the disadvantage that its three-dimensional effect is not sufficient and its quality is inferior.

In addition, when the decorative material sheet is subjected to heat-pressing molding again,
The uneven embossed pattern disappears after 20 years of heat pressure molding. Therefore, when a backing material is laminated onto the decorative sheet by hot pressure molding, a decorative sheet with a three-dimensional effect cannot be obtained. Furthermore, when a new uneven embossed pattern is formed on the surface of the decorative material sheet opposite to the surface having the uneven embossed pattern by hot pressure molding, the initial uneven pattern disappears, and both sides Therefore, it is not possible to obtain a decorative sheet having a concavo-convex pattern.

In contrast, the present invention provides a decorative material sheet that is rich in three-dimensional effect and has various design effects, and a method for manufacturing the same.

[Means to solve the problem]

The present invention solves the above-mentioned problems, and has the following features: ``■ A colored thermoplastic resin film is provided with an uneven embossed pattern on one side, and a transparent or translucent heat-pressure resistant material is provided on the embossed side. A decorative material sheet characterized in that a certain resin and a transparent or translucent thermoplastic resin film are laminated in this order,""■ In the decorative material sheet of (■) above, the transparent or translucent thermoplastic resin film side ``a decorative material sheet characterized in that a further uneven embossed pattern is formed on the surface'', ``■ In the decorative material sheet of ■ or ■, a backing material is laminated on the colored thermoplastic resin film side. A decorative material sheet characterized by the following: ``■ A colored thermoplastic resin film is provided with an embossed pattern of unevenness on one side, and a transparent or translucent heat-pressure resistant resin is coated on the embossed surface side, and a transparent or A method for producing a decorative material sheet characterized by laminating translucent thermoplastic resin films in this order,""■ In the method for producing a decorative sheet according to (■) above, further comprising: A method for manufacturing a decorative sheet characterized by providing another embossed pattern of unevenness", "■ In the method for manufacturing a decorative sheet according to (■) above, a backing material is laminated on the colored thermoplastic resin film side. ``method for manufacturing a decorative material sheet according to item 1 above,'' and ``■ In the method for manufacturing a decorative sheet according to item 1 above, while providing another uneven embossed pattern on the side of the transparent or translucent thermoplastic resin film, the colored thermoplastic A method for manufacturing a decorative material sheet characterized by laminating a backing material on the resin film side."

〔Example〕

The present invention will be explained with reference to the drawings.

FIG. 1 shows an example of a decorative material sheet of the present invention, in which an uneven embossed pattern 5a is provided on the upper surface of a colored thermoplastic resin film 2, and the embossed surface side is transparent or translucent. A heat-resistant and pressure-resistant resin 3 is laminated to fill the unevenness, and a transparent or translucent thermoplastic resin film 1 is placed on top of it.
are layered. In order to manufacture the decorative material sheet shown in FIG. 1, an uneven embossed pattern 5a is provided on one side of the colored thermoplastic film 2 by an embossing method using an appropriate embossing plate and an embossing roll, and then an uneven embossed pattern 5a is provided on one side of the colored thermoplastic film 2. A transparent or translucent heat-pressure resistant resin layer 3 is laminated by painting or the like so as to at least fill in the irregularities, and a transparent or translucent thermoplastic resin film 1 is laminated thereon. The film 1 may be laminated onto the layer 3 by an adhesive method in which a composition forming the layer 3 is applied and the applied layer is used as an adhesive layer, or by other methods.

Further, if necessary, a pattern layer may be provided on the embossed pattern 5a.

Examples of the transparent or translucent thermoplastic resin film 1 include polyolefin resins such as polyethylene and polypropylene, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, ethylene-vinyl acetate copolymer, ethylene-vinyl alcohol copolymer, polyvinyl acetate
Vinyl polymer resins such as vinyl chloride copolymer, polyvinyl fluoride, polyvinyl butyral, polyvinylidene fluoride, vinylon, polystyrene, acrylic styrene, ABS
Styrene resins such as polyethyl methacrylate, polymethyl methacrylate, polybutyl acrylate, acrylic resins such as polyacrylonitrile, polyethylene terephthalate resin, polycarbonate resin, etc. with a thickness of 20 mm.
A film with a hardness of about 500 μm and a vinyl chloride resin film, which corresponds to 0 to 100 phr of plasticizer addition, is used.

The transparent or translucent thermoplastic resin film 1 may be, for example, a pearl clear film, a color clear film, a colorless clear film, etc., as long as the underlying layer can be seen through.

Further, if necessary, a pattern layer 6 may be provided on the upper or lower surface of the transparent or translucent thermoplastic resin film 1 in the drawing.

In addition, the colored thermoplastic resin film 2 is a colored film of about 20 to 100 μm in thickness made of the same thermoplastic resin as that described for the thermoplastic resin film that becomes the transparent or translucent thermoplastic resin film 1. In terms of vinyl resin, those having a hardness corresponding to the addition of a plasticizer of 0 to 100 phr are used.

The colored thermoplastic resin film 2 may be a colored film containing a colorant, or may be a colored film printed or painted using an ink containing a colorant. In addition to the ordinary ones,
Metal powder obtained using metals such as aluminum, copper, and brass, metal foil pieces, pigments with metallic luster obtained by cutting metallized synthetic films, mica coated with titanium oxide, fish scale foil, and acids. Metallic or pearlescent pigments such as bright pigments such as pigments such as bismuth chloride that produce pearlescent to interference luster may also be used.

In addition, as the transparent or semitransparent heat and pressure resistant resin 3, U
Ionizing radiation curable resins such as V and EB are good and have the best heat and pressure resistance. As this ionizing radiation-curable resin, a prepolymer, oligomer or monomer having a polymerizable unsaturated bond or an epoxy group in the molecule is used. Further, the above prepolymers, oligomers and monomers may be used alone or in combination of two or more, if necessary.

The prepolymers and oligomers include unsaturated polyesters such as condensates of unsaturated carboxylic acids and polyhydric alcohols, methacrylates such as polyester methacrylates, polyether methacrylates, polyol methacrylates, and melamine methacrylates, polyester acrylates, epoxy acrylates, and urethanes. There are acrylates such as acrylate, polyether acrylate, polyol acrylate, and melamine acrylate.

In addition, examples of the monomer include styrene monomers such as styrene and α-methylstyrene, methyl acrylate, 2-ethylhexyl acrylate, methoxyethyl acrylate,
Acrylic acid esters such as butoxyethyl acrylate, butyl acrylate, methoxybutyl acrylate, phenyl acrylate, methyl methacrylate, ethyl methacrylate, propyl methacrylate, methoxyethyl methacrylate, ethoxymethyl methacrylate, phenyl methacrylate, Methacrylic acid esters such as lauryl methacrylate, 2-(N,N-dimethylamino)ethyl acrylate, 2-(N,N-dibenzylamino)ethyl acrylate, 2-(N%N) methacrylate -dimethylamino)methyl, acrylic acid-2-(N.

Substituted amino alcohol esters of unsaturated acids such as N-diethylamino)propyl, unsaturated carboxylic acid amides such as acrylamide and methacrylamide, ethylene glycol diacrylate, propylene glycol diacrylate, neopentyl glycol diacrylate, 1.6-
Compounds such as hexanediol diacrylate, diethylene glycol diacrylate, triethylene glycol diacrylate, etc., polyfunctional compounds such as dibroblene gelicol diacrylate, ethylene glycol diacrylate, propylene glycol dimethacrylate, diethylene glycol dimethacrylate, etc., 2 in the molecule There are polythiol compounds having the above thiol groups.

Note that as the transparent or translucent heat-resistant and pressure-resistant resin 3, a two-component curable resin such as a urethane resin or an acrylic resin, or a solvent dry curable resin such as a cellulose acetate resin may be used. Although its heat and pressure resistance is inferior to plastic resins, it has good processability and is inexpensive.

The heat and pressure resistant resin 3 is laminated on the embossed surface side by wiping coating or other coating.

The decorative material sheet shown in FIG. 2 is obtained by providing another uneven embossed pattern 5b on the upper side of the transparent or translucent thermoplastic resin film 1 of the decorative material sheet shown in FIG. 1 by hot pressure molding.

To manufacture the decorative material sheet shown in FIG. 2, after manufacturing the decorative material sheet shown in FIG. 1, the uppermost surface is embossed by an embossing method, or by embossing at the same time as the film 1 is laminated.

The decorative material sheet shown in FIG. 3 is obtained by laminating a backing material 4 on the colored thermoplastic resin film 2 side of the decorative material sheet shown in FIG. 1 by hot pressure molding.

In order to manufacture the decorative material sheet shown in FIG. 3, a backing material is applied to the underside of the colored thermoplastic resin film 2 by an appropriate method during or after the process of manufacturing the decorative material sheet shown in FIG. This is done by laminating 4.

The backing material 4 may be of any material as long as it is commonly used as a substrate for decorative laminates; for example,
Wooden substrates such as plywood, particle board hardboard, insulation board, inorganic substrates such as gypsum board, asbestos perlite board, calcium silicate board, glass wool, rock wool, iron plate, zinc plate, aluminum plate, lead plate, Metal substrates such as copper plates, foamed polyethylene plates, foamed polystyrene plates, foamed plastic plates (foam substrates) such as urethane foam, phenol foam, phenolic resin plates, melamine resin plates, polyester resin plates, acrylic resin plates, vinyl chloride resin plates There are synthetic resin plates such as The above-mentioned substrates may be used as a composite board by bonding the same or different substrates together.

The decorative material sheet shown in FIG. 4 has an uneven embossed pattern 5b formed by hot pressure molding on the upper side of the transparent or semitransparent thermoplastic resin film 1 of the decorative material sheet shown in FIG. 1, and is made of colored thermoplastic resin. A backing material 4 is laminated on the underside of the film 2.

In order to manufacture the decorative material sheet shown in FIG. 4, an embossed pattern 5b is formed on the upper side of the transparent or translucent thermoplastic resin film 1 by an embossing method during or after the manufacturing process of the decorative material sheet shown in FIG. However, if embossing and laminating the backing material are performed at the same time, heating and pressurization are involved. It is efficient because it is common.

In the actual invention having the above structure, an intermediate resin layer of one or more thermoplastic resin films may be provided between the transparent or translucent thermoplastic resin film 1 and the colored thermoplastic resin film 2, if necessary. Further, a pattern layer may be provided on this intermediate resin layer.

Next, the specific structure of the decorative material sheet and the manufacturing method thereof of the present invention will be explained based on drawing examples.

Example 1 In Fig. 2, a pattern layer 6 was provided on the back side of a transparent polyvinyl chloride film (RIKEN VINYL INDUSTRIAL M!Il). After providing an uneven embossed pattern 5a on one side of the embossed surface (manufactured by ■), a transparent or translucent heat-pressure resistant resin 3 was applied to the embossed surface using a flow coater to a thickness of 60 μm.Heat-pressure resistant resin 3 After completely curing the urethane acrylic UV-curable resin by irradiating it with ultraviolet rays (using Nippon Paint), place the transparent polyvinyl chloride film 1 on top of it, and place the pattern layer 6 side on the adhesive surface. The transparent polyvinyl chloride film 1 was further laminated with an uneven embossed pattern 5b on its surface by hot pressure molding.

The obtained decorative material sheet had an uneven pattern on both the surface and inside, and had a three-dimensional appearance.

Example 2 After carrying out the same procedure as in Example 1, a polyvinyl chloride tile 4 was layered on the pearl-kneaded vinyl chloride film 2 side by hot pressure molding.

The resulting decorative material sheet had an internal three-dimensional effect, with the internal uneven pattern maintaining the same uneven shape as before hot-pressing.

Example 3 After carrying out the same procedure as in Example 1, a polyvinyl chloride tile 4 was kneaded with pearls on the polyvinyl chloride film 2 side while providing an uneven embossed pattern 5b on the surface of the transparent polychlorinated beer film 1 by hot pressure molding. Laminated.

The obtained decorative material sheet retains the same uneven pattern on the inside as before hot-pressing molding, and has a three-dimensional effect with uneven patterns on both the surface and inside, and is used as a plastic tile. It was suitable for doing so.

[Action and effect of the invention]

In the decorative material sheet according to claim 1 of the present invention, since the resin 3 having heat and pressure resistance is interposed in the uneven surface of the colored thermoplastic resin film 2 by filling at least the recesses, this resin 3 is also used when manufacturing the decorative material sheet. The embossed pattern 5a does not disappear, and even if the decorative material sheet is subjected to hot-pressure molding again, the embossed pattern 5a does not disappear.

Therefore, the decorative material sheet of the present invention is rich in internal three-dimensionality due to the embossed pattern of internal irregularities.

Further, in the decorative material sheet according to claim 2, another uneven pattern 5b is further provided on the surface of the transparent or translucent thermoplastic resin film 1, and the uneven pattern on the surface adds a three-dimensional effect. The three-dimensional effect of the decorative material sheet is even better.

Furthermore, since the decorative material sheet according to the third aspect has a backing material on the back surface, it is suitable for applications such as plastic tiles that require thickness.

According to the invention of claim 4 or 5, the decorative sheet according to claim 1 or 2, respectively, can be efficiently produced, and according to the invention according to claim 6 or 7, the decorative sheet according to claim 3g can be manufactured efficiently.

[Brief explanation of drawings]

1 to 4 are all cross-sectional views of the decorative material sheet of the present invention. 1 Transparent or translucent thermoplastic resin film 2 Colored thermoplastic resin film Transparent resin backing material Embossed pattern a Embossed pattern pattern layer

Claims (7)

[Claims] (1) An uneven embossed pattern is provided on one side of a colored thermoplastic resin film, and a transparent or translucent heat-pressure resistant resin and a transparent or translucent thermoplastic resin film are placed on the embossed side. A decorative material sheet characterized by being laminated in this order. (2) The decorative material sheet according to claim 1, further comprising another embossed pattern of projections and depressions formed on the side of the transparent or translucent thermoplastic resin film. (3) The decorative material sheet according to claim 1 or 2, wherein a backing material is laminated on the colored thermoplastic resin film side. (4) An uneven embossed pattern is provided on one side of the colored thermoplastic resin film, and a transparent or translucent heat-pressure resistant resin and a transparent or translucent thermoplastic resin film are placed on the embossed side. A method for producing a decorative material sheet, the method comprising sequentially laminating layers. (5) The method for producing a decorative material sheet according to claim 4, further comprising providing another embossed pattern of unevenness on the side of the transparent or translucent thermoplastic resin film. (6) The method for manufacturing a decorative material sheet according to claim 4, wherein a backing material is laminated on the colored thermoplastic resin film side. (7) In the method for producing a decorative material sheet according to claim 4, a backing material is laminated on the colored thermoplastic resin film side while providing another uneven embossed pattern on the transparent or translucent thermoplastic resin film side. A method for producing a decorative material sheet, characterized by: