JPH08300595A - Grain-pattern ornamental sheet and method for producing grain-pattern laminate using the same - Google Patents

Abstract

PURPOSE: To provide a product that has acquired, without a failure, a deep-depressed grain pattern and, therefore, wood-like texture, by sequentially forming a transparent surface protective layer and a colored matte grain layer on a surface of a transparent substrate sheet and sequentially forming on the reverse surface a grain layer and an opaque base layer. CONSTITUTION: A grain pattern ornamental sheet is formed by sequentially forming a transparent surface protective layer 2 and a colored matte grain layer 3 on a surface of a transparent substrate sheet 1 and sequentially forming on the reverse surface a grain layer 4 and an opaque base layer 5. A sheet 1 is made of a polyethylene terephthalate resin, acrylic rubber or the like. Use of the polyethylene terephthalate resin is preferable in terms of printing characteristics, laminate workability, product strength and the like. The thickness of the sheet 1 is preferably 16-21μm. A thickness of 21μm or greater provides the sheet 1 with excessive strength, and renders the sheet 1 difficult to bend in accordance with an angle of a substrate 7 so that the sheet 1 becomes likely to lift from the surface of the substrate. A thickness of 16μm or less results in an insufficient strength such that the sheet 1 becomes subject to wrinkles and easy to break by tension.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a surface material for a furniture, an interior / exterior material for a building, a surface material for a cabinet, an interior material for a kitchen door, an interior material for an automobile, and a plate-like material or a bar-like material used as an outer edge member thereof. The present invention relates to a wood grain pattern decorative sheet used for forming a wood grain pattern on the above materials, and a method for producing a wood grain pattern laminated product using the same.

[0002]

2. Description of the Related Art Conventionally, so-called decorative plywood has been used as a surface material for furniture and an interior / exterior material for construction. Decorative plywood includes (1) single-ply overlay plywood and (2) printed plywood. (1) Veneer overlay Plywood is a laminated plywood made of natural wood, which is attached to the surface of ordinary plywood. (2) Printed plywood is a sheet of vinyl chloride sheet or paper with a wood grain pattern layer (consisting of a wood grain layer and a base layer) printed on it, with the vinyl chloride sheet or paper side facing down. It is attached to the surface. The grain pattern layer is usually the annual rings, fibers, and
There is a print in which a streak-like wood grain layer in which lines such as conduits are expressed in a dark color and a base layer in which a bare color is expressed in a lighter color than the wood grain layer are sequentially stacked.

[0003]

However, since the surface of (1) veneer overlay plywood is made of natural wood, its color tone is not uniform. Especially, in the case of a plywood of 36 pieces (91 cm x 182 cm), the area is large, so even if the decorative veneer is natural wood, it is difficult to have a beautiful wood grain pattern in all parts. In addition, when the seams of the decorative veneer are conspicuous or the decorative veneer is scratched, the correction marks are annoying.

(2) Since the wood grain pattern layer of the printed plywood is exposed on the surface, the wood grain layer of the printed plywood is apt to be damaged by scratches and friction generated when a person grips or stacks the print plywood. , There is no surface strength.
In addition, (2) printed plywood expresses the impression that the wood grain is deeply dented by the shade of color with the wood grain layer as the dark color and the base layer as the light color, but with the shade of the color tone, the wood grain is far away. Even if it is possible to express a deeply dented wood texture, the feeling that the wood grain and the ground are on the same plane still remains in the near future, and it becomes a visually flat wood grain pattern.

The present invention solves the above drawbacks and obtains a wood grain laminate product having a wood grain pattern having a uniform color tone, inconspicuous seams and the like, and having a deep wood grain texture and surface strength. An object of the present invention is to provide a wood grain pattern decorative sheet and a method for manufacturing a wood grain pattern laminated product using the same.

[0006]

In order to achieve the above-mentioned objects, the wood grain decorative sheet according to the present invention has the following features:
As described above, the transparent substrate sheet has a transparent surface protective layer and a colored matte wood grain layer formed in order on the surface, and a wood grain layer and an opaque underlayer formed on the back surface.

According to a second aspect of the present invention, the surface of the surface protective layer may be matte.

According to a third aspect of the present invention, in the wood grain pattern decorative sheet according to the second aspect, the surface of the matte wood grain layer is stronger than the surface of the surface protective layer. Good.

The wood grain pattern decorative sheet according to claim 4 of the present invention is the wood grain pattern decorative sheet according to any one of claims 1 to 3, in which the matte wood grain pattern is in synchronization with the wood grain pattern. You can also use it.

The wood grain pattern decorative sheet according to a fifth aspect of the present invention may be the wood grain pattern decorative sheet according to any one of the first to fourth aspects, in which an adhesive layer is formed on the back surface of the opaque base layer. .

According to the method for producing a wood grain laminate product of the present invention, any one of the wood grain pattern decorative sheets described in claims 1 to 4 is adhered onto a substrate with an opaque underlayer as an adhesive surface. .

The method for producing a wood grain laminate product of the present invention uses the wood grain decorative sheet according to claim 5,
The adhesive layer is used as an adhesive surface to adhere onto the base material.

The present invention will be described in more detail below. In the wood grain decorative sheet 10 of the present invention, a transparent surface protective layer 2 and a colored matte wood layer 3 are sequentially formed on the surface of a transparent base sheet 1, and a wood layer 4 and an opaque base layer 5 are sequentially formed on the back surface. The formed one has a basic structure.

For the transparent substrate sheet 1, polyethylene terephthalate resin, polyester resin, polyacrylic resin, polycarbonate resin, acrylic rubber or the like is used.
The use of polyethylene terephthalate resin is particularly preferable in terms of printability, laminating processability, product strength and the like. A suitable thickness of the base sheet 1 is 12 μm to 50 μm, and 16 μm to 21 μm is particularly preferable. When the thickness is 21 μm or more, the base sheet 1 is too stiff, so that it is difficult to bend along the corners of the base material 7, and the base sheet 1 is easily lifted from the surface of the base material. On the other hand, when the thickness is 16 μm or less, the strength of the base sheet 1 is lowered, so that the base sheet 1 is likely to be wrinkled, or the base sheet 1 is easily cut by pulling.

The transparent surface protective layer 2 is laminated by using a photocurable resin such as an ultraviolet curable resin, a radiation curable resin such as an electron beam curable resin, a thermosetting resin, or a two-component curable resin. It is particularly preferable in that it can strengthen the outer surface of the product and prevent scratches. Examples of the two-component curable resin include acrylic resin and urethane resin. Surface protection layer 2
May be a layer having a so-called hard surface having a scratch-resistant hardness such that the surface is not scratched or dented even if it is subjected to excessive force, or the surface is scratched or dented due to excessive force. Also, it may be a layer having a so-called soft surface that is restored to a surface state without scratches or dents instantly or over time depending on the flexibility of the layer itself. Surface protection layer 2
Is formed by an ordinary printing method such as a gravure printing method or a screen printing method or a roll coating method. The thickness of the surface protective layer 2 is preferably 0.5 μm to 3 μm.

As the base sheet 1 on which the transparent surface protection layer 2 is formed, there is a sheet-like product in which a high hardness resin layer and a low hardness resin layer are laminated. Either the high-hardness resin layer or the low-hardness resin layer may replace the base sheet 1, but there is a type in which the high-hardness resin layer replaces the surface protection layer and the low-hardness resin layer replaces the base sheet 1. . The high hardness resin layer is
For example, methyl methacrylate resin, pencil hardness
There is more than H resin. The low hardness resin layer includes polycarbonate resin, acrylic rubber, styrene resin, vinyl chloride resin, polyethylene resin, polypropylene resin, nylon resin, ABS resin and the like, and generally has a pencil hardness of about HB or less. The sheet-shaped material in which the high hardness resin layer and the low hardness resin layer are laminated is laminated by a coextrusion method. The co-extrusion method is, specifically, a low-hardness resin is extruded from an extruder to be extruded into a film-like or sheet-like low-hardness resin layer, and at the same time, a high-hardness resin is extruded from an extruder to obtain a film-like or sheet-like material. A high-hardness resin layer is molded on the surface of the low-hardness resin layer to obtain a sheet-like product having a multilayer structure. When the transparent surface protective layer 2 is a sheet, the transparent surface protective layer 2 and the base sheet 1 may be laminated by a laminating method or the like.

The surface of the transparent surface protective layer 2 is usually glossy when the above resin is used (FIGS. 1 and 6). The surface of the transparent surface protective layer 2 can be made matte by mixing particles of calcium carbonate, silicon oxide, titanium oxide or the like into the resin (FIG. 2, FIG. 3, FIG. 7, FIG. 8). . The particle size of the particles is 0.1 μm to 10 μm.

The matte wood grain layer 3 is a layer for expressing a wood grain pattern such as annual rings, fibers and conduits that usually appears at the cut end when cutting wood. As a concrete grain pattern,
There are streaks, curved lines, and broken lines due to streaks. The matte wood grain layer 3 is a mixture of a resin such as an acrylic resin, a urethane resin, or an epoxy resin with particles of calcium carbonate, silicon oxide, titanium oxide, or the like. The particle size of the particles is 0.1 μm to 10 μm. The matte wood grain layer 3 may be formed by an ordinary printing method such as a gravure printing method or a screen printing method. The matte wood grain layer 3 is a layer colored in a wood grain color by mixing a colorant such as a pigment or a dye with a mixture of the above resin and particles. Alternatively, it may be a layer that is colored and transmits light. The appropriate thickness of the matte wood grain layer 3 is 0.5 μm to 2 μm.

The surface of the matte wood grain layer 3 may be more matte than the surface of the surface protective layer 2. Specifically, the blending ratio of the particles mixed in the matte wood grain layer 3 may be larger than the blending ratio of the particles mixed in the surface protective layer 2. For example, the mixing ratio of the particles mixed in the surface protective layer 2 is 3% by weight, and the mixing ratio of the particles mixed in the matte wood grain layer 3 is 7% by weight. Alternatively, the particle size of the particles mixed in the matte wood grain layer 3 may be larger than the particle size of the particles mixed in the surface protective layer 2. For example, the particle size of the particles mixed in the surface protective layer 2 is 3 μm, and the particle size of the particles mixed in the matte wood grain layer 3 is 7 μm. When the difference in particle size is 2 μm or more, it is effective in that the matte wood grain layer 3 can obtain a wood texture in which the wood grain is more deeply depressed.

The wood grain layer 4 is a layer for expressing a wood grain pattern such as annual rings, fibers and conduits that appear at the cut end when the wood is cut. Specific wood grain patterns include streaks, curved lines, and line breaks. The wood grain layer 4 uses a thermoplastic resin such as vinyl chloride / vinyl acetate copolymer, polyamide, polyester, polyacrylic, polyurethane, chlorinated rubber, or nitrified cotton as a binder, and contains a dye or pigment having a wood grain pattern as a coloring material. Select one or multiple colors from brown, dark brown, ocher, reddish brown, etc. The wood grain layer 4 is formed by an ordinary printing method such as a gravure printing method or a screen printing method. Alternatively, the wood grain layer 4 is formed on a part or the whole surface of the substrate sheet 1 by gradation so that the color density or the film thickness is changed stepwise or continuously in order to make it closer to the natural wood grain pattern. You may. The thickness of the wood grain layer 4 is adjusted within the range of 0.5 μm to 5 μm.

The opaque underlayer 5 is a layer that expresses the color of the wood other than the wood grain that appears at the cut end when the wood is cut. The opaque base layer 5 is usually a layer that is lighter in color than the color of the wood grain layer 4 and expressed in a single color. The wood grain layer 4 is a vinyl chloride vinyl acetate copolymer, polyamide, polyester,
Using a thermoplastic resin such as polyacryl, polyurethane, chlorinated rubber, or nitrified cotton as a binder and containing a dye or pigment of the color of the underlayer as a coloring material, brown or dark brown, ocher, cream, yellow Select a single or multiple colors from red, brown, etc. If necessary, wood grain layer 4
The color may be darker than the color selected as, or may be lighter. Opaque base layer 5
Is formed by an ordinary printing method such as a gravure printing method or a screen printing method or a roll coating method. Opaque base layer 5
The appropriate thickness is 2 μm to 10 μm.

The grain pattern of the matte grain layer 3 may be synchronized with the grain pattern of the grain layer 4. Entrainment means, for example, that the pattern of the conduit of the matte wood grain layer 3 and the pattern of the wood grain of the wood grain layer 4 (excluding the conduit pattern) can be visually recognized as a unified texture as a wood grain design. Is. Alternatively, the lines of the conduit of the matte wood grain layer 3 and the lines of the conduit of the wood grain layer 4 are arranged in parallel.

The grain pattern of the matte grain layer 3 and the grain pattern of the grain layer 4 may completely overlap with each other (strictly speaking, the surface-hardened layer and the base sheet 1 are sandwiched between them). Will be out) (Figs. 3 and 8). Alternatively,
A part of the grain pattern of the matte grain layer 3 and a part of the grain pattern of the grain layer 4 may overlap. When the matte wood grain layer 3 and the wood grain layer 4 have a relationship in which the wood grain patterns are completely or partially overlapped with each other, the matte wood grain layer 3 is a layer that transmits light, and the color of the wood grain layer 4 is Is effective not only as it is, but also because of the matting effect of the matte wood grain layer 3 it is possible to obtain a wood texture in which the wood grain layer 4 has deeply recessed wood grain. Also, matte wood grain layer 3
Is a transparent layer colored similar to the color of the wood grain layer 4, the color of the wood grain layer 4 and the color of the matte wood grain layer 3 are combined to make the wood grain pattern of the wood grain layer 4 darker. Not only can it be colored, but it is effective in two respects that the matte effect of the matte wood grain layer 3 can provide a wood texture in which the wood grain of the wood grain layer 4 is deeper recessed.

The above is the wood grain decorative sheet 10 of the present invention.
The basic structure of the present invention, the wood grain decorative sheet 10 of the present invention
Then, as a further modification, a transparent surface protective layer 2 and a colored matte wood grain layer 3 are sequentially formed on the surface of a transparent base sheet 1, and a wood grain layer 4, an opaque underlayer 5, and an adhesive layer 6 are formed on the back surface.
May be sequentially formed. The adhesive layer 6 may be made of acrylic resin, urethane resin, polyester resin, polyamide resin, ethylene butyl alcohol resin, ethylene vinyl acetate copolymer, vinyl chloride / vinyl acetate copolymer, or the like.

In the method for producing a wood grain laminate product of the present invention, the wood grain decorative sheet 10 described above is bonded onto the base material 7. As the material of the base material 7, wood, modified wood,
Plywood, metal, plastic, etc. Further, the shape of the base material 7 may be rod-shaped or plate-shaped. Specific examples of the metal include iron, stainless steel, aluminum and the like, and its applications include handrails and exteriors. Specific examples of plastics include acrylic styrene butadiene rubber (ABS) and vinyl chloride, and their applications include skirting boards and sashes.

A method for producing a wood grain pattern laminated product of the present invention is described as a production method (production method A) in which the opaque base layer 5 of the wood grain pattern decorative sheet 10 having no adhesive layer 6 is used as an adhesive surface to adhere to the base material 7. The manufacturing method (manufacturing method B) in which the adhesive layer 6 of the wood grain pattern decorative sheet 10 is bonded as the bonding surface on the base material 7 having no adhesive layer 60 will be described separately. In the manufacturing method A, a method of applying an adhesive to the opaque base layer 5 of the wood grain pattern decorative sheet 10 having no adhesive layer 6 without applying the adhesive to the base material 7 (FIG. 4), and an adhesive layer 6
There is a method (FIG. 5) of applying the adhesive to the base material 7 without applying the adhesive to the opaque base layer 5 of the wood grain decorative sheet 10 that does not have the above. In the case of the former method, after the adhesive is applied to the opaque underlayer 5 of the wood grain pattern decorative sheet 10, the solvent is removed in a drying oven, and the adhesive layer 60 of the wood grain pattern decorative sheet 10 is placed on the base material 7. Are stacked and each surface of the base material 7 is pressed using a rubber roll (not shown) to obtain a wood grain pattern laminated product 100 (FIG. 10). In the case of the latter method, the opaque base layer 5 of the wood grain pattern decorative sheet 10 is superposed on the base material 7 to which an adhesive is applied, and each side of the base material 7 is pressed by using a rubber roll to obtain a wood grain pattern laminated product. 10
0 is obtained (FIG. 10). Normally, the pressure applied by a rubber roll is
One or several rubber rolls are used for one surface of the base material 7, and the same surface of the base material 7 is pressed once or several times. The adhesive may be appropriately selected from a group of resins such as acrylic resin that can be used as the adhesive layer 6 and a two-component curable resin.

In the manufacturing method B, the adhesive layer 6 of the wood grain pattern decorative sheet 10 is superposed on the base material 7 (FIG. 9), and each side of the base material 7 is heated and pressed by using a heated rubber roll. The wood grain pattern laminated product 100 is obtained (FIG. 12). The heating of each surface of the base material 7 using the heated rubber roll is for temporarily melting or softening the solidified adhesive layer 6.

In order to obtain a wood grain pattern laminated product 100 in which the edges of the wood grain pattern decorative sheet 10 are wrapped around and adhered to the back surface of the base material 7 as shown in FIG. 11, the manufacturing method A is more advantageous. Is. Because in the manufacturing method A,
Since there is no need to heat the rubber roll, no light heat or heat source equipment is required, and even the back surface of the base material 7 has a wood grain decorative sheet 1
This is because even if the end portions of 0 are wrapped around and bonded to each other, the manufacturing cost can be lower.

[0029]

In the method of manufacturing a wood grain pattern decorative sheet and a wood grain pattern laminated product of the present invention, since the wood grain pattern is expressed by the wood grain layer and the opaque underlayer, it is possible to solve the drawbacks of the conventional veneer overlay plywood. Thus, a wood grain pattern laminated product which does not require the use of a natural wood grain pattern can be obtained. Further, since the transparent base sheet having the surface protective layer covers and protects the wood grain layer and the opaque underlayer, the wood grain pattern layer is not exposed on the surface, and the drawbacks of the conventional printed plywood are solved. A patterned laminated product is obtained. Furthermore, since the matte wood grain layer is exposed on the surface, the unevenness forming the matte surface of the matte wood grain layer can express visual dents in addition to the dent feeling due to the color tone. Further, not only the wood pattern such as the annual rings due to the wood grain layer, but also the dark part itself such as the conduit due to the matte wood layer colored in dark color can be expressed in a matte shape. Therefore, a more realistic wood grain design and wood texture can be reliably expressed.

[0030]

Since the present invention has the above-mentioned structure and operation, the following effects can be obtained. That is, according to the method for producing a wood grain pattern decorative sheet and a wood grain pattern laminated product of the present invention, since it is not necessary to use natural wood for the wood grain pattern decorative sheet, the color tone is uniform and the seams are not noticeable. In addition, since the wood grain layer is protected by the surface protective layer and the base film, it is possible to obtain a wood grain laminate product having surface strength. further,
Since it has a matte wood grain layer, it is possible to obtain a wood grain pattern laminated product that surely has a wood texture in which the wood grain is deeply recessed.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing an example of a wood grain decorative sheet of the present invention.

FIG. 2 is a cross-sectional view showing an embodiment of another aspect of the wood grain decorative sheet of the present invention.

FIG. 3 is a cross-sectional view showing an embodiment of another aspect of the wood grain decorative sheet of the present invention.

FIG. 4 is a cross-sectional view showing one step of the method for manufacturing a grain-patterned laminated product of the present invention.

FIG. 5 is a cross-sectional view showing a step of another aspect of the method for producing a wood grain laminate product of the present invention.

FIG. 6 is a cross-sectional view showing an embodiment of a wood grain decorative sheet of the present invention.

FIG. 7 is a cross-sectional view showing an embodiment of another mode of the wood grain decorative sheet of the present invention.

FIG. 8 is a cross-sectional view showing an embodiment of another aspect of the wood grain pattern decorative sheet of the present invention.

FIG. 9 is a cross-sectional view showing a step in the method for manufacturing a grain pattern laminated product of the present invention.

FIG. 10 is a cross-sectional view showing a wood grain pattern laminated product obtained by the method for manufacturing a wood grain pattern laminated product of the present invention.

FIG. 11 is a cross-sectional view showing another embodiment of a wood grain pattern laminated product obtained by the method for manufacturing a wood grain pattern laminated product of the present invention.

FIG. 12 is a cross-sectional view showing another embodiment of a wood grain pattern laminated product obtained by the method for manufacturing a wood grain pattern laminated product of the present invention.

[Explanation of symbols]

 1 Base Sheet 10 Wood Pattern Decorative Sheet 100 Wood Pattern Laminated Product 2 Surface Protection Layer 3 Matte Wood Grain Layer 4 Wood Grain Layer 5 Opaque Underlayer 6 Adhesive Layer 60 Adhesive Layer 7 Base Material

Claims (7)

[Claims] 1. A wood grain pattern characterized in that a transparent surface protective layer and a colored matte wood grain layer are sequentially formed on the surface of a transparent substrate sheet, and a wood grain layer and an opaque underlayer are sequentially formed on the back surface. Decorative sheet. 2. The wood grain decorative sheet according to claim 1, wherein the surface of the surface protective layer is matte. 3. The wood grain decorative sheet according to claim 2, wherein the surface of the matte wood grain layer is more matt than the surface of the surface protective layer. 4. The wood grain decorative sheet according to claim 1, wherein the matte wood grain pattern and the wood grain pattern are aligned with each other. 5. The decorative grain decorative sheet according to claim 1, wherein an adhesive layer is formed on the back surface of the opaque underlayer. 6. A method for producing a wood grain laminate product, which comprises adhering the wood grain pattern decorative sheet according to any one of claims 1 to 4 on a substrate with an opaque underlayer as an adhesive surface. 7. A method for producing a wood grain pattern laminated product, which comprises bonding the wood grain pattern decorative sheet according to claim 5 onto a substrate with an adhesive layer as an adhesive surface.