Decorative sheet

Abstract

To provide a decorative sheet that ensures excellent adhesion to an object with adhesives widely used in recent years.SOLUTION: A decorative sheet 1 includes: a body 10 including a substrate layer, a coloring layer, and a pattern layer, and a primer layer 20 disposed on the opposite side of the coloring layer in the substrate layer, wherein the primer layer includes a main layer composed of a synthetic resin and silica particles disposed in the main layer. The particle size of the silica particles is at least 1.5 times and less than 3 times the thickness of the main layer, and the mass of the silica particles is 5% or more and 10% or less of the mass of the synthetic resin.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a decorative sheet. [Background technology]

[0002] 2. Description of the Related Art Conventionally, it has been known to cover the surfaces of building materials such as interior materials, exterior walls, fixtures, and fittings of buildings such as houses with decorative sheets to improve their appearance.

[0003] A decorative sheet is usually stored in a roll until it is used, and the required amount is pulled out when it is applied to a wall surface, etc. At this time, a phenomenon called blocking is known, in which the rolled decorative sheet becomes difficult to peel off from adjacent parts when it is rolled up. When blocking occurs, the handleability of the decorative sheet decreases.

[0004] To address this problem, in Patent Document 1, a backcoat layer of a decorative sheet that is bonded to an object contains at least a predetermined amount of silica, thereby suppressing blocking. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Patent No. 3147735 Summary of the Invention [Problem to be solved by the invention]

[0006] Adhesives used to attach decorative sheets have changed with the times, and in recent years, one-component water-based adhesives, polyurethane-based one-component moisture-curing urethane hot melt adhesives, etc. have been widely used. As a result, there are cases where the backcoat layer described in Patent Document 1 does not necessarily provide good adhesion. The inventors have conducted extensive research in light of this point and have completed the present invention.

[0007] An object of the present invention is to provide a decorative sheet that can be satisfactorily attached to an object even when using adhesives that have been widely used in recent years. [Means for solving the problem]

[0008] The present invention is a decorative sheet comprising a main body having a base layer, a colored layer, and a design layer, and a primer layer provided on the base layer on the side opposite the colored layer. The primer layer includes a main layer formed of a synthetic resin and silica particles disposed in the main layer, the particle size of the silica particles being 1.5 to less than 3 times the thickness of the main layer, and the mass of the silica particles being 5 to 10% of the mass of the synthetic resin. Effect of the Invention

[0009] According to the present invention, it is possible to provide a decorative sheet that can be satisfactorily attached to an object even when using adhesives that have been widely used in recent years. [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 is a schematic cross-sectional view showing a decorative sheet according to one embodiment of the present invention. [Diagram 2] FIG. 2 is a schematic cross-sectional view showing one configuration example of the main body portion of the decorative sheet. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] An embodiment of the present invention will be described with reference to FIGS. 1 is a plan view of a decorative sheet 1 according to this embodiment. The decorative sheet 1 comprises a main body 10, the upper surface of which defines the appearance of the entire sheet, and a primer layer 20 provided on the lower surface of the main body 10.

[0012] There are no particular limitations on the configuration of the main body 10, and various known configurations can be adopted, one example of which is shown in FIG. The main body 10 shown in FIG. 2 has a configuration in which a colored layer 12, a design layer 13, a concave-convex layer 14, and a protective layer 15 are successively formed on a base layer 11.

[0013] The base layer 11 is formed of a synthetic resin film. Examples of the material include polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), polybutylene naphthalate (PBN), etc. Examples of the method for producing the film include a calendar method, an inflation method, a T-die extrusion method, etc. The base layer 11 may be a single layer or may have multiple layers. Furthermore, a layer may contain two or more types of rigid resins.

[0014] The colored layer 12 is also called a concealing layer or a full solid layer that imparts an intended color to the surface of the base layer 11, and is a uniform layer that covers the entire upper surface side of the base layer 11. The colored layer 12 is usually formed in an opaque color, but may be formed in a colored transparent state. It may also be colorless and transparent for the purpose of making use of the base color of the base layer 11.

[0015] The pattern layer 13 imparts design with a desired pattern to the colored layer 12. The type of pattern can be various depending on the form of the colored layer, such as a wood grain pattern, a stone grain pattern, a sand grain pattern, a tiled pattern, a brickwork pattern, a fabric pattern, a leather-stained pattern, a geometric figure, a letter, a symbol, an abstract pattern, etc.

[0016] The uneven layer 14 is made of a transparent resin and determines the tactile feel of the upper surface of the main body 10. The protective layer 15 protects the uneven shape of the uneven layer 14 by covering the uneven layer 14. Examples of materials for the uneven layer 14 and the protective layer 15 include ionizing radiation curable resins and two-component curable urethane resins. The uneven shape of the uneven layer 14 can be formed, for example, by pressing an embossing plate against a material layer that is not completely cured. In cases where the uneven layer 14 has sufficient hardness, the protective layer 15 may be omitted. In cases where the body portion 10 does not require a tactile sensation due to unevenness, the uneven layer 14 may be omitted and only the flat protective layer 15 may be provided on the design layer 13.

[0017] As another example of the configuration of the main body 10, one or more adhesive layers may be present between any of the layers. For example, when the main body is manufactured by separately preparing the uneven layer 14 and the protective layer 15 and the layer below them, and bonding them together with an adhesive layer, the layer configuration is such that the adhesive layer is located between the uneven layer 14 and the design layer.

[0018] The primer layer 20 according to this embodiment has a main layer made of a base resin and silica particles disposed in the main layer. Examples of the base resin include acrylic-modified urethane resins such as block copolymers of acrylic and urethane, polyester urethane / vinyl chloride acetate resins, and polycarbonate resins.

[0019] The particle size of the silica particles is 1.5 times or more and less than 3 times the thickness of the main layer. This ensures that the silica particles are arranged in the primer layer 20 with a part of the silica particles always exposed on the main layer. Furthermore, since at least half of the silica particles are located within the main layer, the silica particles are unlikely to fall off from the main layer.

[0020] The inventors have conducted various studies on the optimal amount of silica particles from the viewpoint of improving the bonding strength to the object when using one-part water-based adhesives and one-part polyurethane-based moisture-curing urethane hot melt adhesives. As a result, they have found that the bonding strength is highest when silica particles are blended in an amount of 5% to 10% of the material forming the main layer. Details of this point will be described later using experimental examples.

[0021] The primer layer 20 can be formed by applying and drying a coating liquid containing the resin material of the main layer, silica particles, and, if necessary, a solvent, onto the base material layer 11 that constitutes the lower surface of the main body 10. The thickness of the primer layer 20 can be, for example, 0.5 μm to 10.0 μm.

[0022] The decorative sheet 1 according to this embodiment can be attached to an object by applying an adhesive to at least one of the object or the primer layer 20, and joining the primer layer 20 to the object. The object is typically MDF (medium density fiberboard), but is not limited thereto, and can also be applied to surfaces made of various materials such as metal plates and concrete.

[0023] The surface area of ​​the primer layer 20 is increased by the silica particles exposed on the main layer, which increases the contact area with the adhesive per unit area of ​​the decorative sheet 1, contributing to improved bonding strength. Furthermore, when bonding to an object, the exposed parts of the silica particles are embedded in the adhesive layer, so after the adhesive hardens, they also function as an anchor that prevents the primer layer from coming off the adhesive. Due to these actions, the primer layer 20 according to this embodiment exhibits good bonding properties not only with one-component water-based adhesives and polyurethane-based one-component moisture-curing urethane hot melt adhesives that have been widely used in recent years, but also with a wide range of adhesives. As a result, the decorative sheet 1 according to this embodiment is highly versatile.

[0024] The primer layer 20 may contain a cellulose additive. By containing a cellulose additive, an additional advantage can be obtained in that sticking (blocking) can be suppressed when the decorative sheet is stored in a rolled state.

[0025] The decorative sheet according to this embodiment will be described in more detail using experimental examples. The technical scope of the present invention is not limited solely by the specific content of the experimental examples.

[0026] (Experimental Example 1) In the decorative sheet according to this embodiment, the layers above the base material layer 11 do not affect the bonding strength with the target object, so in this experimental example, only the base material layer was prepared as the component corresponding to the main body portion. A multi-layered sheet (total thickness 125 μm) using polypropylene and polyethylene was prepared as the base layer. A primer layer was formed on one side of the base layer by coating and drying a coating liquid made by adding an appropriate amount of solvent to the primer layer material of the following composition. The coating amount after drying was 1 g / m2. 2 As a result, the thickness of the main layer in the primer layer was approximately 1 μm. Main layer material: Polyester urethane / vinyl chloride resin Silica particles (average particle size 2μm) 6% by mass (wt%) of main layer material Cellulose additive 10wt% of main layer material In this manner, a decorative sheet according to Experimental Example 1 was produced.

[0027] (Experimental Example 2) A decorative sheet according to Experimental Example 2 was produced in the same manner as in Experimental Example 1, except that the amount of silica particles in the coating liquid was 9 wt % of the main layer material. (Experimental Example 3) A decorative sheet according to Experimental Example 2 was produced in the same manner as in Experimental Example 1, except that the amount of silica particles in the coating liquid was 1.5 wt % of the main layer material. (Experimental Example 4) A decorative sheet according to Experimental Example 2 was produced in the same manner as in Experimental Example 1, except that the amount of silica particles in the coating liquid was 3 wt % of the main layer material. (Experimental Example 5) A decorative sheet according to Experimental Example 5 was produced in the same manner as in Experimental Example 3, except that no cellulose additive was added to the coating liquid.

[0028] The decorative sheets according to the respective examples were evaluated as follows. (Evaluation of bond strength with the target object) The target object was a 3 mm thick MDF, to which the decorative sheet according to each example was attached using an adhesive, and the adhesive layer was allowed to harden by leaving it to stand for 48 hours. The following two types of adhesive were used, and one sample of each was created. BA-10 (Polyurethane-based one-component moisture-curing urethane hot melt adhesive, manufactured by Nippon Coating Resin Co., Ltd.) AE-126 (one-component water-based adhesive, manufactured by Aica Kogyo Co., Ltd.)

[0029] Each sample was cut to a length of 150 mm and a width of 25 mm, held with the decorative sheet facing down, and a 500g weight was attached to one end of the base layer in the longitudinal direction. A 500g load was applied in the 90° direction and left in a room at 60°C for 1 hour. The adhesive layer's bonding strength and durability were examined under accelerated conditions. The following two points were evaluated. Length of peeled decorative sheet (peel distance) Condition of the peeled surface (presence or absence of small pieces of the target object)

[0030] (Blocking evaluation) The decorative sheet of each example was rolled up and stored for a certain period of time, and then unrolled and evaluated for the presence or absence of sticking (blocking). The results are shown in Table 1.

[0031] [Table 1]

[0032] In Experimental Examples 1 and 2, the peel distance was short and sufficient bonding with the object was observed. At the peeled surface, the adhesive layer was located on the decorative sheet side, and adhesion of the object was observed. On the other hand, in Experimental Examples 3 and 4, the peel distance was long, and in the sample using AE-126, the decorative sheet was completely peeled off from the target object. In addition, no adhesion of the target object or adhesive was observed on the primer layer side of the peeled surface, and interfacial peeling occurred between the primer layer and the adhesive layer. These results confirmed that a primer layer containing 5% to 10% silica particles with a particle size between 1.5 and 3 times the thickness of the main layer can improve the bond to the target object. Furthermore, in Experimental Example 5, which did not contain a cellulose additive, the occurrence of blocking was observed, confirming the blocking suppressing effect of the cellulose additive.

[0033] The present invention has been described above using embodiments and experimental examples, but the specific configurations are not limited to these embodiments, and modifications and combinations of the configurations that do not deviate from the gist of the present invention are also included. [Explanation of symbols]

[0034] 1 Decorative sheet 10 Main body 11 Base material layer 12 Colored layer 13 Picture layer 20 Primer layer

Claims

1. A main body portion having a base layer, a coloring layer, and a pattern layer; A primer layer provided on the substrate layer opposite to the colored layer; Equipped with The primer layer is A main layer formed of a synthetic resin; Silica particles disposed in the main layer, the particle size of the silica particles is 1.5 times or more and less than 3 times the thickness of the main layer; The mass of the silica particles is 5% or more and 10% or less of the mass of the synthetic resin. Decorative sheet.

2. The primer layer contains a cellulose additive in an amount of 10% or less by mass of the synthetic resin. The decorative sheet according to claim 1 .

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