Decorative board

Abstract

To provide a decorative board capable of reducing odors emitted from a decorative board containing recycled resin.SOLUTION: A decorative board 10 comprises: a plastic molded base material 11 composed of recycled resin; an odor barrier sheet 20 bonded to the plastic molded base material 11; and an adhesive layer 15 that bonds the odor barrier sheet 20 and the plastic molded base material 11 to each other. The odor barrier sheet 20 comprises a film base material 21, a vapor-deposited barrier layer 22, and a primer layer 23 in this order from the plastic molded base material 11 side.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to decorative laminates. [Background technology]

[0002] In recent years, there has been a demand for recycling plastic products in order to make effective use of limited resources. Generally, recycled resins have limited uses when reused, unless they are highly separated. This is because the resins used as raw materials before recycling contain colorants, additives, and other unintended additives.

[0003] In particular, it is difficult to make the color tone of recycled resin transparent or bright white or pale color and to reproduce this color tone stably. In many cases, a colorant is further added to the recycled resin to make it black or dark color tone. Specifically, benches and flower pots, where color tone is not very important, are known as applications for utilizing recycled resin. In order to solve such problems, there is an invention in which a concealing layer is laminated on the recycled resin to make it a bright white base material (see Patent Document 1). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2010-221665 A Summary of the Invention [Problem to be solved by the invention]

[0005] Incidentally, it has been known that substrates containing recycled resins emit odors. This odor is believed to be caused by highly volatile, low-molecular-weight odorous substances. These substances are considered difficult to separate in existing recycling systems due to reasons such as cost and complicated work. For this reason, in order to use recycled resins on a wider scale, it is necessary to solve the odor problem. In particular, when recycled resins are used as decorative panels for buildings, etc., odors inside the building must be suppressed, and therefore odor control measures are important.

[0006] The present disclosure provides a decorative board that is capable of suppressing odor generation from a decorative board containing recycled resin. [Means for solving the problem]

[0007] The embodiments of the present disclosure relate to the following [1] to

[11] .

[0008] [1] A decorative plate comprising: a plastic molded substrate made of recycled resin; an odor barrier sheet adhered to the plastic molded substrate; and an adhesive layer that adheres the odor barrier sheet and the plastic molded substrate to each other, the odor barrier sheet including, in order from the plastic molded substrate side, a film substrate, a vapor deposition barrier layer, and a primer layer.

[0009] [2] The decorative board according to [1], further comprising a decorative film adhered to the odor barrier sheet.

[0010] [3] The decorative panel described in [1] or [2], wherein the plastic molded substrate has a first surface, a second surface opposite the first surface, a third surface perpendicular to the first surface, and a fourth surface opposite the third surface, and the odor barrier sheet covers the first surface, the third surface, and the fourth surface of the plastic molded substrate.

[0011] [4] A decorative panel described in either [1] or [2], wherein the plastic molded substrate has a first side, a second side opposite the first side, a third side perpendicular to the first side, and a fourth side opposite the third side, and the odor barrier sheet covers the first side, the second side, the third side, and the fourth side of the plastic molded substrate.

[0012] [5] A decorative board comprising a plastic molding substrate made of recycled resin, a decorative film adhered to the plastic molding substrate, and an adhesive layer that adheres the decorative film and the plastic molding substrate to each other, wherein the decorative film includes, in order from the plastic molding substrate side, a primer layer, a film substrate, a colored layer, a picture layer, and a coating layer, and the decorative film or the adhesive layer contains an odor adsorbent.

[0013] [6] The decorative board according to [5], wherein the film substrate contains an odor adsorbent.

[0014] [7] The decorative board according to [5] or [6], wherein the primer layer contains an odor adsorbent.

[0015] [8] The decorative board according to any one of [5] to [7], wherein the adhesive layer contains an odor adsorbent.

[0016] [9] A decorative panel described in any one of [5] to [8], wherein the plastic molding substrate has a first surface, a second surface opposite the first surface, a third surface perpendicular to the first surface, and a fourth surface opposite the third surface, and the decorative film covers the first surface, the third surface, and the fourth surface of the plastic molding substrate.

[0017]

[10] A decorative panel described in any one of [5] to [9], wherein the plastic molding substrate has a first surface, a second surface opposite the first surface, a third surface perpendicular to the first surface, and a fourth surface opposite the third surface, and the decorative film covers the first surface, the second surface, the third surface, and the fourth surface of the plastic molding substrate.

[0018]

[11] A decorative panel according to any one of [1] to

[10] , which is used as a building material. Effect of the Invention

[0019] According to this embodiment, it is possible to suppress the generation of odor from the decorative board containing recycled resin. [Brief description of the drawings]

[0020] [Figure 1] FIG. 1 is a cross-sectional view showing a decorative board according to a first embodiment. [Diagram 2] FIG. 2 is a cross-sectional view showing a decorative board according to a modified example of the first embodiment. [Figure 3A] FIG. 3A is a cross-sectional view showing a decorative board according to a modified example of the first embodiment. [Figure 3B] FIG. 3B is a cross-sectional view showing a decorative board according to a modified example of the first embodiment. [Figure 4] FIG. 4 is a cross-sectional view showing a decorative board according to the second embodiment. [Figure 5A] FIG. 5A is a cross-sectional view showing a decorative board according to a modified example of the second embodiment. [Figure 5B] FIG. 5B is a cross-sectional view showing a decorative board according to a modified example of the second embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] Each embodiment will be specifically described below with reference to the drawings. Each of the figures shown below is a schematic diagram. Therefore, the size and shape of each part are appropriately exaggerated to facilitate understanding. In addition, it is possible to carry out appropriate modifications within the scope of the technical idea. In each of the figures shown below, the same parts are given the same reference numerals, and some detailed descriptions may be omitted. In addition, the numerical values ​​such as dimensions of each member and the material names described in this specification are examples of embodiments, and are not limited thereto, and can be appropriately selected and used. In this specification, terms that specify shapes and geometric conditions, such as parallel, orthogonal, and vertical, include substantially the same state in addition to their strict meanings. In addition, for convenience of explanation, the terms "upper" and "lower" may be used in the explanation, but the up-down direction may be reversed.

[0022] (First embodiment) The first embodiment will be described with reference to Figures 1 to 3B. Figures 1 to 3B are diagrams showing the first embodiment.

[0023] As shown in Fig. 1, a decorative board 10 according to the present embodiment includes a plastic molded substrate 11, an odor barrier sheet 20, and a first adhesive layer 15. The plastic molded substrate 11 is made of recycled resin. The odor barrier sheet 20 is adhered to the plastic molded substrate 11. The first adhesive layer 15 adheres the odor barrier sheet 20 and the plastic molded substrate 11 to each other. The odor barrier sheet 20 includes, in order from the plastic molded substrate 11 side, a first film substrate 21, a vapor deposition barrier layer 22, and a first primer layer 23.

[0024] 2, a decorative film 30 may be adhered to the odor barrier sheet 20 via a second adhesive layer 16. The decorative film 30 includes, in order from the odor barrier sheet 20 side, a second primer layer 31, a second film substrate 32, a colored layer 33, a pattern layer 34, and a coating layer 35.

[0025] Next, each layer constituting the decorative board 10 according to this embodiment will be further described.

[0026] (Plastic molding substrate) The plastic molded substrate 11 is a layer that becomes the core of the decorative board 10. The plastic molded substrate 11 may be in the shape of a plate, a rectangular parallelepiped, or a cylinder. At least one surface of the plastic molded substrate 11 is preferably a flat surface or a cylindrical surface to which the odor barrier sheet 20 can be easily attached. In the following, an example in which the plastic molded substrate 11 is in the shape of a rectangular parallelepiped will be described. The plastic molded substrate 11 may be produced by a molding method such as vacuum / pressure molding or injection molding.

[0027] The plastic molding substrate 11 contains recycled resin. In this specification, "recycled resin" refers to resin obtained by recycling used resin. The plastic molding substrate 11 may contain virgin resin in addition to recycled resin. "Virgin resin" refers to resin that has not been subjected to recycling treatment, i.e., unused resin. When the plastic molding substrate 11 contains virgin resin, the content of the virgin resin is preferably 20 parts by mass or more and less than 100 parts by mass, and more preferably 60 parts by mass or more and 90 parts by mass or less, relative to 100 parts by mass of the total amount of resin material contained in the plastic molding substrate 11.

[0028] The plastic molding substrate 11 may contain mechanically recycled resin. In this specification, "mechanically recycled resin" refers to resin obtained as follows. First, resin collected from the market or production process is sorted, crushed, and washed to remove contaminants and foreign matter to obtain flakes. Next, the flakes are further treated at high temperature and reduced pressure for a certain period of time to remove contaminants inside the resin.

[0029] The main resin material of the plastic molding substrate 11 may be a polyester resin such as polyethylene terephthalate (PET), polybutylene terephthalate, polyethylene naphthalate, polyarylate, polycarbonate, copolymerized polyester (typically 1,4-cyclohexanedimethanol copolymerized polyethylene terephthalate resin, commonly known as PET-G), or a polyolefin resin such as polypropylene (PP). By using the above-mentioned material as the main resin material of the plastic molding substrate 11, the strength and heat resistance of the plastic molding substrate 11 can be increased. In this specification, the term "main resin material" refers to a resin contained in an amount of more than 50 parts by mass per 100 parts by mass of the total amount of resin materials contained in the target object, regardless of whether it is a virgin resin or a recycled resin.

[0030] The plastic molding substrate 11 may be a single layer, or may include multiple layers. The plastic molding substrate 11 may be mixed with a resin other than the above-mentioned resin materials.

[0031] The thickness of the plastic molded substrate 11 may be 0.05 mm or more, or 2 mm or more. The thickness of the plastic molded substrate 11 may be 50 mm or less, or 20 mm or less. The plastic molded substrate 11 may be the thickest layer of the decorative board 10.

[0032] The plastic molding substrate 11 has a first surface 11a, a second surface 11b, a third surface 11c, and a fourth surface 11d. The first surface 11a faces the user when the decorative board 10 is in use. The second surface 11b is located on the opposite side to the first surface 11a. The second surface 11b is parallel to the first surface 11a. The third surface 11c is perpendicular to the first surface 11a and the second surface 11b. The fourth surface 11d is located on the opposite side to the third surface 11c. The fourth surface 11d is parallel to the third surface 11c. The fourth surface 11d is perpendicular to the first surface 11a and the second surface 11b. The first surface 11a and the second surface 11b may be wider than the third surface 11c and the fourth surface 11d.

[0033] (Odor barrier sheet) The odor barrier sheet 20 is a layer that prevents odors generated from the plastic molded substrate 11 from leaking to the outside. The odor barrier sheet 20 preferably covers the entire target surface (the surface that suppresses odors) of the plastic molded substrate 11. The surface to which the odor barrier sheet 20 is adhered may be the widest surface of the plastic molded substrate 11. In this embodiment, the odor barrier sheet 20 covers the entire first surface 11a of the plastic molded substrate 11. As described above, the odor barrier sheet 20 includes, in order from the plastic molded substrate 11 side, the first film substrate 21, the vapor deposition barrier layer 22, and the first primer layer 23.

[0034] (First film substrate) The first film substrate 21 is located closest to the plastic molded substrate 11 in the odor barrier sheet 20. The first film substrate 21 is a layer that suppresses the leakage of odor generated from the plastic molded substrate 11 to the outside. The first film substrate 21 may be a flexible film.

[0035] The main resin material of the first film substrate 21 may be, for example, a polyester-based resin such as polyethylene terephthalate (PET), polybutylene terephthalate, polyethylene naphthalate, polyarylate, polycarbonate, copolymerized polyester (typically 1,4-cyclohexanedimethanol copolymerized polyethylene terephthalate resin, commonly known as PET-G), or a polyolefin resin such as polypropylene (PP), cyclic polyolefin, or a polyamide resin such as various nylons. By using the above-mentioned materials as the main resin material of the first film substrate 21, the odor-retaining property of the odor barrier sheet 20 can be improved. This makes it possible to suppress the odor from the plastic molded substrate 11 from penetrating the odor barrier sheet 20.

[0036] The main resin material of the first film substrate 21 may be the same type of material as the main resin material of the plastic molded substrate 11. In this case, the decorative board 10 can be easily recycled when it is discarded.

[0037] The thickness of the first film substrate 21 may be 5 μm or more, or may be 10 μm or more. The thickness of the first film substrate 21 may be 200 μm or less, or may be 30 μm or less.

[0038] The first film substrate 21 may be produced, for example, by using one type of resin and forming a film using a film-forming method such as an extrusion method, a cast molding method, a T-die method, a cutting method, or an inflation method. The first film substrate 21 may be produced by a multilayer co-extrusion film-forming method using two or more types of resins, or a method in which two or more types of resins are mixed before film formation and formed by the above-mentioned film-forming method. Furthermore, the first film substrate 21 may be a film stretched in a uniaxial or biaxial direction using a tenter method, a tubular method, or the like.

[0039] (Deposition barrier layer) The vapor deposition barrier layer 22 is a layer for more effectively suppressing the transmission of odors from the plastic molding substrate 11. The vapor deposition barrier layer 22 may be disposed directly on the first film substrate 21. The vapor deposition barrier layer 22 may be disposed so as to cover the entire first film substrate 21.

[0040] The deposition barrier layer 22 may be a deposition film of one or more inorganic substances or inorganic oxides, such as silicon, aluminum, magnesium, calcium, potassium, tin, sodium, boron, titanium, lead, zirconium, yttrium, etc. The deposition barrier layer 22 may be composed of two or more types of materials, and may be composed of the same material or different materials.

[0041] The deposition barrier layer 22 may be a transparent deposition layer that can be formed by a conventionally known method. In this case, the deposition barrier layer 22 may be a transparent deposition layer made of a deposition layer of an inorganic oxide. In this way, the deposition barrier layer 22 is a transparent deposition layer, so that it is possible to impart or improve gas barrier properties that prevent the permeation of water vapor and the like while maintaining the permeability of the contents.

[0042] The thickness of the vapor-deposited barrier layer 22 may be 10 nm or more, or may be 20 nm or more. The thickness of the vapor-deposited barrier layer 22 may be 200 nm or less, or may be 100 nm or less.

[0043] Methods for forming the deposition barrier layer 22 include, for example, physical vapor deposition methods such as vacuum deposition, sputtering, and ion plating, or chemical vapor deposition methods such as plasma chemical vapor deposition, thermal chemical vapor deposition, and photochemical vapor deposition.

[0044] (First primer layer) The first primer layer 23 serves to improve adhesion between the odor barrier sheet 20 and, for example, the decorative film 30 shown in Fig. 2. The first primer layer 23 may be disposed directly on the vapor deposition barrier layer 22. The first primer layer 23 may be disposed so as to cover the entire vapor deposition barrier layer 22. The first primer layer 23 may be disposed only in an area of ​​the surface of the vapor deposition barrier layer 22 where, for example, the decorative film 30 is to be disposed.

[0045] The first primer layer 23 may contain a polymer material. A colorless and transparent polymer material may be used as the main material of the first primer layer 23. The first primer layer 23 may also contain a thermoplastic resin such as a urethane resin, a polyamide resin, an acrylic resin, or a vinyl acetate resin, a thermosetting resin such as a thermosetting urethane resin, a two-component curing type urethane resin using an isocyanate as a curing agent, a polyester resin, or an ester polyurethane resin. From the viewpoint of suitably improving the adhesion with the decorative film 30, the content of the polymer material is more preferably 40% by mass or more, and even more preferably 50% by mass or more, based on the mass of the entire first primer layer 23.

[0046] The thickness of the first primer layer 23 may be 1 μm or more, 2 μm or more, or 3 μm or more. The thickness of the first primer layer 23 may be 10 μm or less, 8 μm or less, or 6 μm or less.

[0047] (First adhesive layer) The first adhesive layer 15 is located between the plastic molded substrate 11 and the odor barrier sheet 20. The first adhesive layer 15 is a layer that bonds the plastic molded substrate 11 and the odor barrier sheet 20 to each other.

[0048] The first adhesive layer 15 can be formed by a conventional method, for example, a dry lamination method. When two layers are bonded by the dry lamination method, the first adhesive layer 15 is formed by applying an adhesive to the surface of the layer to be laminated and drying it. The adhesive to be applied can be, for example, a one-component or two-component curing or non-curing type vinyl, (meth)acrylic, polyamide, polyester, polyether, polyurethane, epoxy, rubber, or other solvent-based, water-based, or emulsion-type adhesive. A two-component curing adhesive can be a cured product of a polyol and an isocyanate compound. The above-mentioned lamination adhesive can be applied by, for example, a direct gravure roll coating method, a gravure roll coating method, a kiss coating method, a reverse roll coating method, a Fountain method, a transfer roll coating method, or other methods.

[0049] The thickness of the first adhesive layer 15 may be 1 μm or more, or may be 5 μm or more. The thickness of the first adhesive layer 15 may be 100 μm or less, or may be 50 μm or less.

[0050] (Decorative film) As shown in FIG. 2, a decorative film 30 may be adhered to the odor barrier sheet 20 via a second adhesive layer 16. In this case, the decorative film 30 is located as the outermost layer of the decorative board 10. The decorative film 30 is a layer that imparts design to the decorative board 10. The decorative film 30 may cover the entire odor barrier sheet 20. As described above, the decorative film 30 includes, in order from the odor barrier sheet 20 side, a second primer layer 31, a second film substrate 32, a colored layer 33, a pattern layer 34, and a coating layer 35.

[0051] (Second primer layer) The second primer layer 31 serves to improve the adhesion between the decorative film 30 and the odor barrier sheet 20. The second primer layer 31 may be disposed so as to cover the entire second film substrate 32.

[0052] The second primer layer 31 can be made of a material selected from those listed above as the main materials of the first primer layer 23. The material of the second primer layer 31 may be the same as the material of the first primer layer 23, or may be different from the material of the first primer layer 23.

[0053] The thickness of the second primer layer 31 may be 1 μm or more, 2 μm or more, or 3 μm or more. The thickness of the second primer layer 31 may be 10 μm or less, 8 μm or less, or 6 μm or less.

[0054] (Second film substrate) The second film substrate 32 may be a layer that supports the colored layer 33, the pattern layer 34, etc., and increases the strength of the entire decorative film 30. The second film substrate 32 may be disposed directly on the second primer layer 31. The second film substrate 32 may be a flexible film.

[0055] The main resin material of the second film substrate 32 may be, for example, a polyester-based resin such as polyethylene terephthalate (PET), polybutylene terephthalate, polyethylene naphthalate, polyarylate, polycarbonate, copolymerized polyester (typically 1,4-cyclohexanedimethanol copolymerized polyethylene terephthalate resin, commonly known as PET-G), or a polyolefin resin such as polypropylene (PP). The second film substrate 32 may be colored in a color such as red, blue, yellow, green, brown, black, or white, or may be colorless. The second film substrate 32 may be transparent or opaque.

[0056] The main resin material of the second film substrate 32 may be the same type of material as the main resin material of the plastic molded substrate 11. In this case, the decorative board 10 can be easily recycled when it is discarded.

[0057] The thickness of the second film substrate 32 may be 5 μm or more, or may be 10 μm or more. The thickness of the second film substrate 32 may be 200 μm or less, or may be 30 μm or less.

[0058] (colored layer) The colored layer 33 may be a layer that conceals the color of the plastic molding substrate 11. The colored layer 33 may be disposed directly on the second film substrate 32.

[0059] The colored layer 33 may be a printed layer formed by printing on the second film substrate 32. The colored layer 33 may be a solid printed layer consisting of a single color and not including any pattern or lettering. The colored layer 33 can be formed by printing a colored ink composition on the second film substrate 32 by a printing method such as gravure printing, offset printing, letterpress printing, screen printing, transfer printing, flexographic printing, digital printing, or the like. The colored layer 33 may be colored in red, blue, yellow, green, brown, black, white, or the like, but is preferably white.

[0060] The colored layer 33 is provided below the pattern layer 34 when viewed from the coat layer 35 side (surface). When the colored layer 33 is white, it is obtained by adding a white dye or inorganic pigment, an extender pigment, and other additives to the same binder resin as that used for the pattern layer 34. Examples of the white inorganic pigment include titanium white, zinc oxide, and antimony trioxide, and examples of the extender pigment include calcium carbonate, kaolin, barium sulfate, and aluminum hydroxide. The average particle size of the white inorganic pigment may be 1 μm or more and 10 μm or less. The amount of the white pigment added is appropriately selected depending on the pattern resulting from the desired gloss state, but it is usually preferable that the amount of the white pigment added is a maximum of 30 mass % of the total mass of the colored layer 33.

[0061] The thickness of the colored layer 33 may be 1 μm or more, or may be 5 μm or more. The thickness of the colored layer 33 may be 30 μm or less, or may be 10 μm or less.

[0062] (Picture layer) The design layer 34 is a layer that imparts design to the decorative film 30. The design layer 34 may be disposed directly on the colored layer 33.

[0063] The pattern layer 34 may be a printed layer formed by printing on the colored layer 33. For the pattern layer 34, a pattern suitable for the location where the decorative board 10 is used can be selected, such as a wood grain pattern, a cork pattern, a stone pattern, a sand pattern, a tiled pattern, a brickwork pattern, a fabric pattern, a leather pattern, an abstract pattern, or the like.

[0064] The printing ink for forming the design layer 34 is not particularly limited as long as it has printability and weather resistance. For example, printing inks containing isoindolinone, disazo, polyazo, diketopyrrolopyrrole, quinacridone, phthalocyanine, titanium oxide, or carbon black as a pigment can be used for the printing ink for forming the design layer 34. By adding an ultraviolet absorber, a light stabilizer, or the like to the printing ink for forming the design layer 34, it is possible to improve weather resistance.

[0065] The thickness of the pattern layer 34 is not particularly limited and can be set appropriately depending on the product characteristics, but may be, for example, about 0.1 μm or more and 15 μm or less.

[0066] (Coat layer) The coating layer 35 is a layer that protects the design layer 34. The coating layer 35 is preferably a transparent sheet-like resin layer that allows the design layer 34 to be visually recognized. The coating layer 35 may be disposed directly on the design layer 34.

[0067] For example, a (meth)acrylate-based cured resin can be used as the main resin material of the coating layer 35. The coating layer 35 can be hard and strong because it is formed using a (meth)acrylate-based cured resin. Furthermore, the coating layer 35 has excellent bending processability because it is formed using a urethane (meth)acrylate-based cured resin.

[0068] The thickness of the coating layer 35 may be, for example, not less than 1 μm and not more than 50 μm.

[0069] (Second adhesive layer) The second adhesive layer 16 is located between the odor barrier sheet 20 and the decorative film 30. The second adhesive layer 16 is a layer that bonds the odor barrier sheet 20 and the decorative film 30 to each other.

[0070] The main material of the second adhesive layer 16 can be selected from those listed above as the main materials of the first adhesive layer 15. The main material of the second adhesive layer 16 may be the same as the main material of the first adhesive layer 15, or may be different from the main material of the first adhesive layer 15.

[0071] The thickness of the second adhesive layer 16 may be 1 μm or more, or may be 5 μm or more. The thickness of the second adhesive layer 16 may be 100 μm or less, or may be 50 μm or less.

[0072] At least one of the second primer layer 31, the second film substrate 32, and the second adhesive layer 16 may contain an odor adsorbent, which will be described later.

[0073] (Use of decorative panels) The decorative board 10 according to the present embodiment has excellent weather resistance. The decorative board 10 according to the present embodiment can be used for various purposes as it is or after undergoing a predetermined molding process, etc. For example, it can be laminated to a substrate such as a flat plate, a curved plate, or a sheet (or film) made of various materials and used as an interior and exterior building material, for example, cabinets for furniture and kitchen products, tabletops used for various counters and desks, and building materials for homes such as doors.

[0074] [Manufacturing method of decorative panels] Next, a method for manufacturing the decorative board 10 according to this embodiment will be described.

[0075] First, the plastic molding substrate 11 is prepared. The plastic molding substrate 11 is made of recycled resin. The plastic molding substrate 11 may be a substrate made by thermoforming recycled resin formed using resin materials collected from the market or from production processes, etc., by vacuum / compressed air molding or the like. Alternatively, the plastic molding substrate 11 may be a substrate made by injection molding recycled resin.

[0076] Next, an adhesive constituting the first adhesive layer 15 is applied to the first surface 11a of the plastic molded substrate 11, and then the odor barrier sheet 20 is attached and dried. This results in the decorative board 10 shown in FIG.

[0077] Furthermore, an adhesive constituting the second adhesive layer 16 may be applied to one side of the odor barrier sheet 20, and the decorative film 30 may be attached thereto and then dried. In this way, the decorative board 10 shown in FIG. 2 is obtained.

[0078] The method for applying the first adhesive layer 15 and the second adhesive layer 16 is not particularly limited, and examples thereof include a direct gravure roll coating method, a gravure roll coating method, a kiss coating method, a reverse roll coating method, a Fontaine method, a transfer roll coating method, an extrusion coating method, and the like.

[0079] [Operation of this embodiment] Next, the operation of this embodiment having the above configuration will be described.

[0080] The decorative board 10 according to the present embodiment includes a plastic molded substrate 11 made of recycled resin. The recycled resin contained in the plastic molded substrate 11 may emit, for example, a burnt odor. This odor is believed to be caused by highly volatile, low-molecular odorous substances generated from the recycled resin.

[0081] In contrast, according to the present embodiment, the odor barrier sheet 20 is adhered to the plastic molded substrate 11. This prevents odors from the plastic molded substrate 11 from passing through the odor barrier sheet 20, and prevents odors from the plastic molded substrate 11 from reaching the front side (user side) of the decorative board 10. This reduces the odor of the decorative board 10, reducing the risk that the user will sense an odor.

[0082] Furthermore, according to this embodiment, a decorative film 30 may be adhered to the odor barrier sheet 20. In this case, the design of the decorative board 10 can be improved.

[0083] [Modification of decorative panels] In the above embodiment, the odor barrier sheet 20 covers only the first surface 11a of the plastic molded substrate 11. However, as shown in FIG. 3A, the odor barrier sheet 20 may cover the first surface 11a, the third surface 11c, and the fourth surface 11d of the plastic molded substrate 11. In this case, the odor barrier sheet 20 covers the entire first surface 11a, the entire third surface 11c, and the entire fourth surface 11d. The odor barrier sheet 20 does not need to cover the second surface 11b. This suppresses odors generated not only from the first surface 11a of the plastic molded substrate 11, but also from the third surface 11c and the fourth surface 11d.

[0084] As shown in Fig. 3B, the odor barrier sheet 20 may cover the first surface 11a, the second surface 11b, the third surface 11c, and the fourth surface 11d of the plastic molded substrate 11. In this case, the odor barrier sheet 20 covers the entire first surface 11a, the entire third surface 11c, and the entire fourth surface 11d. The odor barrier sheet 20 covers only a portion of the second surface 11b, but it may cover the entire second surface 11b. This suppresses odors generated not only from the first surface 11a of the plastic molded substrate 11, but also from the second surface 11b, the third surface 11c, and the fourth surface 11d.

[0085] (Second embodiment) Next, a second embodiment will be described with reference to Fig. 4 to Fig. 5B. Fig. 4 to Fig. 5B are diagrams showing the second embodiment. The second embodiment shown in Fig. 4 to Fig. 5B is different from the first embodiment in that odor is suppressed by an odor adsorbent contained in the decorative film 30 or the third adhesive layer 17 instead of the odor barrier sheet 20, and other configurations are substantially the same as those of the first embodiment described above. In Fig. 4 to Fig. 5B, the same parts as those in the first embodiment shown in Fig. 1 to Fig. 3B are denoted by the same reference numerals and detailed description will be omitted.

[0086] The decorative board 10 according to the present embodiment includes a plastic molded substrate 11, a decorative film 30, and a third adhesive layer 17. The plastic molded substrate 11 is made of recycled resin. The decorative film 30 is adhered to the plastic molded substrate 11. The third adhesive layer 17 adheres the odor barrier sheet 20 and the plastic molded substrate 11 to each other. The decorative film 30 includes, in order from the plastic molded substrate 11 side, a second primer layer 31, a second film substrate 32, a colored layer 33, a pattern layer 34, and a coating layer 35. The decorative film 30 or the third adhesive layer 17 contains an odor adsorbent.

[0087] Next, each layer constituting the decorative board 10 according to this embodiment will be described.

[0088] (Plastic molding substrate) The configuration of the plastic molding substrate 11 is similar to that of the plastic molding substrate 11 according to the first embodiment.

[0089] (Decorative film) The decorative film 30 is located on the outermost layer of the decorative board 10. The decorative film 30 is a layer that imparts design to the decorative board 10. The decorative film 30 is adhered to the plastic molding substrate 11 via the third adhesive layer 17. The surface to which the decorative film 30 is adhered may be the widest surface of the plastic molding substrate 11. In this case, the decorative film 30 covers the entire first surface 11a of the plastic molding substrate 11. As described above, the decorative film 30 includes, in order from the plastic molding substrate 11 side, the second primer layer 31, the second film substrate 32, the colored layer 33, the pattern layer 34, and the coating layer 35.

[0090] An odor adsorbent may be contained in the decorative film 30. Specifically, the odor adsorbent may be contained in at least one of the second primer layer 31 and the second film substrate 32.

[0091] The odor adsorbent has a function of adsorbing odorous substances derived from plastic molding substrates. As the odor adsorbent, inorganic porous bodies, hydrophobic zeolites, inorganic chemical odor adsorbents, etc. can be used.

[0092] The odor adsorbent may have any external shape, such as a sphere, a rod, an ellipse, etc., and may be in any form, such as a powder, a lump, or a granule. From the viewpoints of uniform dispersibility, kneading characteristics, film-forming properties, etc., when dispersed in a resin, a powder form is preferred.

[0093] The average particle diameter of the odor adsorbent can be selected as appropriate depending on the application, but an average particle diameter of 0.01 μm or more and 10 μm or less can be used. Here, the average particle diameter is a value measured by dynamic light scattering. When the average particle diameter is 0.01 μm or more, the odor adsorbent is less likely to aggregate and dispersibility is less likely to decrease. When the average particle diameter is 10 μm or less, the film-forming property of the layer containing the odor adsorbent is not reduced, it is not difficult to add the odor adsorbent, and the surface area is not reduced, so that a sufficient deodorizing effect can be obtained.

[0094] Any inorganic compound having a large number of pores on its surface can be used as the inorganic porous body, such as zeolite, silicon dioxide, silicate, activated carbon, titania, inorganic phosphates such as calcium phosphate, alumina, aluminum hydroxide, magnesium hydroxide, and mixtures thereof.

[0095] The SiO2 / Al2O3 molar ratio of the hydrophobic zeolite is preferably 30 / 1 to 10000 / 1, and may be 35 / 1 or more, 40 / 1 or more, 8500 / 1 or less, or 9000 / 1 or less. In general, the higher the SiO2 / Al2O3 molar ratio of the zeolite, the higher the hydrophobicity. In addition, the higher the hydrophobicity, the higher the affinity with odorous substances with low polarity, hydrophobic gases, and lipophilic gases (including solvent-based gases), and the easier it is to adsorb these. Furthermore, due to the effect of alkali metals and alkaline earth metals such as Ca, Na, and K present on the zeolite surface, the zeolite surface exhibits basicity, and acidic gases are easily adsorbed by neutralization reaction.

[0096] The inorganic chemical odor adsorbent is an adsorbent made of an inorganic compound other than zeolite. Specifically, an oxide and / or salt of one or more elements selected from the group consisting of copper, zinc, silver, platinum, gold, iron, and cobalt can be used. As the metal oxide, for example, CuO, Cu2O, ZnO, Ag2O, PtO2, Au2O3, FeO, Fe3O4, Fe2O3, CoO, Co2O3, Co3O4, etc., and aluminosilicates containing various metal oxides can be used.

[0097] In addition, the second primer layer 31, the second film substrate 32, the colored layer 33, the design layer 34, and the coating layer 35 may have the same configurations as those in the first embodiment.

[0098] (Third adhesive layer) The third adhesive layer 17 is located between the plastic forming substrate 11 and the decorative film 30. The third adhesive layer 17 is a layer that bonds the plastic forming substrate 11 and the decorative film 30 to each other.

[0099] The third adhesive layer 17 may contain an odor adsorbent. The odor adsorbent may be contained in the third adhesive layer 17 together with the decorative film 30. The odor adsorbent may be contained in the third adhesive layer 17 without being contained in the decorative film 30. Alternatively, the odor adsorbent may be contained in the decorative film 30 without being contained in the third adhesive layer 17.

[0100] The odor adsorbent can be selected from those described above. The main material and coating method of the third adhesive layer 17 can be selected from those listed as the main material and coating method of the first adhesive layer 15 above.

[0101] The thickness of the third adhesive layer 17 may be 1 μm or more, or may be 5 μm or more. The thickness of the third adhesive layer 17 may be 100 μm or less, or may be 50 μm or less.

[0102] [Modification of decorative panels] 5A, the decorative film 30 covers the first surface 11a, the third surface 11c, and the fourth surface 11d of the plastic molding substrate 11, but does not have to cover the second surface 11b. This suppresses odors emanating not only from the first surface 11a of the plastic molding substrate 11, but also from the third surface 11c and the fourth surface 11d.

[0103] 5B, the decorative film 30 may cover the first surface 11a, the second surface 11b, the third surface 11c, and the fourth surface 11d of the plastic molding substrate 11. This suppresses odors emanating not only from the first surface 11a of the plastic molding substrate 11, but also from the second surface 11b, the third surface 11c, and the fourth surface 11d.

[0104] [Example] Next, a specific example of this embodiment will be described.

[0105] Example 1 The decorative board shown in Figure 1 was produced. The plastic molded substrate was a recycled polyethylene terephthalate substrate (2 mm thick) made from polyethylene terephthalate bottles collected from the city. The first adhesive layer was applied to the plastic molded substrate, and the odor barrier sheet was attached. The first adhesive layer was a two-component curing adhesive (Japan Coating Resin Co., Ltd., water-soluble emulsion adhesive base: "BA-10L", Japan Coating Resin Co., Ltd., modified ethylene-vinyl acetate hardener: "BA-11B", blend ratio: base: hardener = 100:2.5 (mass ratio)) (30 μm thick). The odor barrier sheet was a laminate (Dai Nippon Printing Co., Ltd., IB-PET-PXB2) in which a vapor deposition barrier layer (12 μm thick) was laminated on a polyethylene terephthalate film substrate. The first primer layer was prepared by applying an adhesive (thickness: 3 μm) made of 100 parts by mass of an acrylic polyol-urethane mixed resin to which 11 parts by mass of hexamethylene diisocyanate had been added.

[0106] Example 2 The decorative board shown in FIG. 4 was produced. In the decorative board of Example 2, an odor adsorbent was added to the second film substrate. The plastic molded substrate was the same as the plastic molded substrate of Example 1. A second adhesive layer was applied to the plastic molded substrate, and the decorative film was attached. The second adhesive layer was the same as the first adhesive layer of Example 1. The second primer layer of the decorative film was the same as the first primer layer of Example 1 (thickness 3 μm). The second film substrate was a polyethylene terephthalate film substrate (manufactured by Toyobo Co., Ltd., "A4100") (thickness 50 μm). The odor adsorbent contained in the second film substrate was hydrophobic zeolite, Silton MT400, manufactured by Mizusawa Chemical Industry Co., Ltd., with a SiO2 / Al2O3 molar ratio of 400 / 1 and an average particle size of 5 to 7 μm. 20 parts by mass of hydrophobic zeolite was added to 80 parts by mass of the polyethylene terephthalate resin constituting the second film substrate. The colored layer was a white solid layer (20 μm thick) applied by gravure printing. The design layer was a layer (10 μm thick) applied by gravure printing with printing ink using a mixed resin of nitrocellulose and alkyd resin as a binder. The coating layer was a two-component curing acrylic resin (5 μm thick) with isocyanate as a curing agent.

[0107] Example 3 A decorative board was produced in the same manner as in Example 2, except that an odor adsorbent was contained in the second adhesive layer instead of the second film substrate. In this case, the second adhesive layer contained 30 parts by mass of hydrophobic zeolite as an odor adsorbent relative to 70 parts by mass of the adhesive component constituting the second adhesive layer.

[0108] Comparative Example 1 A decorative board consisting of only a plastic molded substrate was produced. The plastic molded substrate used was the same as that used in Example 1.

[0109] [Odor intensity determination] Five decorative boards each of Examples 1 to 3 and Comparative Example 1 were produced (N=1 to N=5), and the odor intensity of each was judged by a sensory evaluation by an examiner.

[0110] The results are shown in Table 1 below.

[0111] [Table 1]

[0112] In the above table, the ratings A to E refer to odor intensity according to the following criteria. A: Odorless B: Weak odor C: Easily detectable odor D: Strong odor E: Strong odor

[0113] As shown in Table 1, the decorative boards according to Examples 1-3 all had an odor intensity of A (odorless) or B (weak odor). The decorative boards according to Comparative Example 1 all had an odor intensity of E (strong odor). It was found that the decorative boards according to Examples 1-3 had less odor generation than the decorative board according to Comparative Example 1.

[0114] It is also possible to combine the multiple components disclosed in each of the above embodiments and modifications as necessary, or to delete some of the components disclosed in each of the above embodiments and modifications. [Explanation of symbols]

[0115] 10. Decorative Panels 11 Plastic molding substrate 15 First adhesive layer 16 Second adhesive layer 17 3rd adhesive layer 20 Odor Barrier Sheet 21 First film substrate 22 Deposition barrier layer 23 First primer layer 30 Decorative Film 31 Second primer layer 32 Second film substrate 33 Colored layer 34 Picture layer 35 Coating Layer

Claims

1. A plastic molding substrate made of recycled resin; an odor barrier sheet adhered to the plastic molded substrate; an adhesive layer that bonds the odor barrier sheet and the plastic molding substrate to each other; The odor barrier sheet is a decorative board including, in order from the plastic molded substrate side, a film substrate, a vapor deposition barrier layer, and a primer layer.

2. The decorative board of claim 1 further comprising a decorative film adhered to the odor barrier sheet.

3. The plastic molding substrate has a first surface, a second surface opposite to the first surface, a third surface perpendicular to the first surface, and a fourth surface opposite to the third surface; The decorative board of claim 1 , wherein the odor barrier sheet covers a first side, a third side, and a fourth side of the plastic molded substrate.

4. The plastic molding substrate has a first surface, a second surface opposite to the first surface, a third surface perpendicular to the first surface, and a fourth surface opposite to the third surface; The decorative board of claim 1 , wherein the odor barrier sheet covers a first surface, a second surface, a third surface, and a fourth surface of the plastic molded substrate.

5. A plastic molding substrate made of recycled resin; A decorative film adhered to the plastic molding substrate; an adhesive layer that bonds the decorative film and the plastic molding base material to each other; The decorative film includes, in order from the plastic molding substrate side, a primer layer, a film substrate, a colored layer, a design layer, and a coating layer, A decorative board, wherein the decorative film or the adhesive layer contains an odor adsorbent.

6. 6. The decorative board of claim 5, wherein said film substrate contains an odor adsorbent.

7. 6. The decorative board of claim 5, wherein the primer layer contains an odor adsorbent.

8. 6. The decorative board of claim 5, wherein the adhesive layer contains an odor adsorbent.

9. The plastic molding substrate has a first surface, a second surface opposite to the first surface, a third surface perpendicular to the first surface, and a fourth surface opposite to the third surface; The decorative board according to claim 5 , wherein the decorative film covers a first surface, a third surface, and a fourth surface of the plastic molding substrate.

10. The plastic molding substrate has a first surface, a second surface opposite to the first surface, a third surface perpendicular to the first surface, and a fourth surface opposite to the third surface; The decorative board according to claim 5 , wherein the decorative film covers a first surface, a second surface, a third surface, and a fourth surface of the plastic molding substrate.

11. The decorative board according to claim 1 , which is used as a building material.

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