Decorative sheet and decorative material

Abstract

To provide a decorative sheet and a decorative material by which environmental load can be reduced and deterioration of quality and sanitation can be inhibited even if including a recycled resin.SOLUTION: A decorative sheet includes a base material sheet, an ink layer, and a transparent resin layer in this order. At least one of the base material sheet and the transparent resin layer includes a recycled resin. The recycled resin includes a chemical recycled resin. A content percentage of a material recycled resin in the recycled resin is 40 vol% or less.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a cosmetic sheet and a cosmetic material.

Background Art

[0002] As a member constituting a cosmetic sheet, a laminate in which an ink layer forming a pattern or the like is provided on a base sheet is used. Generally, a transparent resin layer formed of a transparent resin material is further laminated on the ink layer to improve the design property. For example, in Patent Document 1 below, a pattern layer, an adhesive layer, a transparent thermoplastic resin layer, and a surface protection layer are laminated in this order on a thermoplastic resin base sheet, an emboss is formed at least on the transparent thermoplastic resin layer, and a surface activation treatment is performed on the back surface of the thermoplastic resin base sheet, and an embossed cosmetic sheet provided with a primer layer on the surface-activated surface is disclosed.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, conventionally, most of the resins used for cosmetic sheets were petroleum-derived resins. However, with the increasing environmental problems, recycled resins are being used to reduce the environmental load.

[0005] However, even if the resins contained in the thermoplastic resin base sheet and the transparent thermoplastic resin layer of the cosmetic sheet described in Patent Document 1 above are recycled resins, when the recycled resin is a recycled resin containing contaminants, so-called material recycled resin, impurities, foreign matters such as gels and aggregates may appear on the surface, and there was room for improvement in terms of quality.

[0006] In addition, in the cosmetic sheet described in Patent Document 1, even if the resin contained in the thermoplastic resin base sheet or the transparent thermoplastic resin layer is a recycled resin, odor components generated due to thermal deterioration of the resin are detected, and there is room for improvement in terms of hygiene.

[0007] An object of the present disclosure is to provide a cosmetic sheet and a cosmetic material that can suppress a decrease in quality and hygiene even when containing a recycled resin while reducing the environmental load.

Means for Solving the Problems

[0008] In order to solve the above problems, the present disclosure provides the following cosmetic sheet and cosmetic material.

[0009] [1] A cosmetic sheet comprising a base sheet, an ink layer, and a transparent resin layer in this order, at least one of the base sheet and the transparent resin layer containing a recycled resin, the recycled resin containing a chemical recycled resin, and the content of the material recycled resin in the recycled resin being 40% by volume or less. [2] The cosmetic sheet according to [1], wherein the recycled resin is made of a post-consumer recycled resin, and the post-consumer recycled resin is made of at least one of polypropylene and polyethylene. [3] The cosmetic sheet according to [1] or [2], wherein the content of the recycled resin in the cosmetic sheet is 98% by volume or less. [4] The cosmetic sheet according to any one of [1] to [3], wherein the base sheet contains a hindered phenol-based antioxidant. [5] The cosmetic sheet according to any one of [1] to [4], further comprising an ink primer layer between the base sheet and the ink layer, the ink primer layer having a thickness of 1 μm or more and 5 μm or less. [6] The cosmetic sheet according to any one of [1] to [5], wherein the base sheet contains an ultraviolet absorber, and the ultraviolet absorber contains at least one of a benzophenone-based ultraviolet absorber and a triazine-based ultraviolet absorber. [7] The cosmetic sheet according to any one of [1] to [6], wherein the base sheet contains a light stabilizer, and the light stabilizer contains a hindered amine light stabilizer. [8] A cosmetic material comprising a base material and a cosmetic sheet adhered to the base material, wherein the cosmetic sheet is the cosmetic sheet according to any one of [1] to [7].

[0010] According to the cosmetic sheet according to [1] above, at least one of the base sheet and the transparent resin layer contains a recycled resin, the recycled resin contains a chemical recycled resin, and the content of the material recycled resin in the recycled resin is 40% by volume or less, so that while reducing the environmental load, even if the recycled resin is contained, a decrease in quality and hygiene can be suppressed.

[0011] The inventor of the present disclosure speculates as follows about the reason why such an effect is obtained. That is, at least one of the base sheet and the transparent resin layer contains a recycled resin. Therefore, it becomes possible to reduce the environmental load.

[0012] In addition, the chemical recycling resin contained in the recycled resin is a recycled resin produced by polymerizing after once reducing the molecular weight through a process such as a process of gasifying, oilifying, and purifying waste resin and then monomerizing it via naphtha, or a process of monomerizing by depolymerization according to the material properties. Therefore, compared with the material recycling resin, which is a resin obtained by washing, pulverizing, and then heating and melting a resin product such as a recovered used packaging material to obtain a raw material again, the chemical recycling resin is less likely to be contaminated with foreign substances such as impurities, gels, and aggregates. Also, unlike the material recycling resin, the chemical recycling resin is not affected by heat treatment such as heating and melting after passing through the recycling process, so thermal degradation is less likely to occur. And by setting the content of the material recycling resin in the recycled resin to 40% by volume or less, the content of the chemical recycling resin in the recycled resin relatively increases. For this reason, unevenness due to foreign substances such as fish eyes is less likely to occur on the surface of the base sheet or the surface of the transparent resin layer, and as a result, a decrease in the quality of the decorative sheet is suppressed. In addition, when unevenness due to foreign substances such as fish eyes is less likely to occur on the surface of the base sheet or the surface of the transparent resin layer, bleeding in the ink layer is less likely to occur, or when the decorative sheet further has a surface protective layer, bleeding in the surface protective layer is less likely to occur.

[0013] Furthermore, by setting the content of the material recycling resin in the recycled resin to 40% by volume or less, the generation of odor components caused by the mechanical recycling resin is suppressed, and a decrease in the hygiene of the decorative sheet is suppressed.

[0014] From the above, the inventor of the present disclosure infers that the above effects can be obtained.

[0015] According to the cosmetic sheet according to [2] above, since the recycled resin contains a post-consumer recycled resin, and the post-consumer recycled resin contains at least one of polypropylene and polyethylene, the flexibility of the cosmetic sheet is improved, and the bendability can be improved. Further, since a large quantity of post-consumer recycled resin can be secured in the market and the quality is stable compared to recycled materials collected from ordinary industrial waste, the cosmetic sheet according to [2] above can also stabilize its quality.

[0016] According to the cosmetic sheet according to [3] above, by setting the content rate of the recycled resin in the cosmetic sheet to 98% by volume or less, it becomes easier to suppress a decrease in quality and hygiene.

[0017] According to the cosmetic sheet according to [4] above, the hindered phenol-based antioxidant contained in the base sheet can function as an antioxidant over a long period of time. Therefore, the cosmetic sheet according to [4] above can suppress its discoloration over a long period of time.

[0018] According to the cosmetic sheet according to [5] above, by making the thickness of the ink primer layer between the base sheet and the ink layer 1 μm or more, the adhesion between the base sheet and the ink layer can be improved. Further, by making the thickness of the ink primer layer 5 μm or less, the flexibility of the cosmetic sheet can be further improved.

[0019] According to the cosmetic sheet according to [6] above, the benzophenone-based ultraviolet absorber and the triazine-based ultraviolet absorber as ultraviolet absorbers contained in the base sheet can function as ultraviolet absorbers over a long period of time. Therefore, a decrease in the weather resistance of the base sheet can be suppressed over a long period of time, and a decrease in the adhesion between the base sheet and the ink layer can be suppressed over a long period of time.

[0020] According to the cosmetic sheet according to [7] above, the hindered amine light stabilizer as a light stabilizer contained in the base material sheet can function as a light stabilizer over a long period of time. Therefore, the deterioration of the weather resistance of the base material sheet can be suppressed over a long period of time, and the deterioration of the adhesion between the base material sheet and the ink layer can be suppressed over a long period of time.

[0021] Since the cosmetic sheet according to [8] above is attached to the base material, it is possible to suppress a decrease in quality and hygiene even when it contains a recycled resin while reducing the environmental load.

Advantages of the Invention

[0022] According to the present disclosure, it is possible to provide a cosmetic sheet and a cosmetic material that can suppress a decrease in quality and hygiene even when containing a recycled resin while reducing the environmental load.

Brief Description of the Drawings

[0023]

Figure 1

Figure 2

Modes for Carrying Out the Invention

[0024] Hereinafter, embodiments of the present disclosure will be described in detail.

[0025] <Cosmetic Sheet> FIG. 1 is a cross-sectional view showing one embodiment of the cosmetic sheet of the present disclosure. The cosmetic sheet 100 shown in FIG. 1 includes a base material sheet 10, an ink layer 20, and a transparent resin layer 30 in this order. At least one of the base material sheet 10 and the transparent resin layer 30 contains a recycled resin, the recycled resin contains a chemical recycled resin, and the content of the material recycled resin in the recycled resin is 40% by volume or less.

[0026] The decorative sheet 100 may further include an ink primer layer 40 between the base material sheet 10 and the ink layer 20. The decorative sheet 100 may further include an adhesive layer 25 between the ink layer 20 and the transparent resin layer 30. In addition, the decorative sheet 100 may further have a surface protection layer 50 on the side of the transparent resin layer 30 opposite to the ink layer 20. Furthermore, the decorative sheet 100 may further have a back primer layer 60 on the side of the base material sheet 10 opposite to the ink layer 20.

[0027] According to the decorative sheet 100, at least one of the base material sheet 10 and the transparent resin layer 30 contains a recycled resin, the recycled resin contains a chemical recycled resin, and the content of the material recycled resin in the recycled resin is 40% by volume or less. Thus, while reducing the environmental load, even if the recycled resin is included, a decrease in quality and hygiene can be suppressed.

[0028] Hereinafter, the base material sheet 10, the ink primer layer 40, the ink layer 20, the adhesive layer 25, the transparent resin layer 30, the surface protection layer 50, and the back primer layer 60 will be described in detail.

[0029] (Base Material Sheet) The base material sheet 10 is a layer made of a resin composition containing a thermoplastic resin. The resin composition may further contain a colorant. Examples of the thermoplastic resin include polyolefin resins and polyester resins. Among them, from the viewpoint of recyclability, polyolefin resins are preferably used. Examples of the polyolefin resin include polyethylene and polypropylene. These can be used alone or in combination of two or more. When the polyolefin resin is composed of at least one of polyethylene and polypropylene, the flexibility of the decorative sheet 100 can be improved, and the bending processability can be improved. Examples of the polyester resin include polyethylene terephthalate and polybutylene terephthalate. These can be used alone or in combination of two or more thereof.

[0030] The thermoplastic resin may be a non-recycled resin, a recycled resin, or a mixture thereof. The recycled resin may be a chemical recycled resin, a material recycled resin, or a mixture thereof. The recycled resin may be a post-consumer recycled resin (PCR), a post-industrial recycled resin (PIR), or a mixture thereof, preferably including PCR. Since PCR can secure a large quantity in the market and has stable quality compared to recycled materials collected from ordinary industrial waste, it can also stabilize the quality of the cosmetic sheet 100. The chemical recycled resin may be composed of a single chemical recycled resin or a mixture of multiple types of chemical recycled resins. The material recycled resin may be composed of a single material recycled resin or a mixture of multiple types of material recycled resins.

[0031] The non-recycled resin may be a petroleum-derived resin obtained using a petroleum-derived raw material monomer, a biomass-derived resin obtained using a biomass-derived raw material monomer, or a mixture thereof. From the perspective of reducing environmental impact, it is preferably a biomass-derived resin.

[0032] Examples of the colorant include pigments and dyes. Examples of the pigment include inorganic pigments such as titanium oxide and iron oxide, and organic pigments such as isoindolinone, disazo, polyazo, diketopyrrolopyrrole, quinacridone, and phthalocyanine. Examples of the dye include dyes such as methylene blue, rhodamine, and indigo. The content rate of the colorant in the base material sheet 10 is not particularly limited, and may be 50% by mass or less, 40% by mass or less, or 30% by mass or less. The content rate of the colorant in the base material sheet 10 may be 1% by mass or more, 5% by mass or more, or 10% by mass or more.

[0033] The base material sheet 10 may further contain additives such as an ultraviolet absorber, a light stabilizer, an antioxidant, an antistatic agent, a plasticizer, a lubricant, and a light-shielding pigment, as necessary.

[0034] Examples of the ultraviolet absorber include benzotriazole-based ultraviolet absorbers, triazine-based ultraviolet absorbers, and benzophenone-based ultraviolet absorbers. The ultraviolet absorber preferably contains at least one of a benzophenone-based ultraviolet absorber and a triazine-based ultraviolet absorber. The benzophenone-based ultraviolet absorber and the triazine-based ultraviolet absorber as the ultraviolet absorber contained in the base material sheet 10 can function as an ultraviolet absorber over a long period of time. Therefore, a decrease in the weather resistance of the base material sheet 10 can be suppressed over a long period of time, and a decrease in the adhesion between the base material sheet 10 and the ink layer 20 can be suppressed over a long period of time.

[0035] Examples of the light stabilizer include, for example, hindered amine-based light stabilizers. The light stabilizer preferably contains a hindered amine-based light stabilizer. The hindered amine-based light stabilizer as the light stabilizer contained in the base material sheet 10 can function as a light stabilizer over a long period of time. Therefore, a decrease in the weather resistance of the base material sheet 10 can be suppressed over a long period of time, and a decrease in the adhesion between the base material sheet 10 and the ink layer 20 can be suppressed over a long period of time.

[0036] Examples of the antioxidant include phenolic antioxidants and phosphorus-based antioxidants. The antioxidant preferably contains a phenolic antioxidant. The phenolic antioxidant contained in the base material sheet 10 can function as an antioxidant over a long period of time. Therefore, discoloration of the base material sheet 10 can be suppressed, and the cosmetic sheet 100 can suppress such discoloration over a long period of time. The antioxidant preferably contains a phenolic antioxidant and a phosphorus-based antioxidant. In this case, discoloration of the base material sheet 10 can be suppressed more effectively than when the antioxidant does not contain a phosphorus-based antioxidant. The phenolic antioxidant preferably contains a hindered phenolic antioxidant. In this case, discoloration of the base material sheet 10 can be effectively suppressed.

[0037] The content of the ultraviolet absorber in the base material sheet 10 is not particularly limited and may be 50% by mass or less, 40% by mass or less, or 30% by mass or less. Also, the content of the ultraviolet absorber in the base material sheet 10 may be 1% by mass or more, 5% by mass or more, or 10% by mass or more.

[0038] The content of the light stabilizer in the base material sheet 10 is not particularly limited and may be 50% by mass or less, 40% by mass or less, or 30% by mass or less. Also, the content of the light stabilizer in the base material sheet 10 may be 1% by mass or more, 5% by mass or more, or 10% by mass or more.

[0039] The content of the antioxidant in the base material sheet 10 is not particularly limited and may be 50% by mass or less, 40% by mass or less, or 30% by mass or less. Also, the content of the antioxidant in the base material sheet 10 may be 1% by mass or more, 5% by mass or more, or 10% by mass or more.

[0040] The thickness of the base material sheet 10 is preferably in the range of 30 μm or more and 70 μm or less, more preferably 40 μm or more and 65 μm or less, and even more preferably 50 μm or more and 60 μm or less. When the thickness of the base material sheet 10 is 30 μm or more, the decorative sheet 100 can absorb irregularities and steps such as those of the floor material serving as the base, making it easier to install the decorative sheet 100 well on the base material (not shown). Further, when the thickness of the base material sheet 10 is 70 μm or less, the bending process of the decorative sheet 11 becomes easier.

[0041] (Ink primer layer) The ink primer layer 40 is a layer that covers the surface of the base material sheet 10, repairs fish eyes on the surface of the base material sheet 10 to a certain extent, and suppresses color bleeding of a pattern or the like formed by the ink layer 20 laminated on the ink primer layer 40. The ink primer layer 40 contains a resin. Examples of the resin include acrylic resins, urethane resins, vinyl chloride - vinyl acetate copolymers, epoxy resins, and the like. The thickness of the ink primer layer 40 is not particularly limited and may be 0.1 μm or more, 1 μm or more, or 5 μm or more. Further, the thickness of the ink primer layer 40 may be 10 μm or less, 8 μm or less, or 6 μm or less. The thickness of the ink primer layer 40 is preferably 0.1 μm or more and 10 μm or less, and more preferably 1 μm or more and 5 μm or less. When the thickness of the ink primer layer 40 is 0.1 μm or more, the adhesion between the base material sheet 10 and the ink layer 20 can be improved. Further, when the thickness of the ink primer layer is 10 μm or less, the flexibility of the decorative sheet 100 can be further improved.

[0042] (Ink layer) The ink layer 20 is a layer containing ink. The ink layer 20 may be a layer forming a pattern or design in a plurality of colors, or may be a plain layer composed of a single color. Examples of patterns and designs include, for example, wood grain patterns, stone grain patterns, cloth grain patterns, leather grain patterns, geometric patterns, letters, symbols, line drawings, and the like.

[0043] The ink layer 20 contains a resin and a colorant. Examples of the resin include acrylic resins, vinyl chloride-vinyl acetate copolymers, epoxy resins, and the like. Examples of the colorant include pigments and dyes. Examples of the pigment include inorganic pigments such as titanium oxide and iron oxide, and organic pigments such as isoindolinone, disazo, polyazo, diketopyrrolopyrrole, quinacridone, and phthalocyanine. Examples of the dye include dyes such as methylene blue, rhodamine, and indigo.

[0044] The thickness of the ink layer 20 is not particularly limited and can be appropriately set according to the characteristics of the decorative sheet 100. For example, it is more than 0 μm and 10 μm or less.

[0045] (Adhesive layer) The adhesive layer 25 is provided between the ink layer 20 and the transparent resin layer 30 and is a layer that adheres the ink layer 20 and the transparent resin layer 30. The adhesive layer 25 contains a resin. Examples of the resin that can be used include urethane resins, acrylic resins, ethylene-vinyl acetate copolymers, vinyl chloride-vinyl acetate copolymers, polyester resins, polyolefin resins, and the like. Particularly, polyolefin resins are preferred from the viewpoint of adhesiveness to the transparent resin layer 30.

[0046] (Transparent resin layer) The transparent resin layer 30 is a layer containing a thermoplastic resin and has a light transmittance that allows the ink layer 20 to be visually recognized. Examples of the thermoplastic resin include polyolefin resins and polyester resins. Among them, from the viewpoint of recyclability, polyolefin resins are preferably used. Examples of the polyolefin resin include polyethylene and polypropylene. These can be used alone or in combination of two or more. When the polyolefin resin is composed of at least one of polyethylene and polypropylene, the flexibility of the cosmetic sheet 100 can be improved, and the bendability can be enhanced.

[0047] The thermoplastic resin may be a non-recycled resin, a recycled resin, or a mixture thereof. The recycled resin may be a chemical recycled resin, a material recycled resin, or a mixture thereof. The recycled resin may be a post-consumer recycled resin (PCR), a post-industrial recycled resin (PIR), or a mixture thereof, preferably including PCR. PCR can secure a large quantity in the market and has stable quality compared to recycled materials collected from ordinary industrial waste, so it can also stabilize the quality of the cosmetic sheet 100. The chemical recycled resin may be composed of a single chemical recycled resin or a mixture of multiple types of chemical recycled resins. The material recycled resin may be composed of a single material recycled resin or a mixture of multiple types of material recycled resins.

[0048] The non-recycled resin may be a petroleum-derived resin obtained using a petroleum-derived raw material monomer, a biomass-derived resin obtained using a biomass-derived raw material monomer, or a mixture thereof. From the perspective of reducing environmental impact, it is preferably a biomass-derived resin.

[0049] The transparent resin layer 30 may further contain additives such as fillers, ultraviolet absorbers, light stabilizers, antioxidants, antistatic agents, plasticizers, lubricants, and light-shielding pigments as required.

[0050] Examples of the ultraviolet absorber include benzotriazole-based ultraviolet absorbers, triazine-based ultraviolet absorbers, and benzophenone-based ultraviolet absorbers. The ultraviolet absorber preferably contains at least one of a benzophenone-based ultraviolet absorber and a triazine-based ultraviolet absorber. The benzophenone-based ultraviolet absorber and the triazine-based ultraviolet absorber as the ultraviolet absorber contained in the transparent resin layer 30 can function as an ultraviolet absorber over a long period of time. Therefore, a decrease in the weather resistance of the transparent resin layer 30 can be suppressed over a long period of time, and a decrease in the adhesion between the transparent resin layer 30 and the ink layer 20 or the surface protection layer 50 can be suppressed over a long period of time. The ultraviolet absorber contained in the transparent resin layer 30 may be the same as or different from the ultraviolet absorber contained in the base material sheet 10.

[0051] Examples of the light stabilizer include, for example, hindered amine-based light stabilizers. The light stabilizer preferably contains a hindered amine-based light stabilizer. The hindered amine-based light stabilizer as the light stabilizer contained in the transparent resin layer 30 can function as a light stabilizer over a long period of time. Therefore, a decrease in the weather resistance of the transparent resin layer 30 can be suppressed over a long period of time, and a decrease in the adhesion between the transparent resin layer 30 and the ink layer 20 or the surface protection layer 50 can be suppressed over a long period of time. The light stabilizer contained in the transparent resin layer 30 may be the same as or different from the light stabilizer contained in the base material sheet 10.

[0052] Examples of the antioxidant include phenolic antioxidants and phosphorus-based antioxidants. The antioxidant preferably contains a phenolic antioxidant. The phenolic antioxidant contained in the transparent resin layer 30 can function as an antioxidant over a long period of time. Therefore, discoloration of the transparent resin layer 30 can be suppressed, and the cosmetic sheet 100 can suppress its discoloration over a long period of time. The antioxidant preferably contains a phenolic antioxidant and a phosphorus-based antioxidant. In this case, discoloration of the transparent resin layer 30 can be more suppressed compared to the case where the antioxidant does not contain a phosphorus-based antioxidant. The phenolic antioxidant preferably contains a hindered phenolic antioxidant. In this case, discoloration of the transparent resin layer 30 can be effectively suppressed. The antioxidant contained in the transparent resin layer 30 may be the same as or different from the antioxidant contained in the base sheet 10.

[0053] The content of the ultraviolet absorber in the transparent resin layer 30 is not particularly limited and may be 50% by mass or less, 40% by mass or less, or 30% by mass or less. Further, the content of the ultraviolet absorber in the transparent resin layer 30 may be 1% by mass or more, 5% by mass or more, or 10% by mass or more.

[0054] The content of the light stabilizer in the transparent resin layer 30 is not particularly limited and may be 50% by mass or less, 40% by mass or less, or 30% by mass or less. Further, the content of the light stabilizer in the transparent resin layer 30 may be 1% by mass or more, 5% by mass or more, or 10% by mass or more.

[0055] The content of the antioxidant in the transparent resin layer 30 is not particularly limited and may be 50% by mass or less, 40% by mass or less, or 30% by mass or less. Further, the content of the antioxidant in the transparent resin layer 30 may be 1% by mass or more, 5% by mass or more, or 10% by mass or more.

[0056] The thickness of the transparent resin layer 30 is preferably in the range of 30 μm or more and 200 μm or less, more preferably 50 μm or more and 100 μm or less, and even more preferably 60 μm or more and 80 μm or less. When the thickness of the transparent resin layer 30 is 30 μm or more, the scratch resistance of the decorative sheet 100 is improved. Further, when the thickness of the transparent resin layer 30 is 200 μm or less, bending of the decorative sheet 11 becomes easy. The ratio R of the thickness of the transparent resin layer 30 to the thickness of the base material sheet 10 is not particularly limited and may be less than 1 or 1 or more. It is preferable that this ratio R is greater than 1, more preferably 1.1 or more, and particularly preferably 1.2 or more. This ratio R may be 2 or less, or 1.5 or less.

[0057] (Surface protection layer) The surface protection layer 50 is a layer that protects the surface of the transparent resin layer 30. The surface protection layer 50 is a transparent layer and can be formed by coating a resin composition containing a hard resin. As the hard resin, for example, an acrylic urethane resin can be used. The surface protection layer 50 is formed by adding an ultraviolet absorber, a hindered amine light stabilizer, and a matting agent to an acrylic polyol as a main agent and hexamethylene diisocyanate as a curing agent and curing them. As the ultraviolet absorber, for example, a triazine-based ultraviolet absorber is used. Since the triazine-based ultraviolet absorber has good compatibility with the acrylic urethane resin, precipitation of the ultraviolet absorber over time is suppressed, the effect of the ultraviolet shielding performance continues over a long period, and the weather resistance is good.

[0058] From the viewpoint of general applicability such as the coatability and storage stability of the surface protection layer 50, the thickness of the surface protection layer 50 is preferably 2 to 7 g / m in terms of the solid content coating amount 2 and more preferably 3 to 6 g / m 2 is.

[0059] (Back primer layer) The back primer layer 60 is a layer for repairing fish eyes that appear on the surface of the base material sheet 10 and suppressing variations in the adhesion of the adhesive applied when laminating the adherend to prevent adhesion failure. The back primer layer 60 contains a resin. Examples of the resin include acrylic resins, urethane resins, vinyl chloride-vinyl acetate copolymers, epoxy resins, and nitrocellulose. The thickness of the back primer layer 60 is not particularly limited and may be 0.1 μm or more, 1 μm or more, or 5 μm or more. Also, the thickness of the back primer layer 60 may be 10 μm or less, 8 μm or less, or 6 μm or less. The thickness of the back primer layer 60 is preferably 0.1 μm or more and 10 μm or less, and more preferably 1 μm or more and 5 μm or less. When the thickness of the back primer layer 60 is 0.1 μm or more, the adhesion between the base material sheet 10 and the ink layer 20 can be improved. Also, when the thickness of the back primer layer 60 is 10 μm or less, the flexibility of the decorative sheet 100 can be further improved. The back primer layer 60 can be formed by applying a resin composition (back primer) containing the above resin and an organic solvent to the surface of the base material sheet 10 and drying it.

[0060] (Decorative sheet) In the decorative sheet 100, the content of the material recycling resin in the recycled resin is 40% by volume or less. From the viewpoint of suppressing a decrease in the quality and hygiene of the decorative sheet 100, the content of the material recycling resin in the recycled resin is preferably 30% by volume or less, more preferably 20% by volume or less, still more preferably 10% by volume or less, and particularly preferably 0% by volume. Note that from the viewpoint of cost, the content of the material recycling resin in the recycled resin may be 5% by volume or more, 10% by volume or more, 20% by volume or more, or 30% by volume or more.

[0061] In the decorative sheet 100, the recycled resin may be contained in at least one of the base material sheet 10 and the transparent resin layer 30, may be contained only in either one of the base material sheet 10 and the transparent resin layer 30, or may be contained in both.

[0062] Also, the content rate of the recycled resin in the cosmetic sheet 100 is not particularly limited as long as it is higher than 0% by volume, but it may be 98% by volume or less, 90% by volume or less, 60% by volume or less, 50% by volume or less, or 40% by volume or less. By setting the content rate of the recycled resin in the cosmetic sheet 100 to 98% by volume or less, it becomes easier to suppress a decrease in quality and hygiene. The content rate of the recycled resin in the cosmetic sheet 100 may be 10% by volume or more, 20% by volume or more, or 30% by volume or more.

[0063] <Cosmetic material> The cosmetic material of the present disclosure includes a base material and a cosmetic sheet adhered to the base material. FIG. 2 is a cross-sectional view showing an embodiment of the cosmetic material of the present disclosure. The cosmetic material 200 shown in FIG. 2 includes a base material 210 and a cosmetic sheet 100 adhered to the base material 210. The cosmetic material 200 may further include an adhesive layer 220 that adheres the cosmetic sheet 100 and the base material 210 therebetween. Since the cosmetic sheet 100 is attached to the base material 210 in the above cosmetic material 200, it is possible to suppress a decrease in quality and hygiene even when it contains a recycled resin while reducing the environmental load.

[0064] The base material 210, which is the adherend of the cosmetic sheet 100, can be appropriately selected according to the use, type, etc. of the cosmetic material 200. For example, base materials made of materials such as inorganic (non-metal) base materials, metal base materials, wood base materials, plastic base materials, etc. can be mentioned.

[0065] Examples of the inorganic base material include tiles and gypsum boards. Examples of the metal base material include steel plates and aluminum plates. Examples of the wood base material include MDF (medium density fiberboard) and plywood. Examples of the base material such as plastic include boards such as polypropylene boards, PVC boards, polyester boards, acrylic boards, and styrene boards.

[0066] The adhesive layer 220 is obtained using an adhesive. Examples of the adhesive include hot melt adhesives, organic solvent-based adhesives, and water-based adhesives. The resin contained in the adhesive may be a urethane resin, an ester resin, an acrylic resin, a vinyl acetate resin, or the like.

Examples

[0067] Hereinafter, the present disclosure will be specifically described with reference to examples, but the present disclosure is not limited to these examples.

[0068] <Production of decorative sheet> (Example 1) A colored film (thickness: 60 μm) containing post-consumer recycled resin (hereinafter also referred to as "PCR"), chemical recycled high-density polyethylene (PCR Chem R100%-HDPE), 5% by mass of a colorant (titanium oxide), 0.05% by mass of a phenolic antioxidant, and 0.05% by mass of a phosphorus-based antioxidant was prepared and used as a base sheet. Note that "PCR Chem R100%-HDPE" means that the content of Chem R HDPE (chemical recycled high-density polyethylene) which is PCR in the resin is 100% by volume (100% by mass). Then, a back primer layer was formed on one surface of the base sheet so as to cover the entire surface. The back primer layer was formed by gravure printing using a gravure roll with a back primer containing 53% by mass of a polyester urethane (PEU) resin, 3% by mass of nitrocellulose, and 44% by mass of an organic solvent. Next, an ink primer layer (thickness: 2 μm) was formed on the other surface of the base sheet so as to cover the entire surface. The ink primer layer was formed by gravure printing using a gravure roll with an ink primer containing a polyester-urethane resin. Next, a wood grain pattern ink layer (thickness: 3 μm) was formed on the ink primer layer. The ink layer was formed by printing a polyester-urethane-based ink by a gravure printing method using a gravure roll. Next, a urethane-based adhesive was applied to the surface of the ink layer, and a transparent resin layer (70 μm thick) made of a petroleum-derived polypropylene (PP) film was overlaid, and the adhesive was dried to form an adhesive layer, thereby attaching the transparent resin layer to the ink layer. Finally, a surface protective layer (6 μm thick) was formed on the surface of the transparent resin layer. Thus, the decorative sheet was manufactured.

[0069] (Example 2) The base sheet was changed to a colored film (55 μm thick) containing petroleum-derived high-density polyethylene (petroleum-derived-HDPE), 5% by mass of a colorant (titanium oxide), 0.05% by mass of a phenolic antioxidant, and 0.05% by mass of a phosphorus-based antioxidant, and the transparent resin layer was changed to a film (70 μm thick) containing chemical recycled polypropylene (PCR Chem R100%-PP) which is PCR, 0.05% by mass of a phenolic antioxidant, and 0.05% by mass of a phosphorus-based antioxidant. A decorative sheet was manufactured in the same manner as in Example 1 except for this. Note that "PCR Chem R100%-PP" means that the content of Chem RPP (chemical recycled polypropylene) which is PCR in the resin is 100% by volume (100% by mass).

[0070] (Example 3) A decorative sheet was manufactured in the same manner as in Example 1 except that the transparent resin layer was changed to a film (70 μm thick) containing chemical recycled polypropylene (PCR Chem R100%-PP), 0.05% by mass of a phenolic antioxidant, and 0.05% by mass of a phosphorus-based antioxidant.

[0071] (Example 4) A decorative sheet was manufactured in the same manner as in Example 1 except that the ink primer layer was not formed.

[0072] (Example 5) A decorative sheet was manufactured in the same manner as in Example 2 except that the ink primer layer was not formed.

[0073] (Example 6) A decorative sheet was manufactured in the same manner as in Example 3, except that an ink primer layer was not formed.

[0074] (Example 7) The base sheet was changed to a colored film (thickness: 55 μm) containing chemical recycled polypropylene (PCR Chem R100%-PP) as PCR, 5% by mass of a colorant (titanium oxide), 0.05% by mass of a phenolic antioxidant, and 0.05% by mass of a phosphorus-based antioxidant. A decorative sheet was manufactured in the same manner as in Example 2, except that an ink primer layer was not formed.

[0075] (Comparative Example 1) The base sheet was changed to a colored film (thickness: 55 μm) containing material recycled high-density polyethylene (PCR MR100%-HDPE) as PCR, 5% by mass of a colorant (titanium oxide), 0.05% by mass of a phenolic antioxidant, and 0.05% by mass of a phosphorus-based antioxidant. The transparent resin layer was changed to a film (thickness: 70 μm) containing chemical recycled polypropylene (PCR Chem R100%-PP) as PCR, 0.05% by mass of a phenolic antioxidant, and 0.05% by mass of a phosphorus-based antioxidant. A decorative sheet was manufactured in the same manner as in Example 1. Note that "PCR MR100%-HDPE" means that the content of MR HDPE (material recycled high-density polyethylene) as PCR in the resin is 100% by volume (100% by mass). "PCR MR100%-PP" means that the content of MR PP (material recycled polypropylene) as PCR in the resin is 100% by volume (100% by mass).

[0076] (Comparative Example 2) The base sheet was changed to a colored film (thickness: 55 μm) containing material recycled high-density polyethylene (PCR MR100%-HDPE) as PCR, 5% by mass of a colorant (titanium oxide), 0.05% by mass of a phenolic antioxidant, and 0.05% by mass of a phosphorus-based antioxidant. A decorative sheet was manufactured in the same manner as in Example 1.

[0077] (Comparative Example 3) The base sheet was changed to a colored film (thickness 55 μm) containing polypropylene and high-density polyethylene derived from petroleum (petroleum-derived PP-HDPE), 0.05% by mass of a phenolic antioxidant, and 0.05% by mass of a phosphorus-based antioxidant. The transparent resin layer was changed to a film (thickness 70 μm) containing chemical recycled polypropylene (PCR Chem R100%-PP) which is PCR, 0.05% by mass of a phenolic antioxidant, and 0.05% by mass of a phosphorus-based antioxidant. A decorative sheet was produced in the same manner as in Example 1 except for the above changes.

[0078] (Comparative Example 4) The base sheet was changed to a colored film (thickness 55 μm) containing chemical recycled high-density polyethylene (PCR Chem R100%-HDPE) which is PCR, 5% by mass of a colorant (titanium oxide), 0.05% by mass of a phenolic antioxidant, and 0.05% by mass of a phosphorus-based antioxidant. The transparent resin layer was changed to a film (thickness 70 μm) containing material recycled polypropylene (PCR MR100%-PP) which is PCR, 0.05% by mass of a phenolic antioxidant, and 0.05% by mass of a phosphorus-based antioxidant. A decorative sheet was produced in the same manner as in Example 1 except for the above changes.

[0079] (Comparative Example 5) The base sheet was changed to a colored film (thickness 55 μm) containing material recycled polypropylene (PCR MR100%-PP) which is PCR, 5% by mass of a colorant (titanium oxide), 0.05% by mass of a phenolic antioxidant, and 0.05% by mass of a phosphorus-based antioxidant. The transparent resin layer was changed to a film (thickness 70 μm) containing chemical recycled high-density polyethylene (PCR Chem R100%-HDPE) which is PCR, 0.05% by mass of a phenolic antioxidant, and 0.05% by mass of a phosphorus-based antioxidant. A decorative sheet was produced in the same manner as in Example 1 except for the above changes.

[0080] (Comparative Example 6) The base sheet was changed to a colored film (thickness: 55 μm) containing material recycled high-density polyethylene (PCRMR100%-HDPE) which is PCR, 5% by mass of a colorant (titanium oxide), 0.05% by mass of a phenolic antioxidant, and 0.05% by mass of a phosphorus-based antioxidant, and the transparent resin layer was changed to a film (thickness: 70 μm) containing material recycled polypropylene (PCRMR100%-PP) which is PCR, 0.05% by mass of a phenolic antioxidant, and 0.05% by mass of a phosphorus-based antioxidant. A decorative sheet was produced in the same manner as in Example 4 except for the above changes.

[0081] (Comparative Example 7) A decorative sheet was produced in the same manner as in Example 4 except that the base sheet was changed to a colored film (thickness: 55 μm) containing material recycled high-density polyethylene (PCRMR100%-HDPE) which is PCR, 5% by mass of a colorant (titanium oxide), 0.05% by mass of a phenolic antioxidant, and 0.05% by mass of a phosphorus-based antioxidant.

[0082] (Comparative Example 8) The base sheet was changed to a colored film (thickness: 55 μm) containing polypropylene and high-density polyethylene derived from petroleum (100% petroleum-derived PP-HDPE), 5% by mass of a colorant (titanium oxide), 0.05% by mass of a phenolic antioxidant, and 0.05% by mass of a phosphorus-based antioxidant, and the transparent resin layer was changed to a film (thickness: 70 μm) containing material recycled polypropylene (PCRMR100%-PP) which is PCR, 0.05% by mass of a phenolic antioxidant, and 0.05% by mass of a phosphorus-based antioxidant. A decorative sheet was produced in the same manner as in Example 5 except for the above changes. Note that "100% petroleum-derived PP-HDPE" means that the total content of petroleum-derived PP and petroleum-derived HDPE in the resin is 100% by volume (100% by mass).

[0083] (Comparative Example 9) A decorative sheet was produced in the same manner as in Example 4, except that the transparent resin layer was changed to a colored film (thickness: 70 μm) containing material recycled polypropylene (PCRMR100%-PP) which is PCR, 0.05% by mass of a phenolic antioxidant, and 0.05% by mass of a phosphorus-based antioxidant.

[0084] (Comparative Example 10) A decorative sheet was produced in the same manner as in Example 4, except that the base material sheet was changed to a colored film (thickness: 55 μm) containing material recycled polypropylene (PCRMR100%-PP) which is PCR, 5% by mass of a colorant (titanium oxide), 0.05% by mass of a phenolic antioxidant, and 0.05% by mass of a phosphorus-based antioxidant, and the transparent resin layer was changed to a film (thickness: 70 μm) containing chemical recycled high-density polyethylene (PCR Chem R100%-HDPE) which is PCR, 0.05% by mass of a phenolic antioxidant, and 0.05% by mass of a phosphorus-based antioxidant.

[0085] (Reference Example) A decorative sheet was produced in the same manner as in Example 1, except that the base material sheet was changed to a colored film (thickness: 55 μm) containing petroleum-derived polypropylene and high-density polyethylene (petroleum-derived 100% PP-HDPE), 5% by mass of a colorant (titanium oxide), 0.05% by mass of a phenolic antioxidant, and 0.05% by mass of a phosphorus-based antioxidant.

[0086] <Appearance Evaluation> (1) Evaluation 1 (Haze) Using an ultraviolet-visible near-infrared spectrophotometer (manufactured by Shimadzu Corporation: "UV-3600"), the haze [%] of the transparent resin layer was measured. When measuring the haze [%] of the transparent resin layer, first, a resin composition having the same composition as the transparent resin layer of the decorative sheets of Examples 1 to 7, the transparent resin layer of the decorative sheets of Comparative Examples 1 to 10, and the transparent resin layer of the decorative sheet of the reference example was extruded with the thickness set within the range of 70 μm or more and 80 μm or less to form a resin film. Next, the haze at a wavelength of 555 nm was measured with a spectrophotometer (integrating sphere) and evaluated based on the following criteria. The results are shown in Tables 1 to 3. (Criteria) ◎ ··· When the haze is less than 15% ○ ··· When the haze is 15% or more and less than 25% × ··· When the haze is 25% or more

[0087] (2) Evaluation 2 (Fish-eye and Defects) Evaluation 2 is an appearance evaluation and also a quality evaluation. <Fish-eye> A sample with dimensions of 1 m × 1 m was cut out, placed on a black table, and the number N1 of protrusions (raised foreign matters) with a diameter of 0.5 mm or more and less than 1 mm was visually counted as fish-eye 1, and the number N2 of protrusions (raised foreign matters) with a diameter of 1 mm or more was visually counted as fish-eye 2. Evaluation was carried out based on the following evaluation criteria. The results are shown in Tables 1 to 3. (Criteria) 〇 ··· N1 is 10 or less and N2 is 0 × ··· N1 is 11 or more and N2 is 0 or more

[0088] <Defects> Regarding the cosmetic sheets manufactured in the examples, comparative examples, and reference examples, under a light source of 1000 lux or more, it was visually confirmed from a position 50 cm away from the cosmetic sheet whether there were defects (points formed by light leakage) in the ink layer or the surface protective layer, and evaluation was carried out based on the following criteria. The results are shown in Tables 1 to 3. (Criteria) 〇 ··· No defects were confirmed in both the ink layer and the surface protective layer × ··· Defects were confirmed in either the ink layer or the surface protective layer

[0089] <Performance Evaluation> (3) Evaluation 3 (Adhesion) For the cosmetic sheets of the examples, comparative examples, and reference examples, a test of repeating heating and cooling (specifically, a test in which the cosmetic sheet was placed in an environment where "heating at 80°C for 2 hours" and "cooling at -20°C for 2 hours" were repeated 10 cycles) was carried out, and then a cellophane tape peeling test was performed to evaluate the adhesion of the ink layer (adhesion between the base material sheet and the ink layer) based on the following criteria. The results are shown in Tables 1 to 3. (Criteria) ○ ··· No peeling occurred in the ink layer × ··· Peeling occurred in part of the ink layer

[0090] (4) Evaluation 4 (Scratch resistance 1) <Pencil hardness> For the cosmetic sheets of the examples, comparative examples, and reference examples, the pencil hardness was measured using a pencil hardness tester (automatic) (manufacturer: Yoshimitsu Seiki, model number: C221A) to evaluate the scratch resistance. Specifically, for the cosmetic sheets of the examples, comparative examples, and reference examples, after performing a pencil hardness test using pencils with different hardnesses on the decorative material obtained by laminating the cosmetic sheet to a base material made of MDF using an emulsion adhesive, the damage (scratches) generated on the surface (surface protective layer) was confirmed, and the pencil hardness of the surface was measured. Then, the scratch resistance was evaluated based on this pencil hardness and the following criteria. The results are shown in Tables 1 to 3. (Criteria) ◎ ··· When damage occurred on the surface after performing a pencil hardness test using a pencil with a pencil hardness of 2B or higher ○ ··· When damage occurred on the surface after performing a pencil hardness test using a pencil with a pencil hardness of 4B or higher × ··· When damage occurred on the surface after performing a pencil hardness test using a pencil with a hardness of 5B or lower

[0091] (5) Evaluation 5 (Scratch resistance 2) <Hoffman scratch> For the cosmetic sheets of the examples, comparative examples, and reference examples, a Hoffman scratch test was conducted to evaluate scratch resistance. In the Hoffman scratch test, a scratch blade (a cylindrical blade with a diameter of Φ7) was set to contact the surface of the cosmetic sheet at an angle of 45 degrees, and the testing machine was moved on the cosmetic sheet. The load (weight) was gradually increased (in increments of 200 g) within the range of 200 - 2000 g to make a scratch, and the load (g) at which the surface of the cosmetic sheet was scratched for the first time was determined. Then, based on this load, the load resistance was obtained, and the scratch resistance was evaluated based on the load resistance and the following criteria. The results are shown in Tables 1 - 3. Note that the load resistance is the load at which scratching occurred minus 200 g. (Standard) ○ ··· The load resistance is 600 g or more. × ··· The load resistance is less than 600 g.

[0092] (6) Evaluation 6 (Weather resistance) For the cosmetic sheets of the examples, comparative examples, and reference examples, weather resistance evaluation was performed. For the weather resistance evaluation of the cosmetic sheets, after conducting a carbon arc weather resistance test in accordance with JIS B7753 using a weather resistance tester (Sunshine Weather Meter: manufactured by Suga Test Instruments Co., Ltd.), the appearance of the cosmetic sheet was visually observed and evaluated based on the following criteria. The results are shown in Tables 1 - 3. Note that the test conditions (weathering time) of the weather resistance test were set to 2,000 hours. (Standard) ○ ··· After the weather resistance test, there was no change (yellowing) in the appearance of the cosmetic sheet. × ··· After the weather resistance test, there were significant appearance changes (yellowing, deterioration) in the appearance of the cosmetic sheet.

[0093] (7) Evaluation 7 (Bending process suitability) Samples were prepared by bonding the cosmetic sheets of the examples, comparative examples, and reference examples to flat MDF. For this MDF (Medium Density Fiberboard) of the sample, V - cut processing was performed in the width direction of the sample. Then, the sample was wound around the core material to check whether cracks occurred in the cosmetic sheet, and the bending process suitability of the cosmetic sheet was evaluated based on the following criteria. The results are shown in Tables 1 - 3. (Standard) ○ ··· No cracks were observed in the cosmetic sheet × ··· Cracks were observed in the cosmetic sheet

[0094] (8) Evaluation 8 (Hygiene) For the cosmetic sheets of the examples, comparative examples, and reference examples, analysis was performed using purge-and-trap gas chromatography-mass spectrometry. Specifically, 1.0 gram of a sample was cut out from the cosmetic sheet, and this sample was placed in a 20 mL vial together with an odor component trap, and heated at 60 °C for 1 hour to adsorb the volatile components from the sample onto the trap. For the volatile components in the trap, analysis was performed using a purge-and-trap gas chromatography-mass spectrometer to obtain a total ion chromatogram. Next, in the total ion chromatogram obtained as described above, the ratio R1 of the peak area of nonanal as an index of the odor component to the total peak area value of all aliphatic hydrocarbon components, and the ratio R2 of the peak area of decanal to the total peak area value of all aliphatic hydrocarbon components were determined. And evaluation was performed based on the following criteria. The results are shown in Tables 1 to 3. (Criteria) ◎ ··· R1 is less than 1.5% and R2 is less than 0.35% ○ ··· R1 is less than 1.5% and R2 is 0.35% or more, or R1 is 1.5% or more and R2 is less than 0.35% × ··· R1 is 1.5% or more and R2 is 0.35% or more

[0095]

Table 1

[0096]

Table 2

[0097]

Table 3

[0098] From the results shown in Tables 1 to 3, it was found that for the cosmetic sheets of Examples 1 to 7, even though they contain recycled resin, no fish eyes were observed in the base sheet and the transparent resin layer, and the odor components were also reduced, and they were equivalent to the cosmetic sheets of the reference example in terms of quality and hygiene. On the other hand, for the cosmetic sheets of Comparative Examples 1 to 10, although they contain recycled resin, fish eyes were observed in the base sheet or the transparent resin layer, and there were also many odor components, and it was found that they were inferior to the cosmetic sheets of the reference example in terms of quality and hygiene. In addition, it was found that both the cosmetic sheets of Examples 1 to 7 and the cosmetic sheets of Comparative Examples 1 to 10 contain recycled resin, and the environmental load can be reduced. From the above, it was confirmed that according to the cosmetic sheet of the present disclosure, the environmental load can be reduced, and even if it contains recycled resin, a decrease in quality and hygiene can be suppressed.

Explanation of Signs

[0099] 10…Base sheet, 20…Ink layer, 30…Transparent resin layer, 40…Ink primer layer, 100…Cosmetic sheet, 200…Cosmetic material, 210…Base material.

Claims

1. It comprises a base sheet, an ink layer and a transparent resin layer in this order, at least one of the base sheet and the transparent resin layer contains a recycled resin, the recycled resin contains a chemical recycled resin, A decorative sheet, wherein the content rate of the material recycled resin in the recycled resin is 40% by volume or less.

2. the recycled resin contains a post-consumer recycled resin, The decorative sheet according to claim 1, wherein the post-consumer recycled resin contains at least one of polypropylene and polyethylene.

3. The decorative sheet according to claim 1, wherein the content rate of the recycled resin in the decorative sheet is 98% by volume or less.

4. The decorative sheet according to claim 1, wherein the base sheet contains a hindered phenol antioxidant.

5. It further comprises an ink primer layer between the base sheet and the ink layer, The decorative sheet according to claim 1, wherein the ink primer layer has a thickness of 1 μm or more and 5 μm or less.

6. the base sheet contains an ultraviolet absorber, The decorative sheet according to claim 1, wherein the ultraviolet absorber contains at least one of a benzophenone-based ultraviolet absorber and a triazine-based ultraviolet absorber.

7. the base sheet contains a light stabilizer, The decorative sheet according to claim 1, wherein the light stabilizer contains a hindered amine light stabilizer.

8. It comprises a base material and a decorative sheet bonded to the base material, A decorative material, wherein the decorative sheet is the decorative sheet according to any one of claims 1 to 7.

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