Decorative sheet and decorative member

Abstract

To provide a decorative sheet and a decorative member which can reduce consumption of petroleum resources while having sufficient designability and weather resistance.SOLUTION: A decorative sheet includes a thermoplastic resin layer, and a pattern layer provided on the thermoplastic resin layer, wherein the thermoplastic resin layer is formed of a resin composition containing a chemically recycled olefin resin.SELECTED DRAWING: Figure 1

Description

Technical Field

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

Background Art

[0002] Generally, printed cosmetic sheets are used for cosmetic members used in the building material field and the like. For example, by attaching a printed cosmetic sheet to a substrate, a stable design can be imparted more efficiently than the method of spraying paints such as paints and inorganic materials.

[0003] As a printed cosmetic sheet, a structure in which a pattern layer is provided on the surface of a base sheet by a printing method and a primer layer is provided on the back surface is known (see, for example, Patent Document 1 below). As the base sheet, paper, a woven or non-woven fabric of fibers, a synthetic resin sheet, etc. are used, but a sheet of a thermoplastic resin is frequently used in terms of weather resistance, productivity, and workability. Sheets of thermoplastic resins are usually formed from petroleum-derived materials such as polyethylene, polypropylene, and polyvinyl chloride.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] In recent years, depletion of fossil fuel resources has been feared. Regarding sheets of thermoplastic resins produced in large quantities, although it is required to reduce the consumption of petroleum resources, there are the following problems.

[0006] Although it is conceivable to recycle the cosmetic sheet, the cosmetic sheet is difficult to recycle because it is difficult to separate from the cosmetic member after disposal, for example, when it is attached to a wooden base material via an adhesive. On the other hand, although the consumption of petroleum resources can be suppressed by reducing the thickness of the base sheet, it is also necessary to ensure the performance of the cosmetic sheet (such as weather resistance and designability), and there is a limit to reducing the thickness of the base sheet.

[0007] The present disclosure has been made in view of the above circumstances, and an object thereof is to provide a cosmetic sheet and a cosmetic member that can reduce the consumption of petroleum resources while having sufficient designability and weather resistance.

Means for Solving the Problems

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

[0009] [1] A cosmetic sheet comprising a thermoplastic resin layer and a pattern layer provided on the thermoplastic resin layer, wherein the thermoplastic resin layer is formed of a resin composition containing a chemically recyclable olefin resin. [2] The cosmetic sheet according to [1], wherein the chemically recyclable olefin resin contains a post-consumer recycled resin. [3] The cosmetic sheet according to [1] or [2], wherein the resin composition further contains a nucleating agent, and the content of the nucleating agent in the resin composition is 0.05 part by mass or more and 0.5 part by mass or less with respect to 100 parts by mass of the chemically recyclable olefin resin. [4] The cosmetic sheet according to any one of [1] to [3], wherein the specific gravity of the thermoplastic resin layer is 0.9 or more and 1.8 or less, and the thickness of the thermoplastic resin layer is 15 μm or more and 330 μm or less. [5] The cosmetic sheet according to any one of [1] to [4], wherein the chemically recyclable olefin resin is chemically recycled polypropylene or chemically recycled polyethylene. [6] The decorative sheet according to any one of [1] to [5], wherein the pattern layer is formed of a resin composition containing a resin derived from biomass. [7] The decorative sheet according to any one of [1] to [6], further comprising a primer layer provided on the side of the thermoplastic resin layer opposite to the pattern layer side, wherein the primer layer is formed of a resin composition containing a resin derived from biomass. [8] The decorative sheet according to any one of claims [1] to [7], further comprising a surface protection layer provided on the side of the pattern layer opposite to the thermoplastic resin layer side, wherein the surface protection layer is formed of a resin composition containing a resin derived from biomass. [9] The decorative sheet according to [8], which is embossed.

[10] A decorative member comprising a base material and the decorative sheet according to any one of [1] to [9] provided on the base material.

Advantages of the Invention

[0010] According to the present disclosure, it is possible to provide a decorative sheet and a decorative member that have sufficient design properties and weather resistance and can reduce the consumption of petroleum resources.

Brief Description of the Drawings

[0011]

Figure 1

Embodiments for Carrying Out the Invention

[0012] Hereinafter, embodiments of the present disclosure will be described in detail. However, the present disclosure is not limited to the following embodiments.

[0013] <Decorative Sheet> The decorative sheet of this embodiment includes a thermoplastic resin layer and a pattern layer provided on the thermoplastic resin layer, and the thermoplastic resin layer is formed of a resin composition containing a chemical recycling olefin resin.

[0014] FIG. 1 is a cross-sectional view schematically showing an example of a cosmetic member including a cosmetic sheet according to the present embodiment. The cosmetic sheet 1 shown in FIG. 1 has a structure in which a primer layer 5, a thermoplastic resin layer 2, a pattern layer 3, and a surface protective layer 4 are laminated in this order.

[0015] (Thermoplastic resin layer) The thermoplastic resin layer 2 is formed of a resin composition containing a chemical recycling olefin resin (hereinafter, may also be referred to as a first resin composition). The thermoplastic resin layer may be a base sheet formed of the first resin composition.

[0016] In the present disclosure, the chemical recycling resin means a resin manufactured by once reducing the molecular weight of a discarded resin by a process such as gasification or monomerization and then polymerizing it. In the case of a chemical recycling olefin resin, it refers to an olefin resin manufactured by the above method.

[0017] By forming the thermoplastic resin layer 2 from the above-described first resin composition, consumption of petroleum resources can be reduced. As a method for reducing consumption of petroleum resources, it is also conceivable to use materials such as mechanical recycling resins, but the thermoplastic resin layer 2 can have the following advantages. (a) It is less likely to cause contamination by impurities and foreign matters compared to the case of using a mechanical recycling resin, which is a resin obtained by washing, pulverizing, and then heating and melting a used resin product such as a recovered packaging material and reusing it as a raw material. Therefore, it is possible to prevent pattern dropout in the pattern printing process and top coat dropout in the top coat printing process caused by foreign matter contamination, and it is easy to ensure designability and weather resistance. (b) Since the chemical recycling resin is less affected by heat treatment such as heating and melting after passing through the recycling process, thermal degradation is less likely to occur. (c) The production line of the base sheet using a petroleum-derived resin can be commonly used.

[0018] The chemical recycling olefin resin may be a post-consumer recycled (PCR) resin, a post-industrial recycled (PIR) resin, or a mixture thereof. In terms of being easy to secure a large quantity in the market and being able to reduce the manufacturing cost of the cosmetic sheet, the chemical recycling olefin resin may be a PCR resin.

[0019] The PCR resin may be obtained from recycled materials such as, for example, bottles and packaging bags for beverages, detergents, and seasonings recovered from the market, food containers for bento boxes and cup noodles, packaging bags for food and garbage bags, and plastic finished products such as hangers, stationery, daily necessities, household appliances, and toys. The PIR resin may be obtained from recycled materials such as, for example, defective products that do not become products discharged from the factory, end materials generated during the process of making products, and plastic products used for transportation and packaging.

[0020] Examples of the chemical recycling olefin resin include chemical recycling polyethylene and chemical recycling polypropylene.

[0021] Polyethylene is a resin containing ethylene as a constituent unit. Examples of polyethylene include homopolyethylene obtained by polymerizing ethylene alone, and ethylene copolymers obtained by copolymerizing ethylene as a main raw material with other monomers. Examples of other monomers include α-olefins, vinyl acetate, and acrylic esters. The α-olefin may be an olefin having 3 to 20 carbon atoms. Examples of the α-olefin include propylene, 1-butene, 1-pentene, 1-hexene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene, 1-eicosene, 3-methyl-1-butene, 4-methyl-1-pentene, and 6-methyl-1-heptene.

[0022] Examples of the polyethylene include high-density polyethylene (HDPE), medium-density polyethylene (MDPE), low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), very-low-density polyethylene (VLDPE), and the like. These may be used alone or in combination of two or more thereof.

[0023] Polypropylene is a resin that contains propylene as a constituent unit and does not contain ethylene as a constituent unit. Examples of the polypropylene include homopolypropylene obtained by polymerizing propylene alone, and propylene copolymers obtained by copolymerizing propylene as a main raw material with other monomers such as block polypropylene and random polypropylene. As the other monomers, the other monomers described above can be used.

[0024] The first resin composition may contain a single chemical recycling olefin resin or may contain a plurality of types of chemical recycling polyolefin resins.

[0025] From the viewpoint of reducing the consumption of petroleum resources while ensuring the designability and weather resistance of the cosmetic sheet, the content of the chemical recycling olefin resin in the first resin composition may be 50 to 100% by mass, 90 to 100% by mass, or 100% by mass based on the total amount of the resin components in the first resin composition.

[0026] When the first resin composition contains chemical recycling polyethylene, the content thereof may be 50 to 100% by mass, 90 to 100% by mass, or 100% by mass based on the total amount of the chemical recycling olefin resin in the first resin composition from the viewpoint of reducing the consumption of petroleum resources while ensuring the designability and weather resistance of the cosmetic sheet.

[0027] When the first resin composition contains chemically recycled polypropylene, its content may be 50 to 100% by mass, 90 to 100% by mass, or 100% by mass based on the total amount of chemically recycled olefin resin in the first resin composition, from the viewpoint of reducing the consumption of petroleum resources while ensuring the designability and weather resistance of the decorative sheet.

[0028] The first resin composition may contain a resin other than the chemically recycled olefin resin, as long as the designability and weather resistance of the decorative sheet and the effect of reducing the consumption of petroleum resources are not significantly impaired. Examples of such resins include virgin resins and mechanically recycled resins. These resins may be of the same type as the chemically recycled olefin resin contained in the first resin composition.

[0029] Also, the first resin composition may contain a chemically recycled resin other than the chemically recycled olefin resin (hereinafter sometimes referred to as other chemically recycled resins), as long as the designability and weather resistance of the decorative sheet and the effect of reducing the consumption of petroleum resources are not significantly impaired.

[0030] The first resin composition may further contain a nucleating agent. Examples of the nucleating agent contained in the first resin composition include sodium 2,2'-methylenebis(4,6-di-tert-butylphenyl)phosphonate and the commercially available "Licmaster CN-002" (trade name, manufactured by Riken Vitamin Co., Ltd.).

[0031] The nucleating agent may be a nano-sized nucleating agent (nanosized nucleating agent). The nano-sized nucleating agent may have an average particle size of 180 nm or less. As the nano-sizing treatment, for example, methods such as a solid-phase method in which mechanical pulverization is mainly performed on the nucleating agent to obtain nano-sized particles, and a liquid-phase method in which synthesis or crystallization of nano-sized particles is performed in a liquid in which the nucleating agent is dissolved or dispersed can be used. Examples of the solid-phase method include a ball mill, a bead mill, a rod mill, a colloid mill, a conical mill, a disk mill, a hammer mill, and a jet mill. Examples of the liquid-phase method include a crystallization method, a coprecipitation method, a sol-gel method, a liquid-phase reduction method, a hydrothermal synthesis method, and a supercritical reverse phase evaporation method.

[0032] The content of the nucleating agent in the first resin composition may be 0.05 parts by mass or more, or 0.1 parts by mass or more, and may be 0.5 parts by mass or less, or 0.3 parts by mass or less, based on 100 parts by mass of the chemical recycling olefin resin. If the content of the nucleating agent is at least the above lower limit value, the crystallization of the resin composition is promoted, so that a decorative sheet having more excellent surface strength and transparency can be obtained. If the content of the nucleating agent is at most the above upper limit value, the flexibility of the decorative sheet is maintained, so that a decorative sheet having more excellent post-processability can be obtained. From the above viewpoints, the content of the nucleating agent may be 0.05 parts by mass or more and 0.5 parts by mass or less, or 0.1 parts by mass or more and 0.3 parts by mass or less, based on 100 parts by mass of the chemical recycling olefin resin.

[0033] The first resin composition may contain other components in addition to the chemical recycling olefin resin and the nucleating agent. Examples of the other components include a colorant, a filler, an ultraviolet absorber, a light stabilizer, a heat stabilizer, an antioxidant, an antistatic agent, a lubricant, a flame retardant, an antibacterial agent, an antifungal agent, a friction reducer, a light scattering agent, and a gloss adjuster. The content of the other components may be 10 to 60% by mass, or 15 to 40% by mass, based on the total mass of the first resin composition.

[0034] The specific gravity of the thermoplastic resin layer 2 may be 0.9 or more and 1.8 or less, or may be 1.0 or more and 1.6 or less. If the specific gravity of the thermoplastic resin layer 2 is within the above range, the concealability of the thermoplastic resin layer can be enhanced. The specific gravity of the thermoplastic resin layer 2 can be adjusted by adding an inorganic substance such as titanium oxide to the thermoplastic resin layer.

[0035] The thickness of the thermoplastic resin layer 2 may be 15 μm or more, 40 μm or more, or 50 μm or more. If the thickness of the thermoplastic resin layer is equal to or greater than the above lower limit value, it has excellent post-processability, and can absorb unevenness and steps of a base material or the like serving as a base, thereby improving the construction finish of the decorative sheet 1. The thickness of the thermoplastic resin layer 2 may be 330 μm or less, 230 μm or less, or 180 μm or less. If the thickness of the thermoplastic resin layer 2 is equal to or less than the above upper limit value, it has excellent post-processability, and can suppress the manufacturing cost of the decorative sheet 1. From the above viewpoints, the thickness of the thermoplastic resin layer may be 15 μm or more and 330 μm or less, 40 μm or more and 230 μm or less, or 50 μm or more and 180 μm or less, and from the viewpoint of productivity, it may be 70 μm or more and 120 μm or less.

[0036] (Pattern layer) The pattern layer 3 is a layer for adding a pattern that imparts design properties to the decorative sheet, and is laminated on one surface (the upper surface in FIG. 1) of the thermoplastic resin layer 2.

[0037] The pattern layer 3 can be formed using a resin composition containing a resin (binder resin) (hereinafter, also referred to as a second resin composition). The resin composition for forming the pattern layer 3 is also called printing ink or paint, and may contain various dyes or pigments as necessary.

[0038] The pattern layer 3 can be formed, for example, by applying a second resin composition to one surface of the thermoplastic resin layer 2 by various printing methods such as a gravure printing method or an offset printing method, or various coating methods such as a gravure coating method or a roll coating method.

[0039] Examples of the resin contained in the second resin composition (printing ink or paint) include urethane resins, acrylic resins, vinyl chloride acetate resins, polyimide resins, nitrocellulose, and mixtures thereof. These resins may be chemical recycling resins, biomass-derived resins, or petroleum-derived resins.

[0040] The urethane resin may be a urethane (meth)acrylate obtained from a polyol, an isocyanate compound, and a hydroxy (meth)acrylate. At least one of the polyol, isocyanate compound, and hydroxy (meth)acrylate constituting the urethane (meth)acrylate may contain a biomass-derived component. In the following description, the urethane (meth)acrylate containing a biomass-derived component is also referred to as bio-urethane (meth)acrylate. In bio-urethane (meth)acrylate, a biomass-derived polyol may be used as the polyol, a biomass-derived isocyanate may be used as the isocyanate, or both the polyol and the isocyanate may be biomass-derived.

[0041] As the polyol, a polyester polyol which is a reaction product of a polyfunctional alcohol and a polyfunctional carboxylic acid, a polyether polyol which is a reaction product of a polyfunctional alcohol and a polyfunctional isocyanate, or a polycarbonate polyol which is a reaction product of a polyfunctional alcohol and a carbonate can be used. The polyfunctional alcohol, polyfunctional carboxylic acid, polyfunctional isocyanate, and carbonate may be biomass-derived or petroleum-derived.

[0042] As polyhydric alcohols derived from biomass, aliphatic polyhydric alcohols such as polypropylene glycol (PPG), neopentyl glycol (NPG), ethylene glycol (EG), diethylene glycol (DEG), butylene glycol (BG), and hexamethylene glycol, which are obtained from plant raw materials such as corn, sugarcane, cassava, and coconut, can be used. As polyhydric alcohols derived from petroleum, in addition to PPG, NPG, EG, DEG, BG, and hexamethylene glycol, conventionally known ones can be used. The polyhydric alcohols derived from biomass and those derived from petroleum may be used alone or in combination of two or more.

[0043] As polyhydric carboxylic acids derived from biomass, polyhydric carboxylic acids obtained from plant raw materials such as sebacic acid, succinic acid, phthalic acid, adipic acid, glutaric acid, and dimer acid can be used. As polyhydric alcohols derived from petroleum, conventionally known ones can be used. The polyhydric carboxylic acids derived from biomass and those derived from petroleum may be used alone or in combination of two or more.

[0044] As polyhydric isocyanates derived from biomass, polyhydric isocyanates obtained by acid amination and reduction of divalent carboxylic acids derived from biomass to convert them into terminal amino groups, and then reacting with phosgene to convert the amino groups into isocyanate groups can be used. Examples of polyhydric isocyanates derived from biomass include diisocyanates derived from biomass such as dimer acid diisocyanate (DDI), octamethylene diisocyanate, and decamethylene diisocyanate. As polyhydric isocyanates derived from petroleum, conventionally known ones can be used. The polyhydric isocyanates derived from biomass and those derived from petroleum may be used alone or in combination of two or more.

[0045] Examples of the carbonate include dimethyl carbonate, dipropyl carbonate, diethyl carbonate, diethylene carbonate, dibutyl carbonate, ethylene carbonate, diphenyl carbonate, etc. These may be used alone or in combination of two or more.

[0046] As the isocyanate compound, a biomass-derived polyfunctional isocyanate and a petroleum-derived polyfunctional isocyanate can be used. As these polyfunctional isocyanates, the above-described polyfunctional isocyanates can be used. The isocyanate compound may be used alone or in combination of two or more.

[0047] Examples of the hydroxy (meth) acrylate include hydroxy (meth) acrylates having one (meth) acryloyl group such as hydroxyethyl (meth) acrylate, hydroxypropyl (meth) acrylate, hydroxybutyl (meth) acrylate, 2-hydroxy-3-phenoxypropyl (meth) acrylate; hydroxy poly (meth) acrylates having two or more (meth) acryloyl groups such as glycerin di (meth) acrylate, pentaerythritol tri (meth) acrylate, ditrimethylolpropane tri (meth) acrylate, dipentaerythritol penta (meth) acrylate, sorbitol penta (meth) acrylate, etc. These may be used alone or in combination of two or more.

[0048] Further, the pattern layer 3 may be formed using a resin composition containing nitrocellulose in addition to the bio urethane (meth) acrylate. Nitrocellulose is a cellulose-based resin which is a nitro group-substituted product obtained by nitrate esterifying a part of the hydroxyl groups of the cellulose skeleton.

[0049] The pattern layer 3 may be formed of a second resin composition containing a biomass-derived resin. In this case, compared with the case of containing a petroleum resource-derived resin, the consumption of petroleum resources can be further reduced.

[0050] The second resin composition may contain other components other than the resin as required. Examples of the other components include weathering agents, plasticizers, fillers, dispersants, solvents, ultraviolet absorbers, heat stabilizers, light stabilizers, antiblocking agents, antibacterial agents, antifungal agents, catalyst scavengers, light scattering agents, gloss modifiers, surfactants, tackifiers, adhesion aids, desiccants, curing agents, curing accelerators, and curing retarders.

[0051] As the pattern of the pattern layer 3, any pattern can be used. For example, a wood grain pattern, a stone grain pattern, a cloth grain pattern, an abstract pattern, a geometric pattern, characters, symbols, a single-color plain surface, etc., or a combination thereof can be used. Further, in order to improve the concealability of the decorative sheet 1, a concealment layer may be provided between the pattern layer 3 and the thermoplastic resin layer 2. The concealment layer can be formed using, for example, an opaque printing ink or paint containing an opaque pigment such as titanium dioxide or iron oxide.

[0052] The thickness of the pattern layer 3 may be 1 μm or more and 10 μm or less. When the thickness of the pattern layer 3 is 1 μm or more, printing can be made clearer. When the thickness of the pattern layer 3 is 10 μm or less, the printing workability in manufacturing the decorative sheet is improved, and the manufacturing cost can be suppressed.

[0053] (Surface protection layer) The decorative sheet of this embodiment may further include a surface protection layer. In this case, as shown in FIG. 1, the surface protection layer 4 can be laminated on the surface of the thermoplastic resin layer 2 of the pattern layer 3 on the opposite side.

[0054] The surface protective layer 4 can be formed using a resin composition containing a resin (hereinafter sometimes referred to as the third resin composition). The third resin composition may contain a chemical recycling resin as the resin, a biomass-derived resin, or a petroleum-derived resin. Examples of the chemical recycling resin include the above-described chemical recycling olefin resin and other chemical recycling resins. Examples of the biomass-derived resin include the urethane resin, acrylic resin, vinyl chloride acetate resin, polyimide resin, nitrocellulose, and polyester resin exemplified in the description of the second resin composition above.

[0055] The surface protective layer 4 can be formed, for example, by applying the third resin composition to the surface of the picture layer 3 on the side opposite to the thermoplastic resin layer 2 by various printing methods such as gravure printing and silk printing, or various coating methods such as die coating and roll coating.

[0056] The third resin composition may contain other components other than the resin, if necessary. Examples of other components include inorganic materials such as silica, inorganic pigments, organic pigments, weathering agents such as ultraviolet absorbers, stain resistance imparting agents, organic fungicides and antibacterial agents, and functional imparting agents such as inorganic antibacterial and antiviral agents.

[0057] The thickness of the surface protective layer 4 may be 1 μm or more and 30 μm or less.

[0058] (Primer layer) The decorative sheet of this embodiment may further include a primer layer. In this case, as shown in FIG. 1, the primer layer 5 can be laminated on the surface of the thermoplastic resin layer 2 on the side opposite to the picture layer 3.

[0059] The primer layer 5 is a base layer and is a layer for improving the adhesion and corrosion resistance between the thermoplastic resin layer and the base material. The primer layer 5 can be formed using a resin composition containing a resin (hereinafter sometimes referred to as the fourth resin composition).

[0060] The fourth resin composition may contain, as the resin, a chemically recycled resin, a biomass-derived resin, or a petroleum-derived resin. Examples of the resin derived from chemical recycling include the above-described chemically recycled olefin resin and other chemically recycled resins. Examples of the biomass-derived resin include the urethane resin, acrylic resin, vinyl chloride acetate resin, polyimide resin, nitrocellulose, and polyester resin exemplified in the description of the second resin composition above.

[0061] The primer layer 5 can be formed, for example, by applying the fourth resin composition to the surface of the thermoplastic resin layer 2 on the side opposite to the pattern layer side by various printing methods such as gravure printing or various coating methods such as die coating and roll coating.

[0062] The fourth resin composition may contain other components other than the resin, if necessary. Examples of other components include inorganic materials such as silica and anti-blocking agents.

[0063] The thickness of the primer layer 5 may be 1 μm or more and 5 μm or less.

[0064] From the viewpoint of further improving the design property of the decorative sheet, the decorative sheet of the present embodiment may be embossed. The embossing may be performed on the entire decorative sheet of the present embodiment, may be performed on at least one of the thermoplastic resin layer and the pattern layer, and when the decorative sheet of the present embodiment has a surface protective layer, may be performed on at least one of the thermoplastic resin layer, the pattern layer, and the surface protective layer.

[0065] The embossing can be performed by a conventionally known method. For example, it is performed by passing a heated and plasticized thermoplastic resin layer or the like between an embossing plate having irregularities on the surface and a back roll (rubber back roll) made of rubber.

[0066] The decorative sheet 1 can be produced, for example, by preparing a base sheet formed from a first resin composition, providing a pattern layer and a surface protective layer on one main surface of the base sheet, and providing a primer layer on one main surface of the base sheet.

[0067] The total thickness of the decorative sheet of this embodiment may be 15 μm or more and 450 μm or less, and may also be 43 μm or more and 275 μm or less. In the case of the decorative sheet 1, the total thickness of the thermoplastic resin layer 2, the pattern layer 3, the surface protective layer 4, and the primer layer 5 may be 15 μm or more and 450 μm or less, and may also be 43 μm or more and 275 μm or less.

[0068] The content of the chemical recycling olefin resin contained in the decorative sheet of this embodiment may be 10% by mass or more, and may also be 70% by mass or more, based on the total amount of the plastic material in the decorative sheet.

[0069] <Decorative member> The decorative member of this embodiment includes a base material and the decorative sheet of this embodiment provided on the base material. FIG. 1 is a cross-sectional view schematically showing an example of a decorative member including the decorative sheet according to this embodiment. The decorative member 7 shown in FIG. 1 includes a base material 6 and a decorative sheet 1 provided on the base material 6, and the decorative sheet 1 is attached to the base material 6 via a primer layer 5.

[0070] The material of the base material 6 can be appropriately selected according to the use, type, etc. of the decorative member. Examples of the base material 6 include inorganic (non-metallic), metallic, wooden, plastic-based, etc. base materials.

[0071] Examples of the inorganic (non-metallic) base material include gypsum board and calcium silicate board. Examples of the metallic base material include steel plate, aluminum plate, and stainless steel plate. Examples of the wooden base material include plywood, MDF (medium density fiberboard), solid wood, and laminated wood. Examples of the plastic-based, etc. base material include polyolefin, acrylic, polystyrene, polyvinyl chloride, polyester, polyurethane, and mixtures thereof.

[0072] An adhesive may be used to attach the decorative sheet 1 to the base material 6. Examples of the adhesive include hot melt adhesives, solvent-based adhesives, and water-based adhesives. The adhesive may be a urethane-based adhesive, an ester-based adhesive, an acrylic-based adhesive, or a vinyl acetate-based adhesive.

Examples

[0073] The present invention will be described in more detail by the following examples, but the present invention is not limited to these examples.

[0074] (Example 1) [Preparation of resin composition] The following resin compositions were prepared to produce each layer of the decorative sheet. <First resin composition> A resin composition containing 100 parts by mass of chemically recycled polypropylene (chemically recycled PP) obtained by post-consumer recycling, 0.15 parts by mass of a nucleating agent (nanosized sodium 2,2'-methylenebis(4,6-di-tert-butylphenyl)phosphonate), and 30 parts by mass of titanium oxide was used as the first resin composition for forming the thermoplastic resin layer.

[0075] <Second resin composition> A printing ink containing 5% by mass or more of a resin containing a biomass-derived polyol, an isocyanate compound, and hydroxy(meth)acrylate was used as the second resin composition for forming the pattern layer.

[0076] <Third resin composition> A resin composition containing 5% by mass or more of a resin containing a biomass-derived polyol, an isocyanate compound, and hydroxy(meth)acrylate was used as the third resin composition for forming the surface protection layer.

[0077] <Fourth resin composition> A resin composition containing a biomass-derived polyester resin was used as the fourth resin composition for forming the primer layer.

[0078] [Production of Cosmetic Sheet and Cosmetic Member] First, a base sheet (thermoplastic resin layer) with a thickness of 120 μm was obtained using a first resin composition. After subjecting both surfaces of the obtained base sheet to corona discharge treatment, a second resin composition was applied to one surface of the base sheet by the gravure printing method and dried and cured to provide a pattern layer. Next, a third resin composition was applied to the pattern layer by the gravure printing method and dried and cured to provide a surface protection layer. Further, a fourth resin composition was applied to the surface of the base sheet on the side opposite to the side where the pattern layer and the surface protection layer were provided by the gravure printing method and dried and cured to provide a primer layer, thereby obtaining a cosmetic sheet.

[0079] An acrylic copolymer emulsion-based adhesive was applied to the surface of the obtained cosmetic sheet on the primer layer side using a roll coater, and a cosmetic member was obtained by laminating MDF (medium density fiberboard).

[0080] (Example 2) In the production of the base sheet (thermoplastic resin layer), a chemical recycled polyethylene (chemical recycled PE) obtained by post-consumer recycling was used instead of the chemical recycled PP obtained by post-consumer recycling, and a cosmetic sheet and a cosmetic member were obtained in the same manner as in Example 1.

[0081] (Example 3) Cosmetic sheets and cosmetic members were obtained in the same manner as in Example 1, except that the addition amount of the nucleating agent was changed to 1.00 part by mass with respect to 100 parts by mass of chemically recycled polypropylene.

[0082] (Example 4) Cosmetic sheets and cosmetic members were obtained in the same manner as in Example 1, except that the thickness of the base sheet (thermoplastic resin layer) was changed to 20 μm.

[0083] (Example 5) A decorative sheet and a decorative member were obtained in the same manner as in Example 1, except that the thickness of the base sheet (thermoplastic resin layer) was set to 300 μm.

[0084] (Example 6) A decorative sheet and a decorative member were obtained in the same manner as in Example 1, except that no nucleating agent was added.

[0085] (Example 7) In the production of the base sheet (thermoplastic resin layer), instead of the chemically recycled PP obtained from post-consumer recycling, chemically recycled polyethylene (chemically recycled PE) obtained from post-consumer recycling was used. A decorative sheet and a decorative member were obtained in the same manner as in Example 1, except that no nucleating agent was added.

[0086] (Example 8) A decorative sheet and a decorative member were obtained in the same manner as in Example 1, except that petroleum-derived components were used instead of biomass-derived components in the production of the pattern layer, the surface protection layer, and the primer layer.

[0087] (Example 9) In the production of the base sheet (thermoplastic resin layer), instead of the chemically recycled PP obtained from post-consumer recycling, chemically recycled PE obtained from post-consumer recycling was used. A decorative sheet and a decorative member were obtained in the same manner as in Example 1, except that petroleum-derived components were used instead of biomass-derived components in the production of the pattern layer, the surface protection layer, and the primer layer.

[0088] (Reference Example 1) In the production of the base sheet (thermoplastic resin layer), instead of the chemically recycled PP obtained from post-consumer recycling, petroleum-derived polypropylene (petroleum-derived PP) was used. A decorative sheet and a decorative member were obtained in the same manner as in Example 1, except that petroleum-derived components were used instead of biomass-derived components in the production of the pattern layer, the surface protection layer, and the primer layer.

[0089] (Comparative Example 1) In the production of the base sheet (thermoplastic resin layer), except that mechanically recycled polypropylene (mechanically recycled PP) obtained by post-consumer recycling was used instead of chemically recycled PP obtained by post-consumer recycling, cosmetic sheets and cosmetic members were obtained in the same manner as in Example 1.

[0090] (Comparative Example 2) In the production of the base sheet (thermoplastic resin layer), except that mechanically recycled polyethylene (mechanically recycled PE) obtained by post-consumer recycling was used instead of chemically recycled PP obtained by post-consumer recycling, cosmetic sheets and cosmetic members were obtained in the same manner as in Example 1.

[0091] (Comparative Example 3) In the production of the base sheet (thermoplastic resin layer), except that mechanically recycled PP obtained by post-consumer recycling was used instead of chemically recycled PP obtained by post-consumer recycling and no nucleating agent was added, cosmetic sheets and cosmetic members were obtained in the same manner as in Example 1.

[0092] (Comparative Example 4) In the production of the base sheet (thermoplastic resin layer), except that mechanically recycled PE obtained by post-consumer recycling was used instead of chemically recycled PP obtained by post-consumer recycling and no nucleating agent was added, cosmetic sheets and cosmetic members were obtained in the same manner as in Example 1.

[0093] (Comparative Example 5) In the production of the base sheet (thermoplastic resin layer), except that mechanically recycled PP obtained by post-consumer recycling was used instead of chemically recycled PP obtained by post-consumer recycling, and in the production of the pattern layer, surface protection layer and primer layer, petroleum-derived components were used instead of biomass-derived components, cosmetic sheets and cosmetic members were obtained in the same manner as in Example 1.

[0094] (Comparative Example 6) In the production of the base sheet (thermoplastic resin layer), instead of the chemically recycled PP obtained by post-consumer recycling, mechanically recycled PE obtained by post-consumer recycling was used. In the production of the pattern layer, surface protection layer, and primer layer, except that petroleum-derived components were used instead of biomass-derived components, a decorative sheet and a decorative member were obtained in the same manner as in Example 1.

[0095] (Evaluation of Decorative Sheet and Decorative Member) The following evaluation tests were conducted on the decorative sheets obtained in Examples 1 to 9, Reference Example 1, and Comparative Examples 1 to 6.

[0096] [Designability] The decorative sheets of each example were visually inspected, and the number of defective parts such as printing pattern dropout, streaks, and scratches per 1000 m was counted. The evaluation was conducted according to the following evaluation criteria. The results are shown in Tables 1 and 2. [Evaluation Criteria] A: The difference from the number of defective parts in Reference Example 1 was two or less. B: The difference from the number of defective parts in Reference Example 1 was three or four. C: The difference from the number of defective parts in Reference Example 1 was five or more.

[0097] [Weather Resistance Evaluation Test] In accordance with JIS B 7753, using an accelerated weather resistance tester (manufactured by Suga Test Instruments Co., Ltd., model number: S80BBR), the weather resistance evaluation test of the decorative sheet of each example was carried out. The evaluation was conducted by visually comparing the state of the decorative sheet of Reference Example 1 with the state of the decorative sheets of Examples 1 to 9 and Comparative Examples 1 to 6 when irradiated for 2000 hours for each example, according to the following evaluation criteria. The results are shown in Tables 1 and 2. [Evaluation Criteria] A: It was in the same state as Reference Example 1. B: There was a slight change compared to Reference Example 1. C: There was a significant change compared to Reference Example 1.

[0098] [Pencil Hardness Test] In accordance with JIS K5600-5-4, a pencil hardness test was conducted on the surface protective layer of the decorative sheet of each example using a pencil hardness tester (automatic) (manufacturer: Yoshimitsu Seiki Co., Ltd., model number: C211A). The test was performed using a 4B pencil and a 5B pencil, and the evaluation was carried out according to the following evaluation criteria. The results are shown in Tables 1 and 2. <Evaluation Criteria> A: After the test was carried out using a 4B pencil, no damage occurred on the surface. B: After the test was carried out using a 4B pencil, damage occurred on the surface, and after the test was carried out using a 5B pencil, no damage occurred on the surface. C: After the test was carried out using a 4B pencil, damage occurred on the surface, and after the test was carried out using a 5B pencil, damage occurred on the surface.

[0099] [Oil Dependency] For the decorative sheet of each example, the dependency on fossil fuels (oil dependency) when producing the decorative sheet was relatively evaluated in five levels: "low", "low to medium", "medium", "medium to high", and "high". The results are shown in Tables 1 and 2.

[0100] [Table 1]

[0101] [Table 2]

[0102] For the decorative sheets and decorative members of Examples 1 to 9, Reference Example 1, and Comparative Examples 1 to 6, the following evaluation tests were also conducted.

[0103] [Productivity] When producing the base sheet (thermoplastic resin layer) of the decorative sheet of each example, it was confirmed whether there were any problems such as being unable to be molded or generating abnormal odors. Those without problems were evaluated as "A", and those with possible problems and those with problems were evaluated as "B". The results are shown in Tables 3 and 4.

[0104] [Surface smoothness] For each decorative member, it was visually confirmed whether the unevenness of the base material appeared on the surface of the decorative sheet. Those in which unevenness was not confirmed on the surface of the decorative sheet were evaluated as "A", and those in which unevenness was confirmed were evaluated as "B". The results are shown in Tables 3 and 4.

[0105] [Post-processing property (bending processability)] For each decorative member, a V-shaped cut was made and it was bent at a right angle, and then the state of the decorative member was observed and evaluated according to the following evaluation criteria. The results are shown in Tables 3 and 4. [Evaluation criteria] A: Almost no cracks, whitening, etc. of the surface protective layer occurred at the top of the bent part. B: Some cracks, whitening, etc. of the surface protective layer occurred at the top of the bent part. C: Many cracks, whitening, etc. of the surface protective layer occurred at the top of the bent part.

[0106]

Table 3

[0107]

Table 4

Explanation of symbols

[0108] 1... Decorative sheet, 2... Thermoplastic resin layer, 3... Pattern layer, 4... Surface protective layer, 5... Primer layer, 6... Base material, 7... Decorative member.

Claims

1. A decorative sheet comprising a thermoplastic resin layer and a pattern layer provided on the thermoplastic resin layer. The decorative sheet wherein the thermoplastic resin layer is formed of a resin composition containing a chemically recycled olefin resin.

2. The decorative sheet according to Claim 1, wherein the chemically recycled olefin resin contains a post-consumer recycled resin.

3. The resin composition further contains a nucleating agent, The decorative sheet according to Claim 1, wherein the content of the nucleating agent in the resin composition is 0.05 parts by mass or more and 0.5 parts by mass or less with respect to 100 parts by mass of the chemically recycled olefin resin.

4. The specific gravity of the thermoplastic resin layer is 0.9 or more and 1.8 or less, The decorative sheet according to Claim 1, wherein the thickness of the thermoplastic resin layer is 15 μm or more and 330 μm or less.

5. The decorative sheet according to Claim 1, wherein the chemically recycled olefin resin is chemically recycled polypropylene or chemically recycled polyethylene.

6. The decorative sheet according to Claim 1, wherein the pattern layer is formed of a resin composition containing a biomass-derived resin.

7. The decorative sheet according to Claim 1, further comprising a primer layer provided on the side of the thermoplastic resin layer opposite to the pattern layer side, The decorative sheet according to Claim 1, wherein the primer layer is formed of a resin composition containing a biomass-derived resin.

8. The decorative sheet according to Claim 1, further comprising a surface protection layer provided on the side of the pattern layer opposite to the thermoplastic resin layer side, The decorative sheet according to Claim 1, wherein the surface protection layer is formed of a resin composition containing a biomass-derived resin.

9. The embossed decorative sheet according to Claim 8.

10. A decorative member comprising a substrate and the decorative sheet according to any one of Claims 1 to 9 provided on the substrate.

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