Method for manufacturing decorative sheet, decorative sheet, and decorative material

Abstract

To provide a method for manufacturing a decorative sheet in which concealability can be secured, and reduction of adhesion strength due to generation of release in a coloring layer can be suppressed.SOLUTION: In manufacturing a decorative sheet 10 in which a substrate resin layer 20, a printed pattern layer 50 and a coloring layer 40 are laminated in this order, the coloring layer 40 is formed by using two pack urethane-based resin ink using methyl ethyl ketone or ethyl acetate as solvent. Because the two pack urethane-based resin ink can be dispersed more uniformly in the solvent in the coloring layer 40 by forming the coloring layer 40 by using the two pack urethane-based resin ink using methyl ethyl ketone or ethyl acetate as solvent, cohesive fracture in the coloring layer 40 can be suppressed. Further, adhesion between the coloring layer 40 and the printed pattern layer 50 can be improved by improving compatibility between the coloring layer 40 and the printed pattern layer 50, and release of the decorative sheet 10 can be suppressed.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a cosmetic sheet, a cosmetic sheet, and a cosmetic material.

Background Art

[0002] Among cosmetic sheets for building materials, there are some that require high concealability in order to make the base material to which the cosmetic sheet is to be attached, the intermediate layer of the cosmetic sheet itself, etc. invisible. Further, due to the increasing concern about environmental problems, thinning of the cosmetic sheet such as resin reduction is desired. As a method for forming a sheet having high concealability and a thin sheet, there is a method of forming a sheet including a layer coated with a paint containing a high-concentration pigment (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] A paint containing a high concentration of pigment easily aggregates and breaks, so there are problems such as insufficient adhesion strength of the sheet and peeling of the colored layer from the sheet during sheet processing or actual use. An object of the present invention is to provide a method for manufacturing a cosmetic sheet, a cosmetic sheet, and a cosmetic material capable of ensuring concealability and suppressing a decrease in adhesion strength due to aggregation breakdown or peeling of the colored layer.

Means for Solving the Problems

[0005] According to one aspect of the present invention, there is provided a method for manufacturing a decorative sheet in which a base resin layer, a printed pattern layer, and a colored layer are laminated in this order, wherein the colored layer is formed using a two-component urethane resin ink having methyl ethyl ketone or ethyl acetate as a solvent.

[0006] Further, according to another aspect of the present invention, there is provided a decorative sheet in which a base resin layer, a printed pattern layer, and a colored layer are laminated in order, and the colored layer contains methyl ethyl ketone or ethyl acetate as a residual solvent and a two-component urethane resin ink.

[0007] Furthermore, according to another aspect of the present invention, there is provided a decorative material including the decorative sheet of the above aspect and a base material provided on the surface of the decorative sheet on the colored layer side.

Advantages of the Invention

[0008] According to one aspect of the present invention, it is possible to obtain a decorative sheet capable of suppressing a decrease in adhesion strength.

Brief Description of the Drawings

[0009]

Figure 1

Figure 2

Modes for Carrying Out the Invention

[0010] Here, the drawings are schematic, and the relationship between the thickness and the planar dimensions, the ratio of the thicknesses of the respective layers, etc. are different from the actual ones. Further, the embodiments shown below are examples of configurations for embodying the technical idea of the present invention, and the technical idea of the present invention is not limited to the materials, shapes, structures, etc. of the constituent parts being as described below. The technical idea of the present invention can be variously modified within the technical scope defined by the claims described in the claims.

[0011] FIG. 1 is a cross-sectional view schematically showing a cosmetic sheet according to an embodiment of the present invention. In FIG. 1, reference numeral 10 denotes a cosmetic sheet. Although not shown, for example, it is used indoors and is pasted on the surfaces of fixtures (interior doors, entrance storage), building materials (dividers, moldings, lintels, window frames, door frames), etc., and is used by matching the patterns of fixtures and building materials for each house or room. The cosmetic sheet 10 includes the following layers, and each layer is provided in order from (1).

[0012] Note that the following (1) to (6) will be described later. (1) Primer layer 30 (2) Barrier layer 35 (3) Coloring layer 40 (4) Printed pattern layer 50 (5) Base resin layer 20 (6) Surface protection layer 60 Note that each layer of the cosmetic sheet 10 is not limited to the above (1) to (6), and may include other layers. That is, other layers may be provided between the base resin layer 20 and the surface protection layer 60, and between the coloring layer 40 and the barrier layer 35.

[0013] Further, the cosmetic sheet 10 may form an embossed portion (not shown) synchronized with the pattern of the printed pattern layer 50 on the surface side of the surface protection layer 60. Further, a base material 70 may be adhered to the surface of the primer layer 30 opposite to the barrier layer 35 to form a decorative material 11. Further, the above “(1) Primer layer 30” may be omitted. That is, if the above “(2) Coloring layer 40” has a function as a primer layer, the primer layer 30 can be omitted. Further, the barrier layer 35 does not necessarily have to be provided.

[0014] (Main features of the cosmetic sheet 10) The main features of the cosmetic sheet 10 are as follows.

[0015] (1) The cosmetic sheet 10 according to an embodiment of the present invention is composed of a single-layer film made of a transparent olefin sheet. On one surface side of a base resin layer 20 formed of a single-layer film, a printed pattern layer 50 formed by printing a pattern, a coloring layer 40, a barrier layer 35, and a primer layer 30 are formed in this order from the side of the base resin layer 20. Further, a surface protection layer 60 is formed on the other surface side of the base resin layer 20, and it is a cosmetic sheet that does not have a laminate layer made of another film on either the front surface side or the back surface side of the base resin layer 20. The base resin layer 20 is a single-layer film manufactured by extrusion molding using, for example, a transparent polypropylene-based thermoplastic resin, and a dispersant as a nano-sized additive is added to this base resin layer 20.

[0016] Since the cosmetic sheet 10 does not have a lamination process with other sheets during manufacturing, the number of manufacturing processes can be reduced, and the manufacturing process from printing to applying the surface protection layer 60 can be performed in one inline process.

[0017] Also, the cosmetic sheet 10 can be synchronized with the pattern by applying a gloss / matte coat to the surface protection layer 60 as needed. Also, by forming the coloring layer 40 using a two-component urethane-based resin ink with methyl ethyl ketone (MEK) or ethyl acetate as a solvent, the two-component urethane-based resin ink can be more uniformly dispersed in the solvent in the coloring layer 40. Therefore, aggregation breakdown in the coloring layer 40 can be suppressed, and the adhesion between the coloring layer 40 and the printed pattern layer 50 can be improved by improving the compatibility between the coloring layer 40 and the printed pattern layer 50.

[0018] (2) Further, since conventional cosmetic sheets are multilayered, there is a limit in film formation when thinning the sheet, and there is also a problem that the hardness of the sheet cannot be obtained. However, the cosmetic sheet 10 according to an embodiment of the present invention is single-layered, so it is easy to thin, and by using a nano-sized additive, the sheet can be hardened even if it is thin.

[0019] (3) According to the decorative sheet 10 according to an embodiment of the present invention, first, if the frame material is made of a single color, it becomes possible to respond in advance to any pattern of the door part. Therefore, it becomes possible to decide the pattern of the door part later, or even when the door part is aged and the pattern is changed, it is possible to respond only by changing the door part without breaking and replacing the frame material. Of course, the door part itself can also be made of a single color. Further, according to the decorative sheet 10, even in an apartment or the like, by unifying all rooms with a single color, it becomes easy to increase the lot and improve productivity or reduce the unit price. Therefore, there is an advantage in using a single-color sheet.

[0020] (4) Since the base material 70 is adhered to the primer layer 30 side of the decorative material 11 using the decorative sheet 10, the decorative material 11 can be easily and quickly used.

[0021] (5) By using the manufacturing method of the decorative sheet 10 according to an embodiment of the present invention, a highly concealing decorative sheet 10 can be easily and quickly manufactured.

[0022] (Configuration of each layer) (Base material resin layer 20) The base material resin layer 20 serves as a support for the decorative sheet 10 and is made of, for example, a transparent olefin sheet. The base material resin layer 20 is formed as a single layer and is formed by adding a dispersant as a nano-sized additive to, for example, a transparent polypropylene-based thermoplastic resin. The base material resin layer 20 is preferably transparent or translucent. Further, it is preferable that a weather-resistant agent is blended with, for example, the transparent polypropylene resin constituting the base material resin layer 20. Since the base material resin layer 20 is a single layer, it is easy to make it into a thin film, and by using a nano-sized additive, the sheet can be made hard even with a thin film.

[0023] (Primer layer 30) As shown in FIG. 1, the primer layer 30 is located on the side opposite to the printed pattern layer 50 of the colored layer 40 and is mainly provided for the purpose of improving adhesiveness. In addition, the functions of the primer layer 30 include not only improving adhesiveness, but also surface stabilization after surface treatment, corrosion prevention of the metal surface, imparting adhesiveness, preventing deterioration of the adhesive, and the like. The primer layer 30 is formed by coating a urethane resin so that the solid content is 1 g / m 2 by, for example, the gravure printing method.

[0024] For the primer layer 30, for example, urethane-based, acrylic-based, ethylene-vinyl acetate copolymer, vinyl chloride-vinyl acetate copolymer-based, polyester-based, etc. can be adopted. In particular, a two-component curable urethane-based primer agent or the like obtained by blending a polyester polyol and a polyisocyanate is preferable. Further, when inorganic powders such as silica, barium sulfate, and calcium carbonate are added to these materials to form the primer layer 30, it is effective for improving the adhesive strength due to the anchoring effect.

[0025] (Barrier layer 35) The barrier layer is mainly provided for the purpose of suppressing gas permeation, and can be provided, for example, by applying or printing a two-component curable acrylic resin by a bar coater or a gravure printing method.

[0026] Here, the decorative sheet 10 is attached to, for example, a wood-based substrate 70 to become a decorative material 11. When the decorative sheet 10 is attached to the wood-based substrate 70, discoloration of the original fabric for light-colored printing due to β-caryophyllene as a terpene, which is a kind of volatile organic compound released from the heat-treated compressed wood that becomes the wood-based substrate 70, is a concern. By providing the barrier layer 35, discoloration due to volatile organic compounds diffused from the substrate 70 can be prevented.

[0027] (Coloring layer 40) As shown in FIG. 1, the coloring layer 40 is located on the surface of the base resin layer 20 of the printed pattern layer 50 opposite to the surface of the base resin layer 20, and is formed by a printing method. The coloring layer 40 is a concealing layer provided mainly for the purpose of imparting concealability. The coloring layer 40 is, for example, printed by a gravure printing method, and is formed using a two-component urethane resin ink with MEK (methyl ethyl ketone) or ethyl acetate as a solvent. The coloring layer 40 may be a solid layer. In the coloring layer 40, since MEK (methyl ethyl ketone) or ethyl acetate is used as a solvent, MEK (methyl ethyl ketone) or ethyl acetate remains in the decorative sheet 10 to some extent as a residual solvent.

[0028] (Printed pattern layer 50) As shown in FIG. 1, the printed pattern layer 50 is located on the surface of the base resin layer 20 opposite to the surface protection layer 60, and is formed by a printing method. The printed pattern layer 50 is provided for the purpose of imparting design characteristics to the decorative sheet 10.

[0029] The printed pattern layer 50 is, for example, a urethane resin pattern printed by a gravure printing method. As the printing method, for example, the gravure printing method is illustrated, but it is not limited thereto. For example, various printing methods such as an offset printing method, a relief printing method, a flexographic printing method, a screen printing method, an inkjet printing method, and an electrostatic printing method can be applied.

[0030] The type of pattern of the printed pattern layer 50 is arbitrary depending on the purpose of use, the preference of the user, etc. For example, a wood grain pattern, a stone grain pattern, an abstract pattern, etc. are common. The type of pattern is not limited to the types illustrated above, and for example, full-surface solid printing etc. may be used. In addition, appropriate additives such as a filler, a tackifier, a plasticizer, a stabilizer, a dispersant, an antifoaming agent, a leveling agent, a surfactant, and a desiccant may be added to the printing ink.

[0031] (Surface protection layer 60) As shown in FIG. 1, the surface protective layer 60 is located on the surface of the base resin layer 20 opposite to the printed pattern layer 50 and is formed using a printing method. The surface protective layer 60 is provided for the purpose of imparting surface physical properties such as abrasion resistance and water resistance. For the surface protective layer 60, for example, an acrylic two-component curable resin (acrylic urethane resin manufactured by DIC Graphics Co., Ltd.) is applied to a thickness of about 6 μm.

[0032] Furthermore, the surface protective layer 60 may be subjected to an antiviral treatment. As the antiviral treatment, an antiviral agent is added to the surface protective layer 60. As the antiviral agent, for example, a silver-based inorganic additive (Bioside TB-B100) manufactured by Taisho Techno Co., Ltd. carrying silver ions is used. Although an antiviral agent is added to the surface protective layer 60, the present invention is not limited thereto, and an antiviral agent may be applied to the surface of the surface protective layer 60.

[0033] (Resin material of the base resin layer 20) The base resin layer 20 is a single-layer film composed of a transparent olefin sheet. A dispersant is added to the base resin layer 20 as a nano-sized additive. In addition, a weathering agent is also blended in the base resin layer 20. Furthermore, an inorganic filler is added to the base resin layer 20. Note that the inorganic filler does not necessarily have to be added. The base resin layer 20 is formed by extrusion molding using, for example, a transparent polypropylene-type thermoplastic resin. The film thickness of the base resin layer 20 is 50 μm or more and 120 μm or less.

[0034] (Nano-sized additives etc. (nucleating agent)) The base resin layer 20 contains an inorganic filler in addition to a dispersant as a nano-sized additive. Hereinafter, the nano-sized additive is also referred to as a "nano-sized nucleating agent". The nano-sized nucleating agent is preferably added to the polypropylene resin in the form of a nucleating agent vesicle, which is encapsulated in a vesicle having an outer membrane of a single-layer film, and used.

[0035] In addition, in the present embodiment, the nucleating agent in the resin constituting the base resin layer 20 may be encapsulated in vesicles with a part of the nucleating agent exposed. Since the base resin layer 20 contains a nucleating agent, the crystallinity can be improved, and the scratch resistance (scuff resistance) of the decorative sheet 10 can be improved.

[0036] (Particle size of the nano-sized nucleating agent) The nano-sized nucleating agent preferably has an average particle size of 1 / 2 or less of the wavelength region of visible light. Specifically, since the wavelength region of visible light is 400 nm or more and 750 nm or less, the average particle size is preferably 375 nm or less.

[0037] Since the nano-sized nucleating agent has an extremely small particle size, the number and surface area of the nucleating agents present per unit volume increase in inverse proportion to the cube of the particle diameter. As a result, the distance between each nucleating agent particle becomes close. When crystal growth occurs from the surface of one nucleating agent particle added to the resin, the end of the growing crystal immediately contacts the end of the crystal growing from the surface of another nucleating agent particle adjacent to the one nucleating agent particle, and the growth of each crystal is inhibited by the mutual inhibition of the crystal ends, stopping the growth of each crystal. Therefore, the average particle size of the spherulites in the crystalline part of the crystalline resin can be reduced. For example, the spherulite size can be reduced to 1 μm or less.

[0038] As a result, a high-hardness resin film with high crystallinity can be obtained, and stress concentration between spherulites generated during bending processing is efficiently dispersed, so that a resin film that suppresses cracking and whitening during bending processing can be realized. When the nucleating agent is simply added, the nucleating agent in the resin undergoes secondary aggregation, increasing the particle size. On the other hand, when the nucleating agent vesicles are added, the dispersibility in the resin is improved, so that the number of crystal nuclei with respect to the amount of the added nucleating agent increases significantly compared to the case where the nucleating agent is simply added.

[0039] Therefore, the average grain size of spherulites in the crystalline part of the resin becomes smaller, and the occurrence of cracks and whitening during bending processing can be suppressed. Thus, by adding the nucleating agent vesicles, the degree of crystallinity can be further increased, making it possible to further balance the improvement of the elastic modulus and processability. The base resin layer 20 is formed of, for example, a resin material in which a nucleating agent is added within a range of preferably 0.05 parts by mass or more and 0.5 parts by mass or less, more preferably 0.1 parts by mass or more and 0.3 parts by mass or less, with respect to 100 parts by mass of a polypropylene resin as the main component.

[0040] When using nucleating agent vesicles, the addition amount of the nucleating agent to the resin material is the addition amount converted to the nucleating agent in the nucleating agent vesicles. When the addition amount of the nucleating agent is less than 0.05 parts by mass, the crystallinity of polypropylene may not be sufficiently improved, and the scratch resistance of the base resin layer 20 may not be sufficiently improved.

[0041] Also, when the addition amount of the nucleating agent exceeds 0.5 parts by mass, the spherulite growth of polypropylene is conversely inhibited due to an excessive number of crystal nuclei, and as a result, the crystallinity of polypropylene may not be sufficiently improved, and the scratch resistance of the base resin layer 20 may not be sufficiently improved. Here, the "main component" refers to a resin material that occupies 50% by mass or more of the resin material constituting the base resin layer 20.

[0042] (Method for nanosizing the nucleating agent) Also, as a method for nanosizing the nucleating agent, for example, a solid phase method in which mainly mechanical grinding is performed on the nucleating agent to obtain nanoparticles, a liquid phase method in which nanoparticles are synthesized or crystallized in a solution in which the nucleating agent or the nucleating agent is dissolved, a gas phase method in which nanoparticles are synthesized or crystallized from a gas or vapor composed of the nucleating agent or the nucleating agent, etc. can be appropriately used.

[0043] 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, a jet mill, etc. In addition, 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 the like. Further, examples of the gas phase method include an electric furnace method, a chemical flame method, a laser method, a thermal plasma method, and the like.

[0044] (Supercritical reverse phase evaporation method) As a method for nanosizing the nucleating agent, the supercritical reverse phase evaporation method is preferred. The supercritical reverse phase evaporation method is a method for creating a capsule (nanosized vesicle) encapsulating a target substance using carbon dioxide under supercritical conditions or under temperature conditions or pressure conditions above the critical point.

[0045] Supercritical carbon dioxide means carbon dioxide in a supercritical state at a critical temperature (30.98 °C) and a critical pressure (7.3773 ± 0.0030 MPa) or higher, and carbon dioxide under temperature conditions or pressure conditions above the critical point means carbon dioxide under conditions where only the temperature or only the pressure exceeds the critical conditions.

[0046] In addition, as a specific nanosizing treatment by the supercritical reverse phase evaporation method, first, an aqueous phase is injected into a mixed fluid of supercritical carbon dioxide, a phospholipid as an outer membrane forming substance, and a nucleating agent as an encapsulating substance, and stirred to generate an emulsion of supercritical carbon dioxide and the aqueous phase.

[0047] Next, by reducing the pressure, carbon dioxide expands and evaporates, causing a phase inversion, and generating a nanocapsule (nanovesicle) in which the phospholipid covers the surface of the nucleating agent particles with a monolayer film. By using this supercritical reverse phase evaporation method, unlike the conventional encapsulation method in which the outer membrane becomes a multi-layer film on the surface of the nucleating agent particles, a capsule with a monolayer film can be easily generated, so that a capsule with a smaller diameter can be prepared.

[0048] The nucleating agent vesicles are prepared, for example, by the Bangham method, the extrusion method, the hydration method, the surfactant dialysis method, the reverse phase evaporation method, the freeze-thaw method, the supercritical reverse phase evaporation method, and the like. Among them, the nucleating agent vesicles are preferably prepared using the supercritical reverse phase evaporation method in particular.

[0049] (Outer membrane constituting the nucleating agent vesicle) The outer membrane constituting the nucleating agent vesicle is composed of, for example, a single-layer membrane. Further, the outer membrane is composed of a substance containing a biological lipid such as a phospholipid, for example. In this specification, a nucleating agent vesicle whose outer membrane is composed of a substance containing a biological lipid such as a phospholipid is referred to as a nucleating agent liposome.

[0050] Examples of the phospholipid constituting the outer membrane include glycerophospholipids such as phosphatidylcholine, phosphatidylethanolamine, phosphatidylserine, phosphatidic acid, phosphatidylglycerol, phosphatidylinositol, cardiolipin, egg yolk lecithin, hydrogenated egg yolk lecithin, soybean lecithin, hydrogenated soybean lecithin, and sphingomyelins such as sphingomyelin, ceramide phosphorylethanolamine, and ceramide phosphorylglycerol.

[0051] (Other substances serving as the outer membrane) Examples of other substances serving as the outer membrane of the vesicle include nonionic surfactants and dispersants such as a mixture of these with cholesterol or triacylglycerol.

[0052] Among these, examples of nonionic surfactants include one or more of polyglycerol ethers, dialkyl glycerols, polyoxyethylene hydrogenated castor oil, polyoxyethylene alkyl ethers, polyoxyethylene sorbitan fatty acid esters, sorbitan fatty acid esters, polyoxyethylene polyoxypropylene copolymers, polybutadiene-polyoxyethylene copolymers, polybutadiene-poly(2-vinylpyridine), polystyrene-polyacrylic acid copolymers, polyethylene oxide-polyethyl ethylene copolymers, polyoxyethylene-polycaprolactam copolymers, and the like. Examples of cholesterol compounds include cholesterol, α-cholestanol, β-cholestanol, cholestane, desmosterol (5,24-cholestadien-3β-ol), sodium cholate, or colecalciferol, and the like can be used.

[0053] Also, the outer membrane of the liposome may be formed from a mixture of a phospholipid and a dispersant. In the cosmetic sheet 10 of the present embodiment, it is preferable that the nucleating agent vesicle is a radical scavenging liposome having an outer membrane made of a phospholipid. By configuring the outer membrane from a phospholipid, the effectiveness of the resin material, which is the main component of the cosmetic sheet 10, and the vesicle can be made good.

[0054] The nucleating agent is not particularly limited as long as it is a substance that serves as a crystallization starting point when the resin crystallizes. Examples of the nucleating agent include metal phosphate esters, metal benzoates, metal pimelates, metal rosins, benzylidene sorbitol, quinacridone, cyanine blue, and talc. In particular, in order to maximize the effect of the nanosizing treatment, it is preferable to use a metal phosphate ester, a metal benzoate, a metal pimelate, or a metal rosin, which is a non-melting type and can be expected to have good transparency. However, when the material itself can be made transparent by the nanosizing treatment, colored quinacridone, cyanine blue, talc, and the like can also be used. Further, a melting type benzylidene sorbitol may be appropriately mixed and used with the non-melting type nucleating agent.

[0055] (Features of the base resin layer 20) As described above, in the decorative sheet 10 of the present embodiment, the base resin layer 20 contains a resin material and a nucleating agent.

[0056] Further, in the decorative sheet 10 of the present embodiment, when forming the base resin layer 20, a nucleating agent encapsulated in vesicles is added to the resin material to crystallize the resin material. By adding the nucleating agent encapsulated in vesicles to the resin composition, the dispersibility of the nucleating agent in the resin material, that is, in the base resin layer 20, is remarkably improved. On the other hand, it is assumed that in some cases, it is difficult and unrealistic to directly specify the structure and properties of the object in the state of the completed decorative sheet 10 for the nucleating agent encapsulated in vesicles. The reasons are as follows.

[0057] The nucleating agent added in the state of vesicles is in a dispersed state with high dispersibility and is highly dispersed in the base resin layer 20 even in the state of the laminate which is the precursor of the produced decorative sheet 10. However, in the manufacturing process of the decorative sheet 10, usually, various treatments such as compression treatment and curing treatment are performed on the laminate, and in such treatments, the outer membrane of the vesicles encapsulating the nucleating agent may be crushed or a chemical reaction may occur.

[0058] For this reason, due to the treatment process of the decorative sheet 10, the state in which the outer membrane of the nucleating agent in the completed decorative sheet 10 is crushed or chemically reacted varies, and there is a high possibility that the nucleating agent is not encapsulated (covered) by the outer membrane. And when the nucleating agent is not encapsulated by the outer membrane, it is difficult to specify the physical properties of the nucleating agent itself within a numerical range, and it is also assumed that it is difficult to determine whether the constituent material of the crushed outer membrane is the outer membrane of the vesicles or a material added separately from the nucleating agent.

[0059] As described above, although the present disclosure differs from the prior art in that the nucleating agent is highly dispersed in the cosmetic sheet 10, it is assumed that in the state of the cosmetic sheet 10, it may be impractical to specify within a numerical range obtained by analyzing its structure and properties based on measurements as to whether this is because it is added in the form of vesicles encapsulating the nucleating agent.

[0060] In the base resin layer 20, if necessary, for example, one or more selected from various additives such as fillers, ultraviolet absorbers, light stabilizers, heat stabilizers, antioxidants, antistatic agents, lubricants, flame retardants, antibacterial agents, antifungal agents, antifriction agents, light scattering agents, and gloss modifiers may be added.

[0061] (Method for manufacturing the cosmetic sheet 10) The cosmetic sheet 10 has the above-described configuration, and its manufacturing method includes the following first to third steps and is manufactured inline.

[0062] Here, "inline" means that since there is no lamination step for laminating films, printing, which usually involves multiple steps, can be processed in one line, that is, on one line. That is, the manufacturing process from printing to applying the surface protective layer 60 can be performed in one inline step.

[0063] (1) First step The first step is a step of manufacturing the base resin layer 20 by adding a dispersant as a nano-sized additive to a transparent polypropylene-based thermoplastic resin and performing extrusion molding.

[0064] (2) Second step The second step is a step of sequentially forming the printed pattern layer 50, the colored layer 40, the barrier layer 35, and the primer layer 30 on one surface (back surface) side of the base resin layer 20 manufactured in the first step.

[0065] (3) Third step The third step is a step of forming a surface protection layer 60 on the other surface (front surface) side of the base resin layer 20 manufactured in the first step, after or prior to the second step.

[0066] The order of the above steps is twofold: the order of the first step, the second step, and the third step, and the order of the first step, the third step, and the second step.

[0067] (Decorative material) The decorative material 11 is obtained by adhering a base material 70 using an adhesive or the like to the side of the primer layer 30 of the decorative sheet 10 having the above-described configuration.

[0068] Here, the base material 70 may be made of any type such as wood, steel, resin material, etc. For example, it may be composed of a non-combustible steel plate or a non-combustible material defined in Notification No. 1400 of the Ministry of Construction. Note that the base material 70 is not limited to being provided in contact with the primer layer 30. If the primer layer 30 is not provided, it may be provided on the barrier layer 35, or if neither the primer layer 30 nor the barrier layer 35 is provided, it may be provided on the coloring layer 40. In short, the base material 70 only needs to be provided in contact with the surface on the side of the coloring layer 40 or via another layer, rather than the surface on the side of the base resin layer 20 of the decorative sheet 10.

[0069] A substrate may be used as the base material 70, and the decorative sheet 10 may be adhered to the substrate to form a decorative board. At this time, a moisture-proof film may be adhered to the surface of the substrate opposite to the surface to which the decorative sheet 10 is adhered.

[0070] (Another embodiment of the layer structure on the back side of the base resin layer 20) Although not shown, the layer structure on the back side of the base resin layer 20 may be in the following aspect.

[0071] (a) Only a printed pattern layer 50 and a coloring layer 40 may be formed in this order on the back side of the base resin layer 20. (b) Only a printed pattern layer 50, a coloring layer 40, and a primer layer 30 may be formed in this order on the back side of the base resin layer 20.

[0072] (Effect of the Embodiment) The cosmetic sheet 10 according to the present embodiment forms the colored layer 40 by applying a two-component urethane-based resin ink using methyl ethyl ketone or ethyl acetate as a solvent.

[0073] Therefore, the printed pattern layer 50 and the colored layer 40 are compatible with each other, and the adhesion between the printed pattern layer 50 and the colored layer 40 can be improved. As a result, the adhesion between the printed pattern layer 50 and the colored layer 40 can be improved, and peeling between the colored layer 40 and the printed pattern layer 50 can be suppressed. Further, since methyl ethyl ketone or ethyl acetate is used as the solvent for the colored layer 40, for example, as compared with the case of using other materials such as MIBK (methyl isobutyl ketone) as the solvent, in the colored layer 40, the two-component urethane-based resin ink can be dispersed more uniformly. Therefore, it is possible to make it difficult for cohesive failure to occur in the colored layer 40.

[0074] As a result, it is possible to suppress peeling between the colored layer 40 and the printed pattern layer 50 or within the colored layer 40 during sheet processing or actual use, that is, it is possible to suppress separation between the substrate side to which the cosmetic sheet 10 is attached and the printed pattern layer 50 side. Further, it is possible to suppress peeling of the colored layer 40 from the cosmetic sheet 10 during construction or actual use.

[0075] Further, by forming the colored layer 40 using a two-component urethane-based resin ink using methyl ethyl ketone or ethyl acetate as a solvent, the adhesion between the printed pattern layer 50 and the colored layer 40 can be improved. Therefore, as the colored layer 40, an ink containing a high concentration of pigment can be used, and a cosmetic sheet 10 with high concealability can be realized.

[0076] In addition, the cosmetic sheet 10 according to the present embodiment does not have a lamination process. Therefore, a series of processes from the first process of forming the base resin layer 20 to the second process of forming the printed pattern layer 50, the colored layer 40, the barrier layer 35, and the primer layer 30, and further to the third process of forming the surface protection layer 60 can be performed in one in-line process.

[0077] In addition, the base resin layer 20 is formed of a resin containing a nano-sized additive with a dispersant added as a nano-sized nucleating agent. By adding the nucleating agent, the base resin layer 20 becomes hard and is less likely to stretch and shrink.

[0078] Therefore, in the process of forming the printed pattern layer 50, the colored layer 40, the barrier layer 35, and the primer layer 30 on the back side of the base resin layer 20, and in the process of forming the surface protection layer 60 on the front side of the base resin layer 20, the expansion and contraction of the base resin layer 20 caused by forming various layers with tension applied to the base resin layer 20, or the expansion and contraction of the base resin layer 20 due to the temperature applied to the base resin layer 20 when drying the ink printed for forming the printed pattern layer 50 after printing the ink for forming the printed pattern layer 50 when forming each layer such as the printed pattern layer 50 can be suppressed. (Modification example) In the above embodiment, the case of forming a single-layer base resin layer 20 has been described, but the base resin layer 20 may be composed of two types and three layers.

[0079] That is, as shown in FIG. 2, the base resin layer 20 is formed of two types and three layers in the order of a transparent skin layer 21, a transparent core layer 22 made of transparent polypropylene, and a transparent skin layer 21. In FIG. 2, the base resin layer 20 is shown with the transparent core layer 22 and the transparent skin layer 21 forming separate layers, but in reality, the transparent core layer 22 and the transparent skin layer 21 are continuous and are a single-layer sheet without an interface.

[0080] The base resin layer 20 is formed by co-extruding a transparent skin layer 21, a transparent core layer 22, and a transparent skin layer 21 so that the thickness ratio is 0.5:9:0.5, and the total thickness is made to be 50 μm or more and 120 μm or less. Further, the transparent skin layer 21 is formed by adding a dispersant as a nano-sized additive and an inorganic filler to a transparent polypropylene-based thermoplastic resin, and the transparent core layer 22 is formed using, for example, a transparent polypropylene resin blended with a weathering agent.

Example

[0081] Hereinafter, examples and comparative examples of the cosmetic sheet according to the present invention will be described. (Example 1) First, a weathering agent, a dispersant as a nano-sized additive, etc. were added to a transparent polypropylene resin, and extrusion molding was performed using the transparent polypropylene resin to which these were added to prepare a base resin layer.

[0082] Second, using a bar coater, a pattern layer was printed on one surface side of the base resin layer using a urethane-based resin ink. Third, using a bar coater, on the surface of the pattern layer opposite to the base resin layer, a two-component urethane-based resin ink obtained by adding 4 parts by mass of a curing agent to 100 parts by mass of a two-component urethane-based resin ink was diluted with MEK as a solvent, and using this diluted ink, a colored layer was formed so that the solid content was 18 g / m 2 Thus, the cosmetic sheet of Example 1 was prepared.

[0083] (Example 2) A cosmetic sheet of Example 2 was prepared in the same procedure as in Example 1, except that the solvent of the colored layer was changed to ethyl acetate instead of MEK.

[0084] (Comparative Example 1) A cosmetic sheet of Comparative Example 1 was prepared in the same procedure as in the example, except that the solvent of the colored layer was changed to MIBK (methyl isobutyl ketone) instead of MEK.

[0085] (Performance Evaluation Method) As an evaluation of the cosmetic sheet, the evaluation of the substrate adhesion strength was carried out.

[0086] (Evaluation of substrate adhesion strength) The evaluation of the substrate adhesion strength was carried out by pasting each cosmetic sheet of the examples and comparative examples on MDF (Medium Density Fiberboard) to prepare a decorative material, and evaluating using this decorative material.

[0087] First, the back surface of each cosmetic sheet of the examples and comparative examples was coated with an aqueous urethane adhesive on 3 mm thick MDF and pasted together, and a weight was placed on it and compression-fixed to form a decorative material. For each of these decorative materials, a cut was made in a 1-inch width from the surface of the decorative material (cosmetic sheet side), and the cosmetic sheet was peeled off from the MDF by 180° peeling at a speed of 50 mm / min using a tensile tester, and the strength (kgf / inch) at that time was measured as the adhesion strength.

[0088] 〔Evaluation criteria〕 Regarding the substrate adhesion strength, 2.0 (kgf / inch) or more was regarded as "qualified", and when it was 1.5 kgf / inch or more and less than 2.0 (kgf / inch), it was regarded as "unqualified". 〔Evaluation results〕 For each cosmetic sheet, the evaluation results are shown in Table 1.

[0089]

Table 1

[0090] As shown in Table 1, when MEK or ethyl acetate was used as the solvent for the colored layer, the substrate adhesion strength was 2.0 (kgf / inch) or more, whereas when MIBK was used as the solvent for the colored layer, the substrate adhesion strength was less than 2.0 (kgf / inch). It was confirmed that good adhesion strength can be obtained by using MEK or ethyl acetate as the solvent for the colored layer.

[0091] In addition, the present invention can take, for example, the following configurations. (1) A method for manufacturing a decorative sheet in which a base resin layer, a printed pattern layer, and a colored layer are laminated in this order, wherein the colored layer is formed using a two-component urethane-based resin ink having methyl ethyl ketone or ethyl acetate as a solvent. A method for manufacturing a decorative sheet. (2) The method for manufacturing a decorative sheet according to (1) above, wherein the printed pattern layer is formed using a urethane-based resin ink. (3) A decorative sheet in which a base resin layer, a printed pattern layer, and a colored layer are laminated in order, wherein the colored layer contains methyl ethyl ketone or ethyl acetate as a residual solvent and a two-component urethane-based resin ink. (4) The decorative sheet according to (3) above, wherein the printed pattern layer contains a urethane-based resin ink. (5) The decorative sheet according to (3) or (4) above, wherein the adhesion strength when the colored layer is bonded to MDF using an aqueous urethane-based adhesive is greater than 2.0 kgf / inch. (6) The decorative sheet according to any one of (3) to (5) above, further comprising a surface protection layer on the surface of the base resin layer opposite to the printed pattern layer. (7) The decorative sheet according to any one of (3) to (6) above, further comprising a barrier layer on the surface of the colored layer opposite to the printed pattern layer. (8) The decorative sheet according to any one of (3) to (6) above, further comprising a primer layer on the surface of the colored layer opposite to the printed pattern layer. (9) The decorative sheet according to any one of (3) to (6) above, wherein a barrier layer and a primer layer are provided in this order on the surface of the colored layer opposite to the printed pattern layer. (10) A decorative sheet according to any one of (3) to (9) above, and A decorative material, comprising a base material provided on the surface of the decorative sheet on the side of the colored layer.

Explanation of reference numerals

[0092] 10 Decorative sheet 20 Base material resin layer 21 Transparent skin layer 22 Transparent core layer 30 Primer layer 35 Barrier layer 40 Colored layer 50 Printed pattern layer 60 Surface protection layer

Claims

1. A method for manufacturing a decorative sheet in which a base resin layer, a printed pattern layer, and a colored layer are laminated in this order, The method for manufacturing a decorative sheet is characterized in that the colored layer is formed using a two-component urethane-based resin ink having methyl ethyl ketone or ethyl acetate as a solvent.

2. The method for manufacturing a decorative sheet according to claim 1, wherein the printed pattern layer is formed using a urethane-based resin ink.

3. A base resin layer, a printed pattern layer, and a colored layer are laminated in order, The decorative sheet is characterized in that the colored layer contains methyl ethyl ketone or ethyl acetate as a residual solvent and a urethane-based resin ink.

4. The decorative sheet according to claim 3, wherein the printed pattern layer contains a urethane-based resin ink.

5. The decorative sheet according to claim 3 or claim 4, characterized in that the adhesion strength when the colored layer is bonded to MDF using an aqueous urethane-based adhesive is greater than 2.0 kgf / inch.

6. The decorative sheet according to claim 3 or claim 4, characterized in that a surface protection layer is provided on the surface of the base resin layer opposite to the printed pattern layer.

7. The decorative sheet according to claim 3 or claim 4, characterized in that a barrier layer is provided on the surface of the colored layer opposite to the printed pattern layer.

8. The decorative sheet according to claim 3 or claim 4, characterized in that a primer layer is provided on the surface of the colored layer opposite to the printed pattern layer.

9. The decorative sheet according to claim 3 or claim 4, characterized in that a barrier layer and a primer layer are provided in this order on the surface of the colored layer opposite to the printed pattern layer.

10. A decorative material comprising the decorative sheet according to claim 3 or claim 4, and a base material provided on the surface of the decorative sheet on the colored layer side.

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