Transfer sheet

Abstract

To provide a transfer sheet capable of suppressing deterioration of a picture layer and a method for manufacturing a decorative sheet using the same.SOLUTION: There is provided a transfer sheet 10, comprising: a release film 11; an expansion suppression layer 12 provided releasably on the release film 11 and having an expansion suppression agent dispersed thereon; a protective layer 13 provided on the expansion suppression layer 12 and made of a resin material containing a weathering agent; and a picture layer 14 provided on the protective layer 13 and having a picture formed thereon.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a transfer sheet.

Background Art

[0002] For example, in a decorative sheet such as a floor covering in which a decorative pattern layer is provided on a resin base material, in order to improve the design property, an emboss with an uneven shape is provided on the surface. Such a decorative sheet can be manufactured by providing a foam suppression layer in which foam suppressants are scattered on a release film, and further using a transfer sheet in which a pattern layer is provided on the foam suppression layer.

[0003] That is, the pattern layer on the surface side of the transfer sheet is laminated so as to overlap the base material, and the pattern layer and the foam suppression layer are heat-transferred to the base material. Then, after peeling off the release film, a foam material layer containing a foaming agent is provided on the foam suppression layer, and a foaming treatment such as heating is performed. The foam material layer foams except for the portions in contact with the scattered foam suppressants, and becomes a foam layer having an uneven emboss on the surface. Thereby, a decorative sheet can be obtained.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] When the above-described decorative sheet is used for an outdoor floor covering or the like, the pattern of the pattern layer gradually fades, and it is likely to cause a decrease in design property.

[0006] For this reason, an object of the present invention is to provide a transfer sheet capable of suppressing deterioration of the pattern layer.

Means for Solving the Problems

[0007] The transfer sheet according to the present invention for solving the above-described problems includes a release film, a foam suppression layer provided detachably on the release film and having foam suppressants scattered therein, a protective layer provided on the foam suppression layer and formed of a resin material containing a weathering agent, and a pattern layer provided on the protective layer and having a pattern formed thereon.

[0008] Further, in the transfer sheet according to the present invention, it is preferable that the protective layer contains the weathering agent in a proportion of 1 to 30 parts by mass with respect to 100 parts by mass of the resin material.

[0009] Further, in the transfer sheet according to the present invention, it is preferable that the weathering agent contains a triazine-based or triazole-based ultraviolet absorber.

[0010] Further, in the transfer sheet according to the present invention, it is preferable that the thickness of the protective layer is 2 μm or more and 6 μm or less.

Advantages of the Invention

[0011] According to the transfer sheet of the present invention, since the protective layer formed of a resin material containing a weathering agent is provided between the foam suppression layer and the pattern layer, even when used for outdoor floor materials or the like, deterioration of the pattern layer can be suppressed.

Brief Description of the Drawings

[0012]

Figure 1

Figure 2

Figure 3

Figure 4

Mode for Carrying Out the Invention

[0013] An embodiment of the transfer sheet according to the present invention will be described with reference to the drawings. Note that the present invention is not limited only to the following embodiments described with reference to the drawings, and various technical matters described in the embodiments can be combined, replaced, omitted, etc. as appropriate.

[0014] [Main Embodiment] The main embodiment of the transfer sheet according to the present invention will be described with reference to FIGS. 1 to 4.

[0015] 〈Overall Configuration of Transfer Sheet〉 As shown in FIG. 1, a foam suppression layer 12 with foam suppressants scattered thereon is disposed on the release film 11. A protective layer 13 formed from a resin material containing a weathering agent is disposed on the foam suppression layer 12. A pattern layer 14 with a pattern formed thereon is disposed on the protective layer 13. That is, the protective layer 13 is interposed between the foam suppression layer 12 and the pattern layer 14. The transfer sheet 10 according to such an embodiment will be described in more detail.

[0016] 〈Release Film 11〉 The release film 11 has a coating layer 11b obtained by coating the surface of a base film 11a such as paper or non-woven fabric with an olefin resin or a polyester resin, etc., and is easily peeled off from the foam suppression layer 12. Examples of the olefin resin include polypropylene resin, low-density polyethylene resin, high-density polyethylene resin, polymethylpentene resin, etc.

[0017] 〈Foam Suppression Layer 12〉 The foam suppression layer 12 is a mixture of a binder resin and a foam suppressant, and can be provided in a scattered manner by being printed on the release film 11 as ink dissolved or dispersed in a medium liquid and then dried.

[0018] Examples of the binder resin include vinyl resins such as vinyl chloride-vinyl acetate copolymer and acrylic-vinyl chloride-vinyl acetate copolymer, acrylic resins, ester resins, urethane resins, and the like. Among them, vinyl resins are preferred, and acrylic-vinyl chloride-vinyl acetate copolymer is more preferred.

[0019] Examples of the foam inhibitor include triazine compounds, triazole compounds such as benzotriazoles and aminotriazoles, trimellitic anhydride, maleic acid, fumaric acid, adipic acid, and the like. Among them, triazole compounds are preferred, and aminotriazoles are more preferred. The foam inhibition layer 12 can also contain extender pigments such as silica to adjust the adhesiveness. Further, various stabilizers and the like can be contained as necessary.

[0020] 〈Protective layer 13〉 The protective layer 13 is a colorless and transparent cover resin mixed with a weathering agent, and can be provided to cover the foam inhibition layer 12 by being printed on the foam inhibition layer 12 as an ink dissolved or dispersed in the medium liquid and dried.

[0021] Examples of the cover resin include vinyl resins such as vinyl chloride-vinyl acetate copolymer and acrylic-vinyl chloride-vinyl acetate copolymer, acrylic resins, ester resins, urethane resins, and the like. Among them, vinyl resins are preferred, and acrylic-vinyl chloride-vinyl acetate copolymer is more preferred.

[0022] Examples of the weathering agent include organic ultraviolet absorbers (UVA) such as triazine-based, triazole-based, benzophenone-based, salicylic acid ester-based, cyano (meth) acrylate-based, and inorganic ultraviolet absorbers such as titanium dioxide, cerium oxide, zinc oxide, and light stabilizers (HALS) such as hindered amine-based. Among them, UVA is preferred. Particularly, triazine-based or triazole-based UVA is more preferred.

[0023] It is preferable that the protective layer 13 contains a weathering agent in a proportion of 1 to 30 parts by mass, more preferably 10 to 20 parts by mass, per 100 parts by mass of the cover resin. If it is less than 1 part by mass, it is difficult to obtain sufficient weather resistance, which is not preferable. If it exceeds 30 parts by mass, it is likely to cause a decrease in productivity and performance, which is not preferable. The protective layer 13 can further contain various stabilizers and the like as necessary.

[0024] It is preferable that the protective layer 13 has a thickness of 2 to 6 μm, more preferably 3 to 4 μm. If it is less than 2 μm, it is difficult to obtain sufficient weather resistance, which is not preferable. If it exceeds 6 μm, it is likely to cause a decrease in productivity and transfer processability, which is not preferable.

[0025] <Pattern layer 14> The pattern layer 14 is formed by mixing a colorant with a binder resin and printing and drying it as ink dissolved or dispersed in a medium liquid on the protective layer 13 so as to form a pattern.

[0026] Examples of the binder resin include vinyl resins such as vinyl chloride-vinyl acetate copolymer and acrylic-vinyl chloride-vinyl acetate copolymer, acrylic resins, ester resins, urethane resins, and the like. Among them, vinyl resins are preferable, and acrylic-vinyl chloride-vinyl acetate copolymer is more preferable.

[0027] Examples of the colorant include inorganic pigments such as carbon black, iron black, titanium white, antimony white, lead yellow, titanium yellow, bengal rose, cadmium red, ultramarine blue, cobalt blue, organic pigments (dyes) such as diketopyrrolopyrrole red, quinacridone red, isoindolinone yellow, nickel azo complex, phthalocyanine blue, azomethine, azo black, metal pigments such as aluminum and brass, and pearl pigments such as titanium dioxide-coated mica and basic lead carbonate.

[0028] The pattern layer 14 can further contain various stabilizers and the like as necessary. As the pattern, the pattern layer 14 can be appropriately applied with various forms such as a wood grain pattern, a wood grain conduit pattern, a cork pattern, a stone pattern, a joint, a geometric pattern, and coloring as required.

[0029] <Manufacturing method of the transfer sheet 10> The transfer sheet 10 according to this embodiment is printed and dried by dotting the ink constituting the foam suppression layer 12 on the coating layer 11b of the release film 11 by various printing methods such as the gravure printing method. Next, the ink constituting the protective layer 13 is printed and dried so as to entirely cover the above. Then, printing is performed by overlaying the ink constituting the pattern layer 14 thereon to form a pattern and drying it. Thereby, the transfer sheet 10 can be produced.

[0030] <Manufacturing method of the decorative sheet> Subsequently, a manufacturing method of a decorative sheet using the transfer sheet 10 according to the above-described embodiment will be described.

[0031] First, a base material 111 formed from a resin material is prepared (see FIG. 2). It is preferable that the material of this base material 111 is a polyvinyl chloride resin. Further, it is also possible to contain various stabilizers and the like as necessary.

[0032] Then, the base material 111 and the transfer sheet 10 are laminated so that the pattern layer 14 of the transfer sheet 10 is overlaid on the base material 111, and the pattern layer 14, the protective layer 13, and the foam suppression layer 12 are heat-transferred onto the base material 111. Next, the release film 11 is peeled off from the foam suppression layer 12 transferred onto the base material 111. Subsequently, as shown in FIG. 3, a sol-gel coat layer 112A is provided on the foam suppression layer 12.

[0033] Examples of the foaming agent in the sol-gel coat layer 112A include azo compounds such as azodicarbonamide (ADCA), 1,1'-azobis(1-acetoxy-1-phenylethane), dimethyl-2,2'-azobisbutyrate, dimethyl-2,2'-azobisisobutyrate, 2,2'-azobis(2,4,4-trimethylpentane), 1,1'-azobis(cyclohexane-1-carbonitrile), 2,2'-azobis[N-(2-carboxyethyl)-2-methyl-propionamidine]; nitroso compounds such as N,N'-dinitrosopentamethylenetetramine (DPT); hydrazine derivatives such as 4,4'-oxybis(benzenesulfonylhydrazide), diphenylsulfone-3,3'-disulfonylhydrazide; semicarbazide compounds such as p-toluenesulfonyl semicarbazide; organic thermally decomposable foaming agents such as trihydrazinotriazine; and inorganic thermally decomposable foaming agents such as bicarbonates such as sodium bicarbonate and ammonium bicarbonate, carbonates such as sodium carbonate and ammonium carbonate, nitrites such as ammonium nitrite, and hydrogen compounds. Among them, ADCA and sodium bicarbonate are preferred.

[0034] After the sol-gel coat layer 112A is provided in this way and a foaming treatment such as heating is performed, the sol-gel coat layer 112A foams except for the portions in contact with the scattered foam suppression layers 12, thereby forming a foamed layer 112 having an embossed pattern 112a with an uneven shape on the surface, as shown in FIG. 4. By performing such a procedure, the decorative sheet 100 can be obtained.

[0035] <Effect> In the decorative sheet 100 according to this embodiment manufactured in this way, since the protective layer 13 is provided on the pattern layer 14, even if it is used for outdoor floor materials or the like, the fading of the pattern of the pattern layer 14 can be greatly suppressed, and a decrease in design property can be prevented.

[0036] Therefore, according to this embodiment, deterioration of the pattern layer 14 can be suppressed.

Example

[0037] Specific examples of the transfer sheet according to the present invention will be specifically described. Note that the present invention is not limited to only the specific examples described below.

[0038] [Preparation of Specimens and Comparative Specimens] 〈Specimen 1〉 《Preparation of Transfer Sheet》 Prepare a release film having a coating layer obtained by laminating a polypropylene resin on a paper-based base film. Onto the coating layer of the release film, ink for a foam suppression layer under the following conditions is printed by a gravure printing method so as to be dotted and dried to form a foam suppression layer.

[0039] Next, ink for a protective layer under the following conditions is printed by a gravure printing method so as to entirely cover the foam suppression layer and dried to form a protective layer (thickness: 4 μm). Then, a pattern is formed by printing ink for a pattern layer under the following conditions on the protective layer by a gravure printing method and dried to form a pattern layer (thickness: 2 μm). Thus, a transfer sheet of Specimen 1 was prepared.

[0040] {Ink for Foam Suppression Layer} ·Binder resin: Acrylic-vinyl chloride-vinyl acetate copolymer ·Foam suppressant: Aminotriazole compound

[0041] {Ink for Protective Layer} ·Cover resin: Acrylic-vinyl chloride-vinyl acetate copolymer ·Weathering agent: Triazine-based UVA (“Tinuvin (registered trademark) 479 (product number)” manufactured by BASF Japan Ltd.) ·Mixing ratio: 20 parts by mass of weathering agent with respect to 100 parts by mass of cover resin

[0042] {Ink for Pattern Layer} ·Binder resin: Acrylic-vinyl chloride-vinyl acetate copolymer ·Colorant: Diketopyrrolopyrrole-based pigment ·Mixing ratio: 20 parts by mass of colorant with respect to 100 parts by mass of binder resin

[0043] "Production of Cosmetic Sheet" Subsequently, the base material and the transfer sheet are laminated so that the pattern layer is stacked on a polyvinyl chloride base material (thickness: 1 mm). After heat-transferring the pattern layer, the protective layer, and the foam suppression layer onto the base material using a transfer machine, the release film is peeled off from the foam suppression layer.

[0044] Next, a sol-gel layer is formed on the foam suppression layer, and the foam treatment is carried out by placing it in an oven and heating (220 °C × 2 minutes) to obtain a foam layer with an embossed uneven shape on the surface. Then, it is taken out of the oven. Thus, the cosmetic sheet of Specimen 1 was produced.

[0045] <Specimen 2> The transfer sheet and the cosmetic sheet of Specimen 2 were produced in the same manner as Specimen 1, except that the thickness of the protective layer was set to 3 μm.

[0046] <Specimen 3> The transfer sheet and the cosmetic sheet of Specimen 3 were produced in the same manner as Specimen 1, except that the thickness of the protective layer was set to 2 μm.

[0047] <Specimen 4> The transfer sheet and the cosmetic sheet of Specimen 4 were produced in the same manner as Specimen 1, except that the thickness of the protective layer was set to 6 μm.

[0048] <Specimen 5> The transfer sheet and the cosmetic sheet of Specimen 5 were produced in the same manner as Specimen 1, except that the thickness of the protective layer was set to 7 μm.

[0049] <Specimen 6> The transfer sheet and the cosmetic sheet of Specimen 6 were produced in the same manner as Specimen 1, except that the mixing ratio of the weathering agent in the protective layer was set to 10 parts by mass.

[0050] <Specimen 7> The transfer sheet and decorative sheet of Test Specimen 7 were produced in the same manner as Test Specimen 1, except that the mixing ratio of the weathering agent in the protective layer was 30 parts by mass.

[0051] <Comparative Specimen 1> The transfer sheet and decorative sheet of Comparative Specimen 1 were produced in the same manner as Test Specimen 1, except that the thickness of the protective layer was 1 μm.

[0052] <Comparative Specimen 2> The transfer sheet and decorative sheet of Comparative Specimen 2 were produced in the same manner as Test Specimen 1, except that the mixing ratio of the weathering agent in the protective layer was 0 parts by mass, that is, the mixing of the weathering agent was omitted.

[0053] <Comparative Specimen 3> The transfer sheet and decorative sheet of Comparative Specimen 3 were produced in the same manner as Test Specimen 1, except that the protective layer was omitted.

[0054] [Evaluation Method] <Weather Resistance> For the decorative sheets of Test Specimens 1 to 7 and Comparative Specimens 1 to 3, a weather resistance test was conducted using a xenon weather meter under the following conditions, and the color difference ΔE before and after the test was measured. The results are shown in Table 1 below. In Table 1, when the color difference ΔE becomes 3.0 or more after 1500 hours, it is indicated by "×", when the color difference ΔE becomes 3.0 or more after 2000 hours, it is indicated by "△", when the color difference ΔE becomes 3.0 or more after 3500 hours, it is indicated by "○", and when the color difference ΔE is less than 3.0 even after 3500 hours, it is indicated by "◎".

[0055] 《Test Conditions》 · Black Panel Temperature (BPT): 63°C · Illuminance: 60 W / m 2 · Cycle: Repeated spraying of water for 18 minutes after 108 minutes of irradiation

[0056] <Productivity> The productivity of the transfer sheets of Test Specimens 1 to 7 and Comparative Specimens 1 to 3 was evaluated when they were manufactured as described above. The results are shown in Table 1 below. In Table 1, when production could be carried out without any problems and in the same manner as in the conventional case, it is indicated by "◎"; when production could be carried out without problems although some effort was required, it is indicated by "○"; when a great deal of effort was required but production was still possible, it is indicated by "△"; and when production was impossible, it is indicated by "×".

[0057] 〈Transfer Processability〉 The transfer processability of the decorative sheets of Test Specimens 1 to 7 and Comparative Specimens 1 to 3 was evaluated when they were manufactured as described above. The results are shown in Table 1 below. In Table 1, when transfer processing could be carried out without any problems and in the same manner as in the conventional case, it is indicated by "◎"; when transfer processing could be carried out without problems although some effort was required, it is indicated by "○"; when a great deal of effort was required but transfer processing was still possible, it is indicated by "△"; and when transfer processing was impossible, it is indicated by "×".

[0058] [Evaluation Results] The results of the above-mentioned evaluations are shown in Table 1 below.

[0059]

Table 1

[0060] As can be seen from Table 1, in Comparative Specimens 1 to 3, the color difference ΔE after 1500 hours became 3.0 or more, and sufficient weather resistance could not be obtained.

[0061] On the other hand, in Test Specimens 1 to 7, the color difference ΔE did not become 3.0 or more even after 1500 hours. In particular, in Test Specimens 1, 2, 4, 5, and 7 in which the protective layer contained 20 parts by mass or more of a weathering agent and had a thickness of 3 μm or more, the color difference ΔE was less than 3.0 even after 3500 hours. Furthermore, in Test Specimens 1 and 2 in which the protective layer contained 20 parts by mass of a weathering agent and had a thickness of 3 to 4 μm, the productivity and transfer processability were also good, and they had excellent practicality.

[0062] From the above, the present invention was found to be capable of suppressing deterioration of the pattern layer.

Industrial Applicability

[0063] Since the present invention can suppress deterioration of the pattern layer even when used for outdoor floor materials and the like, it can be extremely beneficially used in various industries including the construction industry.

Explanation of Signs

[0064] 10 Transfer sheet 11 Release film 11a Base film 11b Coating layer 12 Foam suppression layer 13 Protective layer 14 Pattern layer 100 Decorative sheet 111 Substrate 112 Foam layer 112A Sol-gel coat layer 112a Emboss

Claims

1. A release film, a foam suppression layer that is detachably provided on the release film and in which a foam suppressant is scattered, a protective layer that is provided on the foam suppression layer and formed from a resin material containing a weathering agent, and a pattern layer that is provided on the protective layer and forms a pattern characterized in that it comprises a transfer sheet.

2. The protective layer contains the weathering agent in a proportion of 1 part by mass or more and 30 parts by mass or less with respect to 100 parts by mass of the resin material characterized in that it is the transfer sheet according to Claim 1.

3. The weathering agent contains a triazine-based or triazole-based ultraviolet absorber characterized in that it is the transfer sheet according to Claim 1.

4. The protective layer has a thickness of 2 μm or more and 6 μm or less characterized in that it is the transfer sheet according to Claim 1.

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