Surface material and substrate with surface material

Abstract

To provide a surface material that enables improvement of impact resistance and enables suppression of generation of surface voids.SOLUTION: The surface material according to the present invention is a surface material having a sea-island structure having a sea portion containing a glassy component and island portions containing a rubber component, wherein a contact angle of water with respect to a surface of the surface material is 85.0° or more and 140.0° or less.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a surface material. The present invention also relates to a surface-material-attached substrate comprising a substrate and the surface material. [Background technology]

[0002] Thermoplastic resins are excellent in durability, light weight, moldability, etc. For this reason, thermoplastic resins are used in various fields such as construction, home appliances, and transportation.

[0003] For example, thermoplastic resins are used as exterior materials for buildings and transport vehicles such as railway cars, aircraft, ships, and automobiles. Examples of the exterior materials include flooring materials, wall materials, ceiling materials, exterior decorative materials, handrail materials, deck materials, gutters, window frames, and corrugated sheets.

[0004] Furthermore, in order to protect the surface of a substrate formed from a thermoplastic resin, a surface material may be disposed on the surface of the substrate. The surface material is required to have excellent weather resistance. A thermoplastic resin may be used as the material for the surface material.

[0005] Patent Document 1 listed below discloses a multilayer extrusion molded product including a substrate and a surface material (surface layer material) containing a colored resin with excellent weather resistance as a base resin. The surface of the surface material is sanded, and fine irregularities are formed on the surface of the surface material. The surface of the surface material is matte. The base resin of the surface material is a resin selected from the group consisting of polymethyl methacrylate resin, acrylonitrile / acrylic rubber / styrene copolymer resin, acrylonitrile / ethylene propylene rubber / styrene copolymer resin, and polymethyl methacrylate resin / styrene copolymer resin. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Laid-Open No. 2009-6716 Summary of the Invention [Problem to be solved by the invention]

[0007] In the surface material described in Patent Document 1, when a base resin containing a rubber component is used, the impact resistance of the surface material can be increased. On the other hand, when a base resin not containing a rubber component is used, the impact resistance of the surface material decreases.

[0008] Furthermore, conventional surface materials such as those described in Patent Document 1 may have voids on the surface. In particular, depending on the type of base resin contained in the surface material, there is a problem that voids are more likely to occur on the surface. When voids occur on the surface, the surface material may appear white.

[0009] An object of the present invention is to provide a surface material that can improve impact resistance and suppress the occurrence of voids on the surface. Another object of the present invention is to provide a substrate with a surface material that can improve impact resistance of the surface material and suppress the occurrence of voids on the surface of the surface material. [Means for solving the problem]

[0010] The present specification discloses the following surface materials and substrates with surface materials.

[0011] Item 1. A surface material having a sea-island structure with a sea portion containing a glassy component and an island portion containing a rubber component, wherein the contact angle of water with the surface of the surface material is 85.0° or more and 140.0° or less.

[0012] Item 2. The surface material according to Item 1, wherein the material of the surface material comprises at least one resin component selected from the group consisting of acrylonitrile / ethylene propylene rubber or ethylene propylene diene rubber / styrene copolymer resin, and acrylonitrile / styrene / acrylic rubber copolymer resin.

[0013] Item 3. The melt flow rate of the resin component is 5 cm 3 / 10 minutes or more 50cm 3 Item 3. The surface material according to item 2, wherein the surface roughness is 10 minutes or less.

[0014] Item 4. The Charpy impact strength of the resin component is 2 kJ / m 2 More than 50kJ / m 2 Item 3. The surface material according to item 2, which is as follows:

[0015] Item 5. The surface material according to any one of Items 1 to 4, wherein the material of the surface material includes at least one selected from the group consisting of fatty acid amides and silicone compounds.

[0016] Item 6. The surface material according to any one of Items 1 to 5, having a thickness of 100 μm or more and 500 μm or less.

[0017] Item 7. A surface-material-attached substrate comprising a substrate and the surface material according to any one of items 1 to 6, wherein the surface material is disposed on the surface of the substrate.

[0018] Item 8. The substrate with a surface material according to Item 7, wherein the material of the substrate includes a thermoplastic resin. [Effects of the Invention]

[0019] The surface material according to the present invention has a sea-island structure with a sea portion containing a glassy component and islands containing a rubber component. The contact angle of water with the surface of the surface material according to the present invention is 85.0° or more and 140.0° or less. Because the surface material according to the present invention has the above-mentioned configuration, it is possible to improve impact resistance and suppress the occurrence of voids on the surface. [Brief explanation of the drawings]

[0020] [Figure 1] FIG. 1 is a cross-sectional view showing a substrate with a surface material according to a first embodiment of the present invention. [Figure 2] FIG. 2 is a cross-sectional view showing a substrate with a surface material according to a second embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0021] The present invention will be described in detail below.

[0022] [Surface material] The surface material according to the present invention has a sea-island structure with a sea portion containing a glassy component and islands containing a rubber component, and the contact angle of water with the surface of the surface material according to the present invention is 85.0° or more and 140.0° or less.

[0023] Conventional surface materials have low impact resistance depending on the type of resin used.

[0024] In the surface material according to the present invention, a specific sea-island structure is formed, and the island portions contain a rubber component, so that the impact resistance of the surface material can be improved.

[0025] Furthermore, conventional surface materials can develop voids on their surfaces. When voids develop on the surface, the surface material can appear white (whitening can be seen). This whitening phenomenon occurs because light is scattered by minute voids in the surface material. The larger the total area of ​​the voids on the surface, the more likely the surface material will appear white.

[0026] The surface material according to the present invention has the above-mentioned configuration, and therefore can suppress the occurrence of voids on the surface. The surface material according to the present invention can effectively suppress the occurrence of voids on the surface after a weather resistance test. Since the present invention can suppress the occurrence of voids on the surface, it can suppress the occurrence of whitening (whitening phenomenon) in the surface material.

[0027] The surface material has a sea-island structure with a sea portion containing a glassy component and an island portion containing a rubber component. The following mechanism is thought to be the mechanism by which voids are generated. In a surface material with such a sea-island structure, repeated exposure to the moisture absorption expansion force and drying contraction force of the rubber component causes the glassy component surrounding the rubber component to collapse due to fatigue, resulting in the detachment of the rubber component and the surrounding glassy component. The generation of voids is a particular problem that is likely to occur in surface materials with a specific sea-island structure.

[0028] The surface material according to the present invention has a specific sea-island structure, and the contact angle of water with the surface of the surface material is within a specific range, which prevents the rubber component from being detached from the surrounding glassy component, thereby preventing the generation of voids on the surface.

[0029] To prevent void formation, the water contact angle with the surface of the surface material is 85.0° or more and 140.0° or less. If the water contact angle is below the lower limit, the rubber component is more likely to come into contact with water, accelerating the repetition of moisture absorption expansion and drying contraction of the rubber component, making voids more likely to form on the surface of the surface material and whitening the surface material. If the water contact angle exceeds the upper limit, water droplets remaining on the surface act as lenses, making the surface of the surface material more likely to become stained by sunlight, etc.

[0030] The water contact angle with the surface of the surface material is preferably 90.0° or more, more preferably 95.0° or more, even more preferably 96.5° or more, particularly preferably 97.0° or more, and preferably 135.0° or less, more preferably 130.0° or less, even more preferably 125.0° or less, even more preferably 120.0° or less, particularly preferably 115.0° or less, and most preferably 110.0° or less. When the water contact angle is equal to or greater than the lower limit, the generation of voids can be further suppressed. When the water contact angle is equal to or less than the upper limit, stains are even less likely to occur on the surface of the surface material.

[0031] The contact angle of water with the surface of the surface material is measured as follows.

[0032] The water contact angle is measured as a static contact angle at 23°C using a contact angle meter based on the sessile drop method using the θ / 2 method. The static contact angle obtained is defined as the water contact angle (23°C). Examples of the contact angle meter include the "DMs-401" manufactured by Kyowa Interface Science Co., Ltd.

[0033] The thickness of the surface material is preferably 100 μm or more and preferably 500 μm or less. When the thickness of the surface material is above the lower limit and below the upper limit, the surface material is easier to manufacture and the surface material's performance is more easily exhibited. Furthermore, when the thickness of the surface material is above the lower limit, the protective performance of the surface material can be further improved. When the thickness of the surface material is below the upper limit, the manufacturing cost of the surface material can be further reduced. When the thickness of the surface material varies depending on the surface material portion, the thickness of the surface material means the average thickness.

[0034] The surface material may be a foam. In this case, foam cells in the foam are not considered to be voids. A foaming agent may be used to obtain the foam. The foaming agent may be a physical foaming agent. The average diameter of the foam cells in the foam is preferably 30 μm or more and preferably 200 μm or less. The average diameter of the foam cells in the foam is determined by measuring the circle-equivalent diameter of each foam cell and averaging the measured values.

[0035] The surface material preferably contains a base resin. The surface material may contain an additive in addition to the base resin. The surface material will be described in detail below.

[0036] (Base resin) The surface material has a sea-island structure having a sea portion containing a glassy component and an island portion containing a rubber component. To form such a sea-island structure, an appropriate base resin is selected and used. The sea-island structure is preferably formed from the base resin. Only one type of base resin may be used, or two or more types may be used.

[0037] From the viewpoint of further improving moldability and more favorably forming an island-sea structure, the base resin is preferably a thermoplastic resin.

[0038] The surface material contains a glassy component. The glassy component is contained in the sea portion of the sea-island structure. The glassy component is preferably a glassy resin. Examples of the glassy component include styrene resins such as polystyrene (PS), acrylonitrile / styrene (AS) copolymer, and methyl methacrylate / styrene (MS) copolymer; acrylic resins such as polymethyl methacrylate (PMMA); polycarbonate (PC) resin; vinyl chloride resins such as polyvinyl chloride (PVC); polyphenylene sulfide (PPS) resin; and mixtures thereof.

[0039] From the viewpoint of further improving moldability and more favorably forming a sea-island structure, the glassy component preferably contains at least one resin selected from the group consisting of a styrene resin, an acrylic resin, a PC resin, a vinyl chloride resin, and a PPS resin.

[0040] The surface material includes a rubber component, which is contained in the islands of the sea-island structure. Examples of the rubber component include butadiene rubber, ethylene propylene (EP) rubber, ethylene propylene diene rubber (EPDM), ethylene butylene (EB) rubber, and acrylic rubber.

[0041] From the viewpoint of further improving impact resistance, the rubber component preferably contains at least one selected from the group consisting of butadiene rubber, EP rubber, EPDM, EB rubber, and acrylic rubber.

[0042] The matrix resin is preferably a composite resin containing the glassy component and the rubber component.

[0043] Examples of thermoplastic resins that can be used for the surface material include acrylonitrile / ethylene propylene rubber or ethylene propylene diene rubber / styrene copolymer resin (AES resin), acrylonitrile / styrene / acrylic rubber copolymer resin (ASA resin), acrylonitrile / butadiene rubber / styrene copolymer resin (ABS resin), high-impact polystyrene resin (HIPS resin), methyl methacrylate / butadiene / styrene copolymer resin (MBS resin), elastomer-modified PVC resin, PC / ABS resin, elastomer-modified PPS resin, and alloy resins of polyphenylene ether (PPE) and HIPS. The high-impact polystyrene resin is a resin formed from a sea of ​​polystyrene (PS) and islands of rubber particles (a composite resin containing PS and rubber particles).

[0044] From the viewpoint of forming a sea-island structure more satisfactorily and further enhancing impact resistance, it is preferable that the material of the surface material contains at least one selected from the group consisting of AES resin, ASA resin, ABS resin, HIPS resin, MBS resin, elastomer-modified PVC resin, PC / ABS resin, elastomer-modified PPS resin, and alloy resin of PPE and HIPS.

[0045] From the viewpoint of forming a sea-island structure more satisfactorily and suppressing the occurrence of voids more effectively, the surface material preferably contains at least one resin component (hereinafter sometimes referred to as resin component A) selected from the group consisting of AES resin and ASA resin. The use of resin component A makes it easier to form a good sea-island structure in the surface material. Furthermore, the use of resin component A can further increase the rigidity and weather resistance of the surface material. The surface material may contain an AES resin. The surface material may contain an ASA resin. The surface material may contain an AES resin and an ASA resin.

[0046] From the viewpoint of forming an island-sea structure more satisfactorily and suppressing the occurrence of voids more effectively, it is particularly preferable that the surface material contains an ASA resin.

[0047] The melt flow rate (MFR) of the base resin (when the surface material contains the resin component A, the melt flow rate (MFR) of the resin component A) is preferably 5 cm 3 / 10 minutes or more, preferably 10cm 3 / 10 minutes or more, preferably 15cm 3 / 10 minutes or more, especially 20cm 3 / 10 minutes or more, most preferably 25cm 3 / 10 minutes or more, preferably 50cm 3 / 10 minutes or less, preferably 45cm 3 / 10 minutes or less, more preferably 40cm 3 When the MFR is equal to or greater than the lower limit, the moldability and processability of the surface material during production are further improved. When the MFR is equal to or less than the upper limit, the surface uniformity of the surface material is further improved.

[0048] The MFR is measured in accordance with ISO1133 at 220°C and 10 kg.

[0049] The Charpy impact strength of the base resin (when the surface material contains the resin component A, the Charpy impact strength of the resin component A) is preferably 2 kJ / m 2 More preferably, 3 kJ / m 2 More preferably, 4 kJ / m 2 or more, preferably 50 kJ / m 2 Less than or equal to 45 kJ / m 2 or less, more preferably 40 kJ / m 2 Less than 35 kJ / m, particularly preferably 2 Less than or equal to 30 kJ / m, most preferably 30 kJ / m 2When the Charpy impact strength is equal to or greater than the lower limit, cracks in the surface material are less likely to occur. When the Charpy impact strength is equal to or less than the upper limit, the surface hardness of the surface material is appropriately increased, and the surface of the surface material is less likely to be scratched.

[0050] The Charpy impact strength is measured at 23°C in accordance with ISO179.

[0051] (additives) The surface material preferably contains a water repellent. The use of the water repellent makes it easier to adjust the contact angle of water with the surface of the surface material to an appropriate value. Furthermore, the use of the water repellent can more effectively suppress the occurrence of voids and can further suppress the occurrence of whitening (whitening phenomenon).

[0052] Examples of the water repellent agent include fatty acid amides, silicone compounds, higher alcohols, fluororesins, etc. The water repellent agent may be used alone or in combination of two or more.

[0053] From the viewpoint of more effectively suppressing the generation of voids, it is preferable that the surface material contains at least one selected from the group consisting of fatty acid amides, silicone compounds, higher alcohols, and fluororesins. The surface material may contain fatty acid amides. The surface material may contain silicone compounds. The surface material may contain higher alcohols. The surface material may contain fluororesins.

[0054] The surface material preferably contains at least one water repellent selected from the group consisting of fatty acid amides, silicone compounds, and higher alcohols (hereinafter, at least one water repellent selected from the group consisting of fatty acid amides, silicone compounds, and higher alcohols may be referred to as water repellent A). Use of water repellent A can more effectively suppress the generation of voids.

[0055] The surface material preferably contains at least one water repellent selected from the group consisting of fatty acid amides and silicone compounds (hereinafter, at least one water repellent selected from the group consisting of fatty acid amides and silicone compounds may be referred to as water repellent B). Use of water repellent B can further effectively suppress the occurrence of voids. The surface material may contain fatty acid amides and silicone compounds.

[0056] Examples of the fatty acid amide include ethylene bisstearic acid amide, stearic acid amide, etc. Examples of commercially available fatty acid amides include "Kaowax EB-FF" manufactured by Kao Corporation.

[0057] Examples of the silicone compound include silicone oil, etc. Commercially available silicone compounds include "Rikeaid SG-100P" and "Rikeaid SG-170P" manufactured by Riken Vitamin Co., Ltd., and "X-22-2184-30" manufactured by Shin-Etsu Chemical Co., Ltd.

[0058] Examples of the higher alcohol include stearyl alcohol.

[0059] The content of the water repellent agent is preferably 0.1 parts by mass or more, more preferably 0.5 parts by mass or more, even more preferably 1 part by mass or more, and preferably 10 parts by mass or less, more preferably 7 parts by mass or less, and even more preferably 5 parts by mass or less, per 100 parts by mass of the base resin. Furthermore, when the surface material contains the resin component A, the content of the water repellent agent is preferably 0.1 parts by mass or more, more preferably 0.5 parts by mass or more, even more preferably 1 part by mass or more, and preferably 10 parts by mass or less, more preferably 7 parts by mass or less, and even more preferably 5 parts by mass or less, per 100 parts by mass of the resin component A. When the content of the water repellent agent is above the lower limit, the water repellency is further improved, and the generation of voids can be further suppressed. When the content of the water repellent agent is below the upper limit, the MFR of the surface material is appropriately reduced, and the surface uniformity of the surface material is further improved.

[0060] When the surface material contains the water repellent A, the content of the water repellent A is preferably 0.1 parts by mass or more, more preferably 0.5 parts by mass or more, even more preferably 1 part by mass or more, and preferably 10 parts by mass or less, more preferably 7 parts by mass or less, and even more preferably 5 parts by mass or less, relative to 100 parts by mass of the base resin. When the surface material contains the resin component A and the water repellent A, the content of the water repellent A is preferably 0.1 parts by mass or more, more preferably 0.5 parts by mass or more, even more preferably 1 part by mass or more, and preferably 10 parts by mass or less, more preferably 7 parts by mass or less, and even more preferably 5 parts by mass or less, relative to 100 parts by mass of the resin component A. When the content of the water repellent A is above the lower limit, the water repellency is further improved, and the generation of voids can be further suppressed. When the content of the water repellent A is below the upper limit, the MFR of the surface material is appropriately reduced, and the surface uniformity of the surface material is further improved.

[0061] When the surface material contains the water repellent B, the content of the water repellent B is preferably 0.1 parts by mass or more, more preferably 0.5 parts by mass or more, even more preferably 1 part by mass or more, and preferably 10 parts by mass or less, more preferably 7 parts by mass or less, and even more preferably 5 parts by mass or less, relative to 100 parts by mass of the base resin. When the surface material contains the resin component A and the water repellent B, the content of the water repellent B is preferably 0.1 parts by mass or more, more preferably 0.5 parts by mass or more, even more preferably 1 part by mass or more, and preferably 10 parts by mass or less, more preferably 7 parts by mass or less, and even more preferably 5 parts by mass or less, relative to 100 parts by mass of the resin component A. When the content of the water repellent B is above the lower limit, the water repellency is further improved, and the generation of voids can be further suppressed. When the content of the water repellent B is below the upper limit, the MFR of the surface material is appropriately reduced, and the surface uniformity of the surface material is further improved.

[0062] The material for the surface material preferably contains wood flour. By using wood flour, properties derived from wood flour can be imparted to the surface material, making it easier to obtain a wood-like texture when touched and seen with the eyes. Furthermore, the use of wood flour can reduce the manufacturing cost of the surface material.

[0063] Examples of the wood flour include ground wood products such as coniferous trees, broad-leaved trees, and lauan wood; ground bark, grain husks, and waste wood; and the like.

[0064] The average diameter of the wood flour is preferably 30 μm or more and preferably 400 μm or less. When the average diameter of the wood flour is equal to or more than the above lower limit and equal to or less than the above upper limit, the surface material tends to have a more excellent wood texture when touched by hand and when viewed with the naked eye.

[0065] The above-mentioned average diameter is the average diameter measured on a number basis, and is the value of the median diameter (D50) at 50%. The above-mentioned average diameter can be measured by a laser diffraction / scattering method, an image analysis method, a Coulter method, a centrifugal sedimentation method, or the like. Measurement by the laser diffraction / scattering method is preferred.

[0066] The content of the wood flour is preferably at least 1 part by mass, more preferably at least 5 parts by mass, even more preferably at least 10 parts by mass, and preferably at most 100 parts by mass, more preferably at most 50 parts by mass, even more preferably at most 20 parts by mass, and particularly preferably at most 15 parts by mass, per 100 parts by mass of the base resin. Furthermore, when the surface material contains the resin component A, the content of the wood flour is preferably at least 1 part by mass, more preferably at least 5 parts by mass, even more preferably at least 10 parts by mass, and preferably at most 100 parts by mass, more preferably at most 50 parts by mass, even more preferably at most 20 parts by mass, and particularly preferably at most 15 parts by mass, per 100 parts by mass of the resin component A. When the content of the wood flour is above the lower limit, the surface material more easily conveys a woody texture when touched and viewed with the naked eye. When the content of the wood flour is below the upper limit, the wood flour is less likely to fall off from the surface of the surface material, and the surface material more easily maintains a woody texture when touched and viewed with the naked eye even after aging.

[0067] The surface material may contain additives other than the water repellent and wood flour. Examples of the additives include colorants, lubricants, processing aids, light stabilizers, UV inhibitors, antioxidants, and antistatic agents. Only one type of the additives may be used, or two or more types may be used.

[0068] The colorant is used, for example, to impart a desired color tone to the surface material. Examples of the colorant include pigments and dyes. Examples of the pigment include organic pigments and inorganic pigments. Only one type of the colorant may be used, or two or more types may be used in combination.

[0069] Examples of the pigment include organic pigments such as azo-based, azomethine-based, methine-based, indanthrone-based, anthraquinone-based, pyranthrone-based, flavanthrone-based, benzenethrone-based, phthalocyanine-based, quinophthalone-based, perylene-based, perinone-based, dioxazine-based, thioindigo-based, isoindolinone-based, isoindoline-based, pyrrulepyrrole-based, and quinacridone-based pigments.

[0070] Examples of the pigments include black pigments such as carbon black, graphite, titanium black, and black iron oxide; white pigments such as calcium carbonate, titanium oxide, zinc oxide, and zinc sulfide; yellow pigments such as cadmium yellow, yellow lead, titanium yellow, zinc chromate, ochre, and yellow iron oxide; red pigments such as red pigment, umber, red iron oxide, and cadmium red; blue pigments such as iron blue, ultramarine, and cobalt blue; and green pigments such as chrome green.

[0071] The lubricants are used, for example, to improve processability and moldability. Examples of the lubricants include silicone compounds, fatty acids, fatty acid esters, and fatty acid metal salts. In this specification, silicone compounds that function as both lubricants and water repellents are classified as water repellents. Examples of the silicone compounds include alkylsiloxanes, alkylphenylsiloxanes, and alkylhydrogensiloxanes. Examples of the fatty acids include stearic acid, behenic acid, hydroxystearic acid, erucic acid, and oleic acid. Examples of the fatty acid esters include butyl stearate and stearyl stearate. Examples of the fatty acid metal salts include lithium stearate, magnesium stearate, calcium stearate, barium stearate, zinc stearate, calcium laurate, barium laurate, zinc laurate, calcium ricinoleate, barium ricinoleate, zinc ricinoleate, and zinc octoate.

[0072] Such processing aids include acrylic processing aids, acrylate copolymers, styrene-acrylonitrile copolymers, and methyl methacrylate / styrene / vinyl acetate copolymers.

[0073] Examples of the light stabilizer and the ultraviolet inhibitor include 2-(2'-hydroxy-5'-methylphenyl)-benzotriazole, 2-hydroxy-4-octoxybenzophenone, 2-(2'-hydroxy-5'-tert-octylphenyl)benzotriazole, 2-(2'-hydroxy-3,5'-di-tert-butylphenyl)-benzotriazole, 2-(2'-hydroxy-3,5'-di-tert-butylphenyl)-5-chlorobenzotriazole, 2-(2'-hydroxy-3'-tert-butyl-5'-methylphenyl)-5-chlorobenzotriazole, 2 ... hydroxy-4-methoxybenzophenone, poly[1-(2'-hydroxyethyl)-2,2,6,6-tetramethyl-4-hydroxypiperidyl succinate], bis(2,2,6,6-tetramethyl-4-piperidine) sebacate, 2-hydroxy-4-methoxybenzophenone-5-sulfonic acid, 2-phenyl-1H-benzo[d]imidazole-5-sulfonic acid, 2-(2'-hydroxy-3'-5'-di-tert-butyl)benzotriazole, 2,2'-dihydroxy-4-methoxybenzotriazole, hindered amine light stabilizers (HALS), and titanium dioxide.

[0074] Examples of the antioxidant include tetrakis[methylene(3,5-di-tert-butyl-4-hydroxyhydrocinnamate)]methane, octadecyl 3-(3,5-tert-butyl-4-hydroxyphenyl)propionate, tris-(2,4-tert-butylphenyl)phosphite, didodecyl-3,3-thiodipropionate, bis(2,4-dicumylphenyl)pentaerythritol diphosphite, hindered phenols, secondary aromatic amines, and benzofuranone.

[0075] Examples of the antistatic agent include nonionic antistatic agents such as polyoxyethylene alkyl ethers, polyoxylethylene derivatives, sorbitan acid fatty acid esters, polyoxyethylene sorbitan acid fatty acid esters, polyoxyethylene sorbitol fatty acid esters, glycerin fatty acid esters, polyoxyethylene hydrogenated castor oil, polyoxyethylene alkylamines, and alkyl alkanolamides; cationic antistatic agents such as alkylamine salts and quaternary ammonium salts; alkyl sulfate ester salts, polyoxyethylene alkyl ether sulfate esters, alkylbenzene sulfonates, dialkyl sulfonates, and the like. Examples of the antistatic agents include anionic antistatic agents such as sodium sulfosuccinate and sodium alkyldiphenyl ether disulfonate; cationic antistatic agents having cationic groups such as pyridinium bases and primary to tertiary amino groups; anionic antistatic agents having anionic groups such as sulfonate bases, sulfate ester bases, phosphate ester bases, and sulfonate bases; amino acid antistatic agents; amphoteric antistatic agents such as amino sulfate ester antistatic agents; amino alcohol antistatic agents; nonionic antistatic agents such as polyethylene glycol antistatic agents; and polymeric antistatic agents obtained by increasing the molecular weight of these antistatic agents.

[0076] [Base material with surface material] The substrate with a surface material according to the present invention comprises a substrate and a surface material. In the substrate with a surface material according to the present invention, the surface material is disposed on the surface of the substrate. The substrate with a surface material is a laminate.

[0077] In the substrate with a surface material according to the present invention, the impact resistance of the surface material can be increased and the occurrence of voids on the surface of the surface material can be suppressed. Because the impact resistance of the surface material can be increased, the impact resistance of the substrate with a surface material can also be increased. Because the occurrence of voids on the surface of the surface material can be suppressed, the substrate with a surface material is less likely to appear white (whitening phenomenon is less visible).

[0078] FIG. 1 is a cross-sectional view showing a substrate with a surface material according to a first embodiment of the present invention.

[0079] The surface-material-attached substrate 1 shown in FIG. 1 includes a substrate 2 and a surface material 3. The substrate 2 and the surface material 3 constitute the surface-material-attached substrate 1. The surface material 3 is disposed on a surface 2a of the substrate 2. The surface 2a of the substrate 2 is covered with the surface material 3. The contact angle of water with the surface 3a of the surface material 3 opposite to the substrate 2 side is 85.0° or more and 140.0° or less.

[0080] In the substrate 1 with a surface material, the substrate 2 is in the form of a plate. On one flat surface 2a of the substrate 2, a surface material 3 is disposed.

[0081] FIG. 2 is a cross-sectional view showing a substrate with a surface material according to a second embodiment of the present invention.

[0082] The surface-material-attached substrate 11 shown in Figure 2 includes a substrate 12 and a surface material 13. The substrate 12 and the surface material 13 constitute the surface-material-attached substrate 11. The surface material 13 is disposed on a surface 12a of the substrate 12. The surface 12a of the substrate 12 is covered with the surface material 13. The contact angle of water with the surface 13a of the surface material 13 opposite to the substrate 12 side is 85.0° or more and 140.0° or less.

[0083] In the substrate 11 with a surface material, the substrate 12 is not plate-shaped. In this embodiment, the substrate 12 is shaped like a truncated cone. A surface material 13 is disposed on a surface 12a of the substrate 12, which includes the upper surface and side surfaces. The surface material 13 is also disposed on the corners of the surface 12a of the substrate 12.

[0084] The shape of the substrate is not particularly limited. The shape of the substrate may be plate-like or may be a shape other than plate-like. The substrate may have convex or concave portions on the surface. The substrate may have corners on the surface. The substrate may have curved portions on the surface. By using the specific surface material according to the present invention, even if the substrate has convex portions, concave portions, corners, or curved portions on the surface, the adhesion between the substrate and the surface material can be increased, and the generation of voids between the substrate and the surface material can be effectively suppressed.

[0085] In the substrate with a surface material, the surface material may be disposed on a portion of the surface of the substrate, or the surface material may be disposed on the entire surface of the substrate. The surface material can be disposed in a portion of the substrate where the performance derived from the surface material is to be imparted.

[0086] The material of the substrate preferably contains a thermoplastic resin. When the material of the surface material contains a thermoplastic resin, the thermoplastic resin that is the material of the substrate and the thermoplastic resin that is the material of the surface material may be the same or different.

[0087] Examples of thermoplastic resins that can be used as the substrate include vinyl chloride resins such as polyvinyl chloride (PVC), polystyrene (PS), polypropylene (PP), polyethylene (PE), acrylic resins such as polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polycarbonate (PC), polyamide (PA), acrylonitrile / styrene (AS) copolymers, and acrylonitrile / butadiene rubber / styrene (ABS) copolymers. The thermoplastic resins may be used alone or in combination of two or more.

[0088] From the viewpoint of further improving moldability and processability during the preparation of the substrate and the substrate with the surface material, the material of the substrate preferably contains a thermoplastic resin, more preferably a vinyl chloride resin, which can further improve mechanical strength, weather resistance, heat resistance, and chemical resistance.

[0089] The substrate with a surface material can be produced by compression molding, extrusion molding, injection molding, etc. The substrate with a surface material is preferably a multilayer molded article.

[0090] The present invention will be described in more detail below with reference to examples, but the present invention is not limited to the following examples.

[0091] The following surface materials were prepared:

[0092] (Base resin) AES resin (MFR:20cm 3 / 10 min, Charpy impact strength: 8kJ / m 2 ) ASA resin (MFR:27cm 3 / 10 min, Charpy impact strength: 5kJ / m 2 )

[0093] (Water repellent) Fatty acid amide (Kao Corporation's "Kaowax EB-FF") Silicone-containing PP resin 1 (Rikeaid SG-100P, manufactured by Riken Vitamin Co., Ltd.) Silicone-containing PP resin 2 (Rikeaid SG-170P, manufactured by Riken Vitamin Co., Ltd.) Higher alcohol (Kao Corporation's "Kalcol 8688")

[0094] The following substrates were prepared:

[0095] Polyvinyl chloride (PVC) base material (thickness 2.0 mm)

[0096] Example 1 Surface preparation: A surface material was obtained by kneading 100 parts by mass of AES resin and 2 parts by mass of fatty acid amide for 3 minutes using a Labo Plastomill at 180°C and 50 rpm. The obtained surface material was hot-pressed at 160°C to obtain a plate-shaped (sheet-shaped) surface material (thickness 200 μm).

[0097] Preparation of substrate with surface material: The surface material (thickness 200 μm) was laminated with the polyvinyl chloride (PVC) substrate (thickness 2.0 mm) and hot pressed at 180°C to obtain a substrate with a surface material (multilayer laminate) in which the surface material and the substrate were bonded together.

[0098] (Examples 2 to 8 and Comparative Examples 1 and 2) Surface preparation: Surface materials were obtained in the same manner as in Example 1, except that the types and contents of the materials in the surface material were changed as shown in Tables 1 and 2 below.

[0099] Preparation of substrate with surface material: A substrate with a surface material was obtained in the same manner as in Example 1, except that the obtained surface material was used.

[0100] Example 9 Preparation of surface materials: 100 parts by mass of ASA resin and 2 parts by mass of fatty acid amide were placed in an extruder and melt-kneaded at 180° C. for 5 minutes to obtain a surface material.

[0101] Preparation of substrate with surface material: Using an extruder, the obtained surface material was co-extruded with the above polyvinyl chloride (PVC) substrate (thickness 2.0 mm) at 180°C to obtain a substrate with a surface material (multilayer laminate) in which the surface material (thickness 200 μm) and the above substrate were bonded together.

[0102] (Examples 10 and 11 and Comparative Example 3) Preparation of surface materials: Surface material was obtained in the same manner as in Example 9, except that the type and content of the surface material was changed as shown in Table 3 below.

[0103] Preparation of substrate with surface material: A substrate with a surface material was obtained in the same manner as in Example 9, except that the obtained surface material was used.

[0104] (evaluation) (1) Contact angle of water on the surface of the surface material The static contact angle of water on the surface of the surface material opposite the substrate side was measured for the resulting substrate with the surface material by the θ / 2 method at 23°C using a contact angle meter ("DMs-401" manufactured by Kyowa Interface Science Co., Ltd.) based on the sessile drop method. The static contact angle obtained was taken as the contact angle of water on the surface of the surface material (23°C).

[0105] (2) Area ratio of voids in the surface material The substrates with surface materials obtained in Examples 1 to 8 and Comparative Examples 1 and 2 were subjected to the following weather resistance test 1. The substrates with surface materials obtained in Examples 9 to 11 and Comparative Example 3 were subjected to the following weather resistance test 2.

[0106] Weather resistance test 1: The substrate with the surface material was placed flat with the surface material facing up. Using a metal weather tester (manufactured by Daipla Co., Ltd.), the illuminance was 560 W / m 2 The weather resistance test was conducted for 216 hours (total irradiation time: 72 hours, total non-irradiation time: 144 hours) under the following conditions: panel temperature 50°C, repeated irradiation (1 hour) and non-irradiation (2 hours), humidity 30% during irradiation, humidity 90% during non-irradiation, and precipitation.

[0107] Weather resistance test 2: The substrate with the surface material was placed flat with the surface material side facing up and left to stand outdoors (Saijo City, Ehime Prefecture) for 7 months (April 6, 2024 to November 6, 2024) to conduct a weather resistance test.

[0108] After weather resistance tests 1 and 2, the surface of the substrate with the surface material was randomly selected and observed at 10,000x magnification using an electron microscope (Hitachi's "SU3500") to obtain images. Using the obtained images, image analysis software (Mitani Shoji's "WinROOF") was used to binarize the void area from other areas using a threshold value that allows the outline of the voids to be distinguished, and the area ratio of the void area in the surface material was calculated.

[0109] The compositions of the surface materials and the evaluation results are shown in the following Tables 1 to 3. In the surface materials of Examples 1 to 11 and Comparative Examples 1 to 3, a sea-island structure was formed, having a sea portion containing a glassy component and islands containing a rubber component.

[0110] [Table 1]

[0111] [Table 2]

[0112] [Table 3]

[0113] When wood flour was further added to the surface material materials of Examples 1 to 11, the properties derived from the wood flour were imparted to the surface material, and the surface material had a wood-like texture when touched with the hand and when viewed with the eye. [Explanation of symbols]

[0114] 1,11...Base material with surface material 2,12...Base material 2a,12a…Surface 3,13…Surface material 3a,13a…Surface

Claims

1. The surface material has a sea-island structure having a sea portion containing a glassy component and an island portion containing a rubber component, A surface material having a water contact angle with respect to the surface of the surface material of 85.0° or more and 140.0° or less.

2. 2. The surface material according to claim 1, wherein the material of the surface material comprises at least one resin component selected from the group consisting of acrylonitrile / ethylene propylene rubber or ethylene propylene diene rubber / styrene copolymer resin, and acrylonitrile / styrene / acrylic rubber copolymer resin.

3. The melt flow rate of the resin component is 5 cm ３ / 50cm for 10 minutes or more ３ 3. The surface material according to claim 2, wherein the curing time is 10 minutes or less.

4. The Charpy impact strength of the resin component is 2 kJ / m ２ More than 50kJ / m ２ 3. The surfacing material of claim 2, wherein:

5. The surface material according to any one of claims 1 to 4, wherein the material of the surface material comprises at least one selected from the group consisting of fatty acid amides and silicone compounds.

6. The surface material according to any one of claims 1 to 4, having a thickness of 100 µm or more and 500 µm or less.

7. A substrate and a surface material according to any one of claims 1 to 4, A substrate with a surface material, wherein the surface material is disposed on the surface of the substrate.

8. The substrate with a surface material according to claim 7 , wherein the material of the substrate comprises a thermoplastic resin.

Images