Recoating decorative sheet and method for producing the same

Abstract

Provided is a decorative sheet for recoating that has a recoating layer that is laminated using sufficient adhesive strength and good inking properties for holding a coloring agent in the recoating layer.　The recoating decorative sheet comprises: a base material; a recoating layer that is provided on at least one surface side of the base material, contains thermoplastic resin fibers as constituent component fibers thereof, and has spaces between the fibers; and an adhesive layer between the base material and the recoating layer, that has at least some of the thermoplastic resin fibers melt-deposited or flow-deposited therein.

Description

[Technical field]

[0001] The present invention relates to a decorative sheet for recoating and a method for producing a decorative sheet for recoating. [Background technology]

[0002] For surface finishing of furniture, architectural interior materials, home appliances, etc., decorative sheets having a base material with a wood grain pattern or the like are laminated on the surface of the above-mentioned products. There are decorative sheets that are already colored and those that are not colored and are later coated with paint such as stain, the latter being called decorative sheets for recoating. Here, stain is a paint for coloring the surface of wood, and is made by adding pigments and dyes to linseed oil and resin in the form of liquid, gel, spray, etc. There are water-based and oil-based ones, and they are called oil stain, stain varnish, water-based stain, etc. After assembling a product using a material on which a decorative sheet for recoating is laminated for surface finishing, a paint such as stain is applied to the decorative sheet on the surface of the product to color it, so that the product can be easily colored to any color.

[0003] Conventional recoat decorative sheets have been proposed in which a pattern is printed on a substrate using printing ink, and then a topcoat paint is applied (see, for example, Patent Document 1). However, because conventional recoat decorative sheets have a smooth surface, even if a thick coat of stain or the like is applied, the stain drips, making it difficult to obtain a surface with excellent ink-receptivity that can retain colorants. Therefore, in order to obtain a surface with excellent ink-receptivity when a thick coating of stain or the like is applied, a decorative sheet for recoating has been proposed in which a pattern is printed on a substrate using printing ink and a nonwoven fabric is used for the recoat layer located on the surface (see, for example, Patent Document 2). The decorative sheet for recoating proposed in Patent Document 2 securely holds colorants such as stains in the voids in the nonwoven fabric, preventing the paint from dripping off the surface of the decorative sheet, and enabling coating with excellent ink-receptivity. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Unexamined Patent Publication No. 149457 / 1983 [Patent Document 2] Japanese Patent Application Publication No. 9-262934 Summary of the Invention [Problem to be solved by the invention]

[0005] In the decorative sheet for recoat proposed in Patent Document 2, a means by thermal welding is disclosed as a means for laminating a recoat layer (

[0012] and

[0036] in Patent Document 2). As the means by thermal welding, a means for thermal compression bonding using a thermoplastic resin for the base material or the printing ink for the picture printing, and a means for thermal compression bonding using a thermoplastic resin for the fibers of the nonwoven fabric of the recoat layer are disclosed. However, in these means by thermal compression bonding, if the heating is insufficient, there is a problem that the recoat layer cannot obtain sufficient adhesive strength. In addition, in these means by thermal compression bonding, if the heating is excessive in order to obtain sufficient adhesive strength of the recoat layer, there is a problem that the voids in the nonwoven fabric are filled with the thermoplastic resin, or the fibers of the nonwoven fabric are dissolved and the fiber form cannot be maintained, resulting in a loss of ink adhesion to hold the colorant. In addition, in the decorative sheet for recoating proposed in Patent Document 2, a means for laminating the recoat layer is disclosed that uses an adhesive (

[0036] of Patent Document 2). However, in the means using an adhesive, if there is too much adhesive, there is a problem that the adhesive seeps out from the surface of the recoat layer, and if there is too little adhesive, there is a problem that the recoat layer does not have sufficient adhesive strength. Furthermore, in the means using an adhesive, in order to obtain sufficient adhesive strength of the recoat layer, it is necessary to select an adhesive according to the material to be bonded, and it is difficult to select an adhesive that satisfies the conditions.

[0006] In view of the above problems, the present invention aims to provide a recoat decorative sheet in which a recoat layer is laminated with sufficient adhesive strength and in which the recoat layer has good ink-receiving properties for retaining a colorant, and a method for manufacturing the recoat decorative sheet. [Means for solving the problem]

[0007] In order to solve the above problems, the present inventors have conducted extensive research and found that the above problems can be solved by providing an adhesive layer between the substrate and the recoat layer, in which at least a part of the components of the recoat layer is melt-deposited or flow-deposited. That is, the present invention provides the following items [1] to [9]. [1] A decorative sheet for recoating comprising a substrate, a recoat layer provided on at least one side of the substrate, the recoat layer containing thermoplastic resin fibers as a constituent fiber and having voids between the fibers, and an adhesive layer between the substrate and the recoat layer, in which at least a portion of the thermoplastic resin fibers are melt-deposited or flow-deposited. [2] The decorative sheet for recoat according to [1], wherein the recoat layer has a resin coating on at least a portion of the surface of the fibers while maintaining at least a portion of the voids. [3] The decorative sheet for recoat according to [1] or [2], wherein the substrate is a resin substrate. [4] The decorative sheet for recoat according to any one of [1] to [3], wherein the fibers constituting the recoat layer contain two or more types of thermoplastic resin fibers having different melting points. [5] The decorative sheet for recoating according to [4], wherein the main component of the adhesive layer is formed by melting the thermoplastic resin fiber having the lower melting point among two or more types of thermoplastic resin fibers having different melting points. [6] The decorative sheet for recoat according to any one of [1] to [5], wherein the fibers constituting the recoat layer contain two or more types of thermoplastic resin fibers having different glass transition temperatures. [7] The decorative sheet for recoating according to [6], wherein the main component of the adhesive layer is formed by melting or flowing the thermoplastic resin fiber having a lower glass transition temperature among two or more types of thermoplastic resin fibers having different glass transition temperatures. [8] The decorative sheet for recoat according to any one of [1] to [7], wherein the recoat layer has a colorant in voids and at least a portion of the surface of the fibers. [9] A method for producing a decorative sheet for recoating, comprising the steps of: preparing a substrate; preparing a nonwoven fabric containing, as a component fiber, two or more types of thermoplastic resin fibers having different melting points; obtaining a laminate in which the nonwoven fabric is disposed on the substrate; heating the laminate to a temperature equal to or higher than the lowest melting point of the thermoplastic resin fibers; and compressing the heated laminate, so that a portion of the thermoplastic resin fibers, which have become more fluid, is deposited on the substrate side to form an adhesive layer. Effect of the Invention

[0008] According to the present invention, it is possible to provide a recoat decorative sheet in which a recoat layer is laminated with sufficient adhesive strength and in which the recoat layer has good ink-receiving properties for retaining a colorant, and a method for manufacturing the recoat decorative sheet. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is a schematic cross-sectional view (part 1) of a decorative sheet for recoating according to an embodiment of the present invention. [Diagram 2] FIG. 1 is a cross-sectional view (part 1) of an actual photograph of a decorative sheet for recoating according to an embodiment of the present invention. [Diagram 3] FIG. 2 is a cross-sectional view (part 2) of an actual photograph of a decorative sheet for recoating according to an embodiment of the present invention. [Figure 4] FIG. 2 is a schematic cross-sectional view (part 2) of a decorative sheet for recoating according to an embodiment of the present invention. [Diagram 5] FIG. 2 is a cross-sectional view of an actual photograph of a nonwoven fabric used in the recoat decorative sheet according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. In the following description of the drawings, the same or similar parts are denoted by the same or similar reference numerals. However, the drawings are schematic, and the relationship between thickness and planar dimensions, the thickness ratio of each layer, and the like differ from the actual ones. Therefore, the specific thickness and dimensions should be determined in light of the following description. In addition, it goes without saying that the drawings include parts with different dimensional relationships and ratios.

[0011] (Embodiment) [Decorative sheet for recoating] As shown in Fig. 1, the recoat decorative sheet 1 according to the embodiment of the present invention comprises a substrate 10, a recoat layer 30 provided on at least one side of the substrate 10, containing thermoplastic resin fibers as a constituent fiber and having voids between the fibers, and an adhesive layer 20 in which at least a portion of the thermoplastic resin fibers are melt-deposited or fluidized between the substrate 10 and the recoat layer 30. Figs. 2 and 3 show cross-sectional photographs of an actual recoat decorative sheet 1 according to the embodiment of the present invention.

[0012] <Base material> The substrate 10 is not particularly limited as long as it is normally used as a decorative sheet, and may be appropriately selected from resin substrates, metal substrates, ceramic substrates, fibrous substrates, wood substrates, etc. according to the application. From the viewpoint of good thermal conductivity, the substrate 10 is preferably a resin substrate or a metal substrate, and from the viewpoint of the balance between tensile strength and elongation properties, a resin substrate is more preferable. The substrate 10 used in the recoat decorative sheet 1 shown in Figures 2 and 3 is a polyvinyl chloride resin substrate. Each of the above substrates may be used alone, or may be a laminate of any combination, such as a composite of a resin substrate and a wood-based substrate, a composite of a resin substrate and a metal substrate, etc. When the substrate 10 is a laminate, an adhesive layer and a primer layer may be further provided between each layer of the laminate.

[0013] Examples of the resin substrate used as the substrate 10 include those made of various synthetic resins. Examples of the synthetic resin include olefin resins such as polyethylene, polypropylene, polymethylpentene, and various olefin-based thermoplastic elastomers, vinyl resins such as polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, vinyl chloride-vinyl acetate copolymer, ethylene-vinyl acetate copolymer, and ethylene-vinyl alcohol copolymer, polyester resins such as polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, ethylene glycol-terephthalic acid-isophthalic acid copolymer, and various polyester-based thermoplastic elastomers, acrylic resins such as polymethyl methacrylate, polyethyl methacrylate, and polybutyl acrylate, polyamide resins such as nylon 6 or nylon 66, cellulose resins such as cellulose triacetate and cellophane, polystyrene, polycarbonate resins, polyarylate resins, and polyimide resins.

[0014] Examples of metal substrates used as the substrate 10 include those made of aluminum, duralumin-aluminum alloys, iron, iron alloys such as stainless steel, titanium, copper, copper alloys such as brass, etc. Substrates made of other materials with the surfaces coated with these metals by plating or the like can also be used as the substrate 1.

[0015] Examples of the ceramic base material used as the substrate 10 include ceramic building materials such as gypsum, calcium silicate, cement, and wood chip cement, as well as ceramics, glass, enamel, and fired tiles.

[0016] Examples of fibrous substrates used as the substrate 10 include paper substrates such as tissue paper, kraft paper, titanium paper, linter paper, paperboard, and base paper for gypsum board. These paper substrates may further contain resins such as acrylic resin, styrene butadiene rubber, melamine resin, and urethane resin (impregnated with resin after papermaking, or filled in during papermaking) in order to increase inter-fiber strength of the paper substrate or inter-layer strength between other layers and the paper substrate, and to prevent fuzzing. Examples of paper substrates to which resins have been added include inter-layer reinforced paper and resin-impregnated paper. Examples of fibrous substrates that can be used as the substrate 10 include vinyl wallpaper rolls that are often used in the field of building materials and have a vinyl chloride resin layer on the surface of a paper substrate. Examples of fibrous substrates that can be used as the substrate 10 include coated paper, art paper, parchment paper, glassine paper, parchment paper, wax paper, and Japanese paper, which are used in the office field or in ordinary printing and packaging. The fibrous substrate used as the substrate 10 is different from the above-mentioned paper substrate, but may be woven or nonwoven fabrics of various fibers having an appearance and properties similar to those of paper. Examples of the various fibers include inorganic fibers such as glass fiber, asbestos fiber, potassium titanate fiber, alumina fiber, silica fiber, and carbon fiber. Examples of the various fibers include synthetic resin fibers such as polyester fiber, acrylic fiber, and vinylon fiber.

[0017] Examples of wood-based substrates that can be used as the substrate 10 include veneers, plywood, laminated lumber, particle boards, and medium density fiberboards (MDF), made of various types of wood such as cedar, pine, cypress, oak, lauan, and teak.

[0018] The thickness of the substrate 10 is not particularly limited, but taking into consideration the physical properties of the recoat decorative sheet 1 such as strength, mass, and flexibility, it is preferably 50 μm or more and 250 μm or less, more preferably 80 μm or more and 230 μm or less, and even more preferably 100 μm or more and 200 μm or less.

[0019] For the purpose of enhancing the design, the decorative sheet for recoat 1 preferably further comprises a pattern ink layer 11 and a colored concealing layer 12 between the substrate 10 and the recoat layer 30 as shown in FIG.

[0020] "Picture Ink Layer" The pattern (design) of the picture ink layer 11 can be selected arbitrarily according to the desired design appearance, such as wood grain, stone grain, fabric grain, leather grain, geometric pattern, etc. In the decorative sheet for recoat 1, for example, when expressing a wood grain design appearance, a wood grain pattern can be selected as the picture ink layer 11. The pattern ink layer 11 may be formed at any desired location on the substrate 10, and may be formed over the entire surface of the substrate 10. The picture ink layer 11 can be formed, for example, by printing. The picture ink layer 11 may be a single layer, or may be formed of two or more layers.

[0021] The ink used to form the picture ink layer 11 is a mixture of a binder component, a pigment, a coloring component such as a dye, an extender pigment, a solvent, a stabilizer, a plasticizer, a catalyst, a hardener, etc., as appropriate. The binder component is not particularly limited, and examples thereof include acrylic resins, urethane resins, vinyl chloride-vinyl acetate copolymers, styrene resins, polyester resins, chlorinated polyolefin resins, polyvinyl butyral resins, alkyd resins, petroleum-based resins, ketone resins, epoxy resins, melamine resins, fluororesins, silicone resins, cellulose derivatives, rubber-based resins, etc. These resins as binder components can be used alone or in combination of two or more. The coloring component can be appropriately selected from known pigments, such as inorganic pigments such as titanium white, lead white, carbon black, iron black, yellow lead, titanium yellow, red iron oxide, cadmium red, ultramarine blue, and cobalt blue; organic pigments or dyes such as quinacridone red, isoindolinone yellow, nickel azo complex, and phthalocyanine blue; metal pigments consisting of scaly foil flakes of aluminum, brass, and the like; and pearlescent pigments consisting of scaly foil flakes of titanium dioxide-coated mica, basic lead carbonate, and the like.

[0022] The thickness of the pattern ink layer 11 is not particularly limited, but from the viewpoint of exhibiting a good design by the pattern, it is preferably 0.1 μm to 10 μm, more preferably 0.5 μm to 7.5 μm, and even more preferably 1.0 μm to 5.0 μm. When the pattern ink layer 11 is formed of two or more layers, the total thickness of each pattern ink layer 11 is preferably within the above range.

[0023] The pictorial ink layer 11 may contain additives such as antioxidants and ultraviolet absorbing agents, to the extent that they do not impair the effects of the present invention. The preferred means for applying the picture ink layer 11 are gravure printing, silk screen printing, gravure offset printing, flexographic printing and ink jet printing, with gravure printing being more preferred for large lots and ink jet printing being more preferred for small lots.

[0024] Colored Concealing Layer As shown in FIG. 4, the decorative sheet for recoat 1 is preferably further provided with a colored concealing layer 12 on the resin substrate 10 side as part of the picture ink layer 11. The colored concealing layer 12 can impart an intended color to the substrate 10 in cases where the substrate 10 has color unevenness, thereby adjusting the surface color and improving the design of the recoat decorative sheet 1. The colored concealing layer 12 is often formed in an opaque color for the purpose of concealing the substrate 10, but it can also be formed in a colored transparent color to make use of the pattern that the substrate 10 has.

[0025] The colored concealing layer forming composition used to form the colored concealing layer 12 is a mixture of a binder component, a pigment, a coloring component such as a dye, an extender pigment, a solvent, a stabilizer, a plasticizer, a catalyst, a hardener, etc., as appropriate. The binder component and coloring component of the colored concealing layer 12 may be appropriately selected based on the use of the recoat decorative sheet 1 and its compatibility with the picture ink layer 11, and the same binder component and coloring component as those of the picture ink layer 11 can be used.

[0026] The thickness of the colored concealing layer 12 is not particularly limited, but is preferably 1.0 μm to 15 μm, more preferably 2.0 μm to 12 μm, and even more preferably 3.0 μm to 10 μm, from the viewpoint of exhibiting good design properties by concealing the substrate 10. When the colored concealing layer 12 is formed of two or more layers, the total thickness of the colored concealing layers 12 is preferably within the above range.

[0027] <Recoat layer> The recoat layer 30 contains thermoplastic resin fibers as a fiber component, and is preferably composed mainly of thermoplastic resin fibers. Here, the term "main component" refers to a component that constitutes more than 50% by mass of the components constituting the recoat layer 30, preferably more than 60% by mass, more preferably more than 70% by mass, and even more preferably more than 80% by mass.

[0028] The thermoplastic resin fiber constituting the recoat layer 30 is not particularly limited, and examples thereof include (meth)acrylic resins such as poly(meth)acrylic acid ester; polyvinyl acetal (butyral resins) such as polyvinyl butyral; polyester resins such as polyethylene terephthalate and polybutylene terephthalate; polyolefin resins such as polyethylene and polypropylene; styrene resins such as polystyrene and α-methylstyrene; acetal resins such as polyoxymethylene; thermoplastic elastomers such as polyolefin thermoplastic elastomers, polystyrene thermoplastic elastomers, polydiene thermoplastic elastomers, polyurethane thermoplastic elastomers, polyester thermoplastic elastomers, and fluororesin thermoplastic elastomers; fluororesins such as vinyl chloride resins, polyurethane resins, and ethylene-4-fluoroethylene copolymers, polyamide resins, polyimide resins, polylactic acid resins, polycarbonate resins, polyvinyl acetal resins, and liquid crystal polyester resins. Among these, polyolefin resins and polyurethane resins are preferred in terms of dimensional stability.

[0029] The fibers constituting the recoat layer 30 have a melting point T m It is preferable that the thermoplastic resin fiber contains two or more types of thermoplastic resin fibers having different melting points. For example, the thermoplastic resin fiber may contain a thermoplastic resin fiber having a low melting point (minimum melting point T m1 Thermoplastic resin fibers with high melting points (highest melting point T m2 Thermoplastic resin fiber having a melting point T m It is preferable that the thermoplastic resin fiber contains two types of thermoplastic resin fibers having different m1 <T m2In this way, the thermoplastic resin fiber contains two or more kinds of thermoplastic resin fibers having different melting points (for example, the lowest melting point T m1 and a thermoplastic resin fiber having a maximum melting point T m2 By carrying out the lamination process of the recoat layer 30 at a temperature T (T m1 <T<T m2 ) the lowest melting point T m1 The thermoplastic resin fiber melts to form the adhesive layer 20, thereby exerting adhesive strength, while the thermoplastic resin fiber has a maximum melting point T m2 The thermoplastic resin fiber maintains its fiber shape, and thus the coloring agent can be retained with good ink adhesion. m As for two or more types of thermoplastic resin fibers with different properties, m1 <T<T m2 It is preferable that the above relationship is satisfied. The minimum melting point T of thermoplastic resin fibers m1 and the temperature T of the lamination process of the recoat layer 30 (T m1 From the viewpoint of easily forming the adhesive layer 20, the temperature T is preferably -35°C or higher and 25°C or lower, more preferably -25°C or higher and 15°C or lower, and even more preferably -15°C or higher and 5°C or lower. Maximum melting point T of thermoplastic resin fiber m2 and the temperature T of the lamination process of the recoat layer 30 (T m2 From the viewpoint of maintaining the shape of the fiber and improving the ink receptivity to retain the colorant, the temperature (T) is preferably 40°C or higher and 110°C or lower, more preferably 50°C or higher and 100°C or lower, and even more preferably 60°C or higher and 90°C or lower. The minimum melting point T of thermoplastic resin fibers m1 and the highest melting point T m2 Difference with (T m2 -T m1 ) is preferably 50°C or higher and 120°C or lower, more preferably 60°C or higher and 110°C or lower, and even more preferably 70°C or higher and 100°C or lower.

[0030] The fibers constituting the recoat layer 30 have a glass transition temperature T gIt is preferable that the thermoplastic resin fiber contains two or more types of thermoplastic resin fibers having different glass transition temperatures. For example, the thermoplastic resin fiber may contain a thermoplastic resin fiber having a low glass transition temperature (minimum glass transition temperature T g1 Thermoplastic resin fibers with high glass transition temperature (maximum glass transition temperature T g2 It is preferable that the thermoplastic resin fiber contains two types of thermoplastic resin fibers having different glass transition temperatures (T g1 <T g2 In this way, the thermoplastic resin fiber contains two or more types of thermoplastic resin fibers with different melting points (for example, the lowest glass transition temperature T g1 and a thermoplastic resin fiber having a maximum glass transition temperature T g2 By carrying out the lamination process of the recoat layer 30 at a temperature T (T g1 <T<T g2 ), the minimum glass transition temperature T g1 The flowability of the thermoplastic resin fiber is increased, and the adhesive layer 20 is formed to exert adhesive strength, while the maximum glass transition temperature T g2 The thermoplastic resin fiber maintains its fiber shape, and thus the coloring agent can be retained with good ink adhesion. g As for two or more types of thermoplastic resin fibers with different properties, g1 <T<T g2 It is preferable that the above relationship is satisfied. Minimum glass transition temperature T of thermoplastic resin fibers g1 and the temperature T of the lamination process of the recoat layer 30 (T g1 From the viewpoint of easily forming the adhesive layer 20, the temperature T is preferably -160°C or higher and -90°C or lower, more preferably -150°C or higher and -100°C or lower, and even more preferably -140°C or higher and -110°C or lower. Maximum glass transition temperature T of thermoplastic resin fibers g2 and the temperature T of the lamination process of the recoat layer 30 (T g2(-T) is preferably from -140°C to -70°C, more preferably from -130°C to -80°C, and even more preferably from -120°C to -90°C from the viewpoint of maintaining the fiber form and having good coloring agent retention property. The lowest glass transition temperature T of the thermoplastic resin fiber g1 and the highest glass transition temperature T g2 The difference between them (T g2 -T g1 ) is preferably from 0°C to 50°C, more preferably from 0°C to 40°C, and even more preferably from 10°C to 30°C.

[0031] Also, as described above, in the configuration where the fibers constituting the recoat layer 30 contain two or more types of thermoplastic resin fibers having different glass transition temperatures T g , even when the temperature T of the lamination step of the recoat layer 30 is carried out under the condition of T g1 <T g2 <T, the same effects as described above can be expected. That is, the fluidity of the thermoplastic resin fiber having the lowest glass transition temperature T g1 tends to be high, and while the adhesive force is exhibited by forming the adhesive layer 20, the thermoplastic resin fiber having the highest glass transition temperature T g2 does not have such a high fluidity and can maintain the fiber form to some extent, thereby achieving good coloring agent retention property. In addition, in the case of the condition of T g1 <T g2 <T, from the viewpoint of easily obtaining the above effects, it is preferable to satisfy 0°C ≤ T m1 -T, more preferably to satisfy 0°C < T m1 -T, and even more preferably to satisfy 10°C ≤ T m1 -T.

[0032] Other fibers constituting the recoat layer 30 include, for example, biodegradable fibers made from lactic acid obtained from starch such as corn, cellulose-based artificial fibers such as rayon, polynosic, cupra, acetate, and triacetate, inorganic fibers such as glass fiber, carbon fiber, ceramic fiber, and asbestos fiber, and regenerated fibers obtained from textile products using these fibers. These fibers constituting the recoat layer 30 can be used alone or in combination of two or more kinds.

[0033] The recoat layer 30 is preferably one that allows the pattern of the pattern ink layer 20 to be visually recognized, and is preferably one that has transparency such as transparent paper or translucent paper. Specifically, the transparency of the recoat layer 30 is preferably 50% or less, more preferably 40% or less, and even more preferably 30% or less, in terms of opacity measured in accordance with JIS P8138:2000 (the smaller the value, the better the transparency). The lower limit of the opacity is about 10%. The recoat layer 30 can be obtained by any of the well-known manufacturing methods, such as a method of treating paper with concentrated sulfuric acid to make it transparent, a method of highly beating chemical pulp to make paper, a method of impregnating base paper with a clarifying agent such as wax and synthetic resin, and a method of heating and pressurizing synthetic fiber and synthetic pulp mixed paper to make it transparent, and may be obtained by any of the known manufacturing methods.

[0034] The basis weight of the recoating layer 30 is not particularly limited, but from the viewpoint of obtaining mechanical strength of the recoating layer 30, it is set to 5 g / m 2 It is preferable that the content is 10 g / m or more. 2 More preferably, it is 15 g / m or more. 2 The basis weight of the recoat layer 30 is preferably 40 g / m2 or more from the viewpoint of being able to perform coating with excellent ink-receptivity and ability to retain a colorant. 2 Preferably, it is 35 g / m or less. 2 More preferably, it is 30 g / m or less. 2 It is even more preferable that:

[0035] The thickness of the recoat layer 30 is not particularly limited, but from the viewpoint of reliably holding recoat paint such as stain, preventing the paint from dripping, and providing a coating with excellent ink-receiving properties that retains colorant, it is preferably 40 μm or more and 110 μm or less, more preferably 50 μm or more and 100 μm or less, and even more preferably 60 μm or more and 90 μm or less.

[0036] The recoat layer 30 has a filling portion (not shown) formed by melting at least a part of the thermoplastic resin fiber and filling a part of the voids of the fiber on the side of the surface on which the adhesive layer 20 is provided in the thickness direction of the layer. The filling portion ensures the adhesion between the adhesive layer 20 and the recoat layer 30.

[0037] The recoating layer 30 has a fiber portion (not shown) in which at least a part of the fiber voids and surface is present on the side opposite to the side on which the adhesive layer 20 is provided in the thickness direction within the layer. The fiber portion of the recoating layer 30 can have the colorant (recoating paint) in the fiber voids and at least a part of the surface by ensuring the ink-receiving ability to hold the colorant (recoating paint) in the fiber voids and on the surface.

[0038] Resin coating The recoat layer 30 preferably has a resin coating (not shown) on at least a portion of the surface of the fibers while maintaining at least some voids. The resin coating improves the function of the recoat layer 30 as a stain paint receiving layer. The resin coating is present on some of the fibers of the recoat layer 30 and improves the wettability of the fibers, thereby preventing the stain paint from dripping and providing a coating with excellent ink-receiving properties that retains the colorant.

[0039] Resins used for the resin coating film include thermoplastic resins, thermosetting resins, ionizing radiation curable resins, etc. The resin used for the resin coating film can be used as a coating composition by adding a crosslinking agent, a curing agent such as a polymerization initiator, a polymerization accelerator, a solvent, a viscosity adjuster, an extender pigment, etc., as necessary.

[0040] Examples of thermoplastic resins include natural or synthetic resins such as cellulose derivatives such as ethyl cellulose, cellulose nitrate, cellulose acetate, ethylhydroxyethyl cellulose, and cellulose acetate propionate; styrene resins or styrene copolymers such as polystyrene and poly-α-methylstyrene; acrylic resins such as polymethyl methacrylate, polyethyl methacrylate, polyethyl acrylate, and polybutyl acrylate; vinyl polymers such as polyvinyl chloride, polyvinyl acetate, vinyl chloride-vinyl acetate copolymers, and polyvinyl butyral; rosin, rosin-modified maleic acid resins, rosin-modified phenolic resins, and rosin ester resins such as polymerized rosin; coumarone resins, vinyl toluene resins, and polyamide resins.

[0041] Examples of the thermosetting resin include phenol resin, urea resin, diallyl phthalate resin, melamine resin, guanamine resin, unsaturated polyester resin, polyurethane resin, epoxy resin, aminoalkyd resin, melamine-urea co-condensation resin, silicon resin, and polysiloxane resin.

[0042] The ionizing radiation curable resin may be a resin that has been conventionally used as an ionizing radiation curable resin, for example, a (meth)acrylate-based resin having a (meth)acryloyl group, which is an ionizing radiation curable functional group. Here, "(meth)acrylate" means "acrylate or methacrylate". Examples of the (meth)acrylate resin include monomers, oligomers, and prepolymers such as urethane (meth)acrylate, acrylic (meth)acrylate, polyester (meth)acrylate, and epoxy (meth)acrylate. Among these (meth)acrylate resins, from the viewpoint of the balance between adhesion to a heat seal layer and the like and coating strength, acrylate resins having an acryloyl group such as urethane acrylate, acrylic acrylate, polyester acrylate, and epoxy acrylate are preferred, and among these, urethane (meth)acrylate is preferred. Here, ionizing radiation refers to electromagnetic waves or charged particle beams that have an energy quantum capable of polymerizing or crosslinking molecules. Usually, ultraviolet rays (UV) or electron beams (EB) are used, but other types of radiation, such as electromagnetic waves (X-rays) and gamma rays, and charged particle beams (α-rays, ion beams) can also be used.

[0043] When the ionizing radiation curable resin is ultraviolet ray curable, the ionizing radiation curable resin composition preferably contains additives such as a photopolymerization initiator and a photopolymerization accelerator. The photopolymerization initiator may be one or more selected from acetophenone, benzophenone, α-hydroxyalkylphenone, Michler's ketone, benzoin, benzyl methyl ketal, benzoyl benzoate, α-acyloxime ester, thioxanthones, and the like. The photopolymerization accelerator can reduce polymerization inhibition caused by air during curing and increase the curing speed, and examples of the accelerator include one or more types selected from p-dimethylaminobenzoic acid isoamyl ester and p-dimethylaminobenzoic acid ethyl ester.

[0044] <Adhesive layer> The adhesive layer 20 is a layer in which at least a portion of the thermoplastic resin fibers provided between the substrate 10 and the recoat layer 30 is melt-deposited or flow-deposited. The adhesive layer 20 is disposed between the substrate 10 and the recoat layer 30, and has the function of adhering the substrate 10 and the recoat layer 30 together. In the process of producing the adhesive layer 20, first, a recoat layer such as a nonwoven fabric containing thermoplastic resin fibers as a component fiber is heated, so that some of the thermoplastic resin fibers become fluid. Then, the part of the thermoplastic resin fibers with high fluidity is compressed in the lamination process, and is pushed out from the remaining part of the component fibers toward the substrate 10, and is deposited on the substrate 10 to form the adhesive layer 20.

[0045] The main component of the adhesive layer 20 has a melting point T m Of two or more types of thermoplastic resin fibers having different melting points, it is preferable that the thermoplastic resin fiber having the lowest melting point Tm1 and the highest melting point T m2 The thermoplastic resin fiber contains two different types of fibers having the following properties (T m1 <T m2 ), and the lamination process of the recoat layer 30 is performed at a temperature T (T m1 <T<T m2 ) the lowest melting point T m1 The thermoplastic resin fibers melt to form the adhesive layer 20, thereby exerting adhesive strength. Here, the term "main component" refers to a component that constitutes more than 50 mass % of the components constituting the adhesive layer 20, preferably a component that constitutes more than 60 mass %, more preferably a component that constitutes more than 70 mass %, and even more preferably a component that constitutes more than 80 mass %.

[0046] The main component of the adhesive layer 20 has a glass transition temperature T g Of two or more types of thermoplastic resin fibers having different glass transition temperatures, it is preferable that the thermoplastic resin fiber having a lower glass transition temperature is melted or flowed. g1 and maximum glass transition temperature T g2 The thermoplastic resin fiber contains two different types of fibers having the following properties (T g1 <T g2 ), and the lamination process of the recoat layer 30 is performed at a temperature T (T g1 <T<T g2 ), the minimum glass transition temperature T g1 The fluidity of the thermoplastic resin fibers is increased, and adhesive strength can be exerted by forming the adhesive layer 20. Here, the main component refers to a component that accounts for more than 50 mass% of the components constituting the adhesive layer 20, preferably more than 60 mass%, more preferably more than 70 mass%, and even more preferably more than 80 mass%.

[0047] The thickness of the adhesive layer 20 is not particularly limited, but from the viewpoint of fully exerting the adhesive strength between the substrate 10 and the recoat layer 30, it is preferably 20 μm or more and 80 μm or less, more preferably 30 μm or more and 70 μm or less, and even more preferably 40 μm or more and 60 μm or less.

[0048] [Method of manufacturing decorative sheet for recoating] The method for producing the recoatable decorative sheet 1 of the present invention will be described by taking as an example the recoatable decorative sheet shown in FIG. 1, which is one of the preferred embodiments of the recoatable decorative sheet of the present invention.

[0049] First, a substrate 10 is prepared. In addition, the fiber component has a melting point of T m or glass transition temperature T g Two or more types of thermoplastic resin fibers with different melting points (for example, m1 and a thermoplastic resin fiber having a maximum melting point T m2 A nonwoven fabric 31 (see FIG. 5) containing two types of thermoplastic resin fibers (one having a thickness of 100 μm and the other having a thickness of 100 μm) is prepared.

[0050] Next, a melting point T m A laminate is obtained in which nonwoven fabrics 31 containing two or more types of thermoplastic resin fibers having different molecular weights are arranged.

[0051] Next, the laminate of the substrate 10 and the nonwoven fabric is heated to a predetermined temperature T. The temperature T is, for example, the minimum melting point T of the thermoplastic resin fiber. m1 It is preferable that the temperature T is set to the following (1) to (3). In (3), 0° C. or more is preferable. <T m1 -T, and more preferably 10°C ≤ T m1 It is more preferred that it is -T. (1)T m1 <T<T m2 (2)T g1 <T<T g2 (3) T g1 <T g2 <T、かつ、0℃≦T m1 -T

[0052] In addition, when heating the laminate, defects such as wrinkles can be reduced by gradually increasing the temperature to the desired temperature T rather than all at once. By heating the laminate, some of the thermoplastic resin fibers contained in the nonwoven fabric 31 become more fluid.

[0053] Furthermore, by compressing the heated laminate by laminating or the like, a portion of the thermoplastic resin fibers that have become more fluid are deposited on the substrate 10 side to form an adhesive layer 20. The remaining portion of the fibers that make up the nonwoven fabric that did not become more fluid forms a recoat layer 30 that maintains the shape of the fibers. The difference (T1-T) between the temperature T1 during compression such as lamination and the temperature T during heating is preferably 0°C or more and 100°C or less. As conditions for compression such as lamination, the heating time is preferably 10 seconds or more and 2 minutes or less, and the pressure is 8.0 kg / cm. 2 More than 10.0kg / cm 2 It is preferable that: By the above steps, the substrate 10, adhesive layer 20 and recoat layer 30 are laminated in order, and a decorative sheet for recoating 1 can be produced which has good adhesion between the substrate 10 and the recoat layer 30 via the adhesive layer 20, and has good ink-receiving properties for retaining colorant due to the fibrous form of the recoat layer 30.

[0054] The method for producing the recoat decorative sheet 1 preferably further includes a step of arranging a pattern ink layer 11 on the substrate 10 using a composition for forming a pattern ink layer by a known printing method such as gravure printing. In addition, it is preferable that the manufacturing method of the recoatable decorative sheet 1 further includes a step of arranging a colored concealing layer 12 on at least one of the substrate 10 and the pattern ink layer 11 using a composition for forming a colored concealing layer by a known printing method such as gravure printing. By including these steps, the design of the decorative sheet for recoat 1 can be improved.

[0055] The method for producing the decorative sheet 1 for recoating preferably further includes a step of applying a resin coating film-forming composition from the surface side of the recoat layer 30 of the decorative sheet 1 for recoating. By including this step, it is possible to produce a decorative sheet for recoat 1 having a resin coating on at least a portion of the surface of the fibers while maintaining at least some of the voids in the recoat layer 30 .

[0056] [How to color decorative sheets for recoating] The coloring method of the recoatable decorative sheet 1 according to the embodiment of the present invention involves applying a recoat paint to the recoat layer 30 of the recoatable decorative sheet 1 using a general coating method, thereby coloring the recoat layer 30. The recoat layer 30 of the recoat decorative sheet 1 has a fiber part on the coated surface side that maintains the fiber voids and surface, so that the fiber voids and surface can ensure the ink-receiving ability to retain colorants such as water-based stain paint and oil-based stain paint. Therefore, the recoat decorative sheet 1 according to the embodiment of the present invention can be easily colored any color by applying a colorant such as a stain to the recoat layer 30 to color it. EXAMPLES

[0057] The present invention will now be described in more detail with reference to examples, but the present invention is not limited to these examples in any way.

[0058] [evaluation] The decorative recoat sheets obtained in the Examples and Comparative Examples were evaluated as follows. The results are shown in Table 1.

[0059] <Adhesiveness> The decorative recoat sheets prepared in the Examples and Comparative Examples were cut to a size of 300 mm x 300 mm to prepare test pieces for adhesion tests. Only the recoat layer was peeled off from the end of the test piece to evaluate adhesion. A: The adhesion between the recoat layer and the substrate is extremely high and the layer will not peel off (the material will break). B: The adhesion between the recoat layer and the substrate is high and it hardly peels off. C: The adhesion between the recoat layer and the substrate is moderate, and it is difficult to peel off. D: The adhesion between the recoat layer and the substrate was low, and the layer peeled off lightly.

[0060] <Meatability> The recoat layer side of the recoatable decorative sheets prepared in the Examples and Comparative Examples was coated with an oil-based stain paint and a water-based stain paint, and the ink receptivity was evaluated. A: Good adhesion of oil-based stain paint and water-based stain paint B: Oil-based stain paint and water-based stain paint have slightly poor adhesion. C: Poor adhesion of oil-based stain paint and water-based stain paint

[0061] Example 1 A polyvinyl chloride resin substrate having a thickness of 100 μm was prepared as the substrate, and a pattern ink layer forming composition was gravure printed on the substrate to form a pattern ink layer having a thickness of 3.0 μm. Basis weight 25g / m 2 A nonwoven fabric having a thickness of 130 μm and containing thermoplastic resin A (melting point 165° C., glass transition temperature 50° C.) and thermoplastic resin B (melting point 250° C., glass transition temperature 70° C.) was prepared. A laminate was obtained in which the prepared nonwoven fabric was placed on a pattern ink layer that was placed on a substrate. The resulting laminate was then subjected to thermal lamination (150°C, 12 minutes, 50 kg / cm 2 ), some of the thermoplastic resin fibers contained in the nonwoven fabric became more fluid, and by further pressing the laminate, some of the thermoplastic resin fibers with increased fluidity were deposited on the substrate side to form a 50 μm thick adhesive layer. The remaining part of the fibers that made up the nonwoven fabric, which did not become more fluid, formed an 80 μm thick recoat layer that maintained the shape of the fibers. Next, a composition for forming a resin coating film containing a vinyl chloride-vinyl acetate copolymer resin was applied from the surface side of the recoat layer to form a resin coating film on the recoat layer. Through the above steps, a decorative sheet for recoating was obtained in which the substrate 10, the adhesive layer 20, and the recoating layer 30 were laminated in this order. The resulting decorative recoat sheet was evaluated, and the results are shown in Table 1.

[0062] Example 2 The nonwoven fabric in Example 1 has a basis weight of 25 g / m 2The recoat decorative sheet of Example 2 was obtained in the same manner, except that the nonwoven fabric had a thickness of 130 μm and contained thermoplastic resin C (melting point 180° C., glass transition temperature 60° C.) and thermoplastic resin D (melting point 250° C., glass transition temperature 70° C.). The evaluation results of the obtained recoat decorative sheet are shown in Table 1.

[0063] Example 3 The nonwoven fabric in Example 1 has a basis weight of 25 g / m 2 The recoat decorative sheet of Example 3 was obtained in the same manner, except that the nonwoven fabric had a thickness of 130 μm and contained thermoplastic resin C (melting point 150° C., glass transition temperature 40° C.) and thermoplastic resin D (melting point 250° C., glass transition temperature 70° C.). The evaluation results of the obtained recoat decorative sheet are shown in Table 1.

[0064] Comparative Example 1 The nonwoven fabric in Example 1 has a basis weight of 25 g / m 2 The decorative recoat sheet of Comparative Example 1 was obtained in the same manner, except that the nonwoven fabric contained a thermoplastic resin having a melting point of 250° C. and a glass transition temperature of 70° C. and a pressure-sensitive adhesive was used to bond the substrate and the nonwoven fabric with a 20 μm thick adhesive layer. The decorative recoat sheet obtained was evaluated and the results are shown in Table 1.

[0065] Comparative Example 2 The nonwoven fabric in Example 1 has a basis weight of 25 g / m 2 The decorative recoat sheet of Comparative Example 2 was obtained in the same manner, except that the nonwoven fabric contained a thermoplastic resin having a melting point of 250° C. and a glass transition temperature of 70° C. and a pressure-sensitive adhesive was used to bond the substrate and the nonwoven fabric with an adhesive layer having a thickness of 1 μm. The decorative recoat sheet obtained was evaluated and the results are shown in Table 1.

[0066] Comparative Example 3 The nonwoven fabric in Example 1 has a basis weight of 25 g / m 2A decorative recoat sheet of Comparative Example 3 was obtained in the same manner, except that the nonwoven fabric had a thickness of 130 μm and contained a thermoplastic resin (melting point 165° C., glass transition temperature 50° C.). The obtained decorative recoat sheet was evaluated and the results are shown in Table 1.

[0067] Comparative Example 4 The nonwoven fabric in Example 1 has a basis weight of 25 g / m 2 The same procedure was followed except that the nonwoven fabric had a thickness of 130 μm and contained a thermoplastic resin (melting point 250° C., glass transition temperature 70° C.), to obtain a decorative sheet for recoating of Comparative Example 4. The evaluation results of the obtained decorative sheet for recoating are shown in Table 1.

[0068] [Table 1]

[0069] As can be seen from Table 1, in Examples 1 to 3, the results of both adhesion and colorability were good. On the other hand, in Comparative Example 1, the adhesive seeped out from the surface of the recoat layer, and the colorability was poor. In Comparative Example 2, the amount of adhesive was small, and the adhesiveness was poor. In Comparative Example 3, the adhesiveness was evaluated as good because the thermoplastic resin fiber contained in the nonwoven fabric was heated to form an adhesive layer, but the colorability was poor because a recoat layer that maintained the fiber form was not formed. In Comparative Example 4, the adhesiveness was evaluated as poor because the thermoplastic resin fiber contained in the nonwoven fabric did not form an adhesive layer even when heated, but the colorability was good because a recoat layer that maintained the fiber form was formed. [Industrial Applicability]

[0070] The decorative recoat sheet of the present invention has sufficient adhesion between the substrate and the nonwoven fabric and has good colorability, and is suitable for use as a layer constituting interior or exterior components of buildings such as walls, ceilings, and floors, fittings and fixtures such as window frames, doors, handrails, baseboards, moldings, and other building materials, as well as surface decorative panels for kitchen equipment, furniture, or cabinets for low-voltage and office automation equipment, and interior or exterior components of vehicles. [Explanation of symbols]

[0071] 1: Recoat decorative sheet 10: Base material 11: Picture ink layer 12: Colored concealing layer 20: Adhesive layer 30: Recoat layer 31:Nonwoven fabric

Claims

1. A substrate; a recoat layer provided on at least one surface side of the substrate, containing thermoplastic resin fibers as a component fiber and having voids between the fibers; and an adhesive layer between the substrate and the recoat layer, in which at least a portion of the thermoplastic resin fibers are melt-deposited or flow-deposited; The fibers constituting the recoat layer contain two or more types of thermoplastic resin fibers having different melting points, The minimum melting point T ｍ１ and the highest melting point T ｍ２ Difference with (T ｍ２ -T ｍ１ ) is 50°C or higher and 120°C or lower.

2. The decorative sheet for recoating according to claim 1 , wherein the recoat layer has a resin coating on at least a portion of the surface of the fibers while maintaining at least a portion of the voids.

3. The decorative sheet for recoat according to claim 1 or 2, wherein the substrate is a resin substrate.

4. The recoat decorative sheet according to any one of claims 1 to 3, wherein the main component of the adhesive layer is a melted thermoplastic resin fiber having a lower melting point among two or more types of thermoplastic resin fibers having different melting points.

5. The decorative sheet for recoating according to any one of claims 1 to 4, wherein the fibers constituting the recoat layer contain two or more types of thermoplastic resin fibers having different glass transition temperatures.

6. The decorative sheet for recoating according to claim 5, wherein the main component of the adhesive layer is a melted or flowed thermoplastic resin fiber having a lower glass transition temperature among two or more types of thermoplastic resin fibers having different glass transition temperatures.

7. The decorative sheet for recoating according to any one of claims 1 to 6, wherein the recoat layer has a colorant in voids and at least a portion of the surface of the fibers.

8. Providing a substrate; The fibers constituting the fiber component include two or more types of thermoplastic resin fibers having different melting points, and the lowest melting point T ｍ１ and the highest melting point T ｍ２ The difference between ｍ２ -T ｍ１ preparing a nonwoven fabric having a temperature of 50° C. or higher and 120° C. or lower; obtaining a laminate in which the nonwoven fabric is disposed on the substrate; heating the laminate to a temperature T equal to or higher than the minimum melting point of the thermoplastic resin fibers; and compressing the heated laminate, so that a portion of the thermoplastic resin fibers, which have become more fluid, are deposited on the substrate side to form an adhesive layer.

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