JP6451991B2 - Mirror surface decorative board - Google Patents

Description

  The present invention relates to a decorative plate used for a building material such as an indoor wall surface of a building or furniture, and particularly relates to a decorative plate having high specularity.

  In recent years, in the system kitchen and the bathroom market, a decorative sheet with high specularity has been widely used because it has a sense of quality and cleanliness and has high cleanability. Conventionally, in the production of such a mirror surface decorative plate, a method of forming each layer by painting has been widely used. However, the painting requires a plurality of coating processes such as undercoating and intermediate coating, and it is necessary to repeat coating and polishing alternately, resulting in a large number of processes and poor productivity.

  In order to solve such a problem, a mirror decorative sheet in which a decorative sheet and a base material are bonded together with an adhesive is disclosed as a mirror decorative sheet that reduces the steps of coating and polishing (see Patent Document 1). The said mirror surface decorative board implement | achieves a mirror surface property by bonding the mirror surface sheet | seat of a synthetic resin to a base material with a reactive hot melt adhesive.

Japanese Patent Laid-Open No. 2002-248689

  The decorative board having the structure is obtained by reducing the man-hour by bonding the mirror sheet to the base material. However, since a reactive hot-melt adhesive is used for the bonding, it is caused by the reaction of the adhesive at the time of bonding. In some cases, the mirror sheet is partially swollen by the gas and the appearance is impaired. In particular, when using a wood-based substrate, smoothing treatment by applying a sealing treatment to the substrate surface is required to obtain a high degree of specularity. It was.

  The problem to be solved by the present invention is to provide a specular decorative board that can suppress the swelling of the specular sheet even when a reactive hot-melt adhesive is used, and can realize high specularity.

  In particular, even when a wood-based substrate is used, it is an object of the present invention to provide a specular decorative board that can suppress swelling of the specular sheet even after the specular sheet is laminated and can realize high specularity.

  In the present invention, a decorative sheet in which a decorative sheet is laminated via an adhesive on a sealing layer of a gas-permeable substrate having a sealing layer on a surface layer, the adhesive being a reactive hot-melt adhesive And the said subject was solved by the mirror surface decorative board which the at least one surface of the said decorative sheet consists of a resin film, and the said sealing layer consists of an ionizing radiation curable composition containing an extender.

  The mirror surface decorative board of the present invention uses a reactive hot-melt adhesive as an adhesive for laminating a gas-permeable substrate and a decorative sheet, and an ionizing radiation curable resin containing an extender pigment on the substrate surface. By using such a sealing layer, high specularity can be realized, and since the swelling of the specular sheet can be suitably suppressed even after the specular sheets are laminated, excellent specular design can be realized.

2 is a photograph showing the observation results of surface smoothness of the decorative board obtained in Example 1. FIG. 6 is a photograph showing the observation results of the surface smoothness of the decorative board obtained in Comparative Example 2.

  The mirror surface decorative board of the present invention is a decorative board in which a decorative sheet is laminated via an adhesive on a sealing layer of a gas-permeable substrate having a sealing layer on the surface layer, and the adhesive is reactive hot It is a melt adhesive, and at least one surface of the decorative sheet is made of a resin film, and the sealing layer is a decorative board made of an ionizing radiation curable composition containing extender pigments.

[Air-permeable substrate]
As the air-permeable base material used in the present invention, various base materials used for a decorative board can be used, and for example, air-permeable base materials such as a woody base material, an inorganic base material, and a foamed resin base material can be used. Among them, the woody base material can be preferably used because it is inexpensive. According to the configuration of the present invention, high specularity can be realized even in a woody base material.

  As the wood base material, various wood base materials such as veneer, plywood, insulation board, hard board, medium density fiber board (MDF), and particle board (PB) can be widely used.

[Seamless layer]
The sealing layer used in the present invention is a sealing layer made of an ionizing radiation curable resin containing extender pigments. As the ionizing radiation curable resin, ultraviolet curable resins such as epoxy acrylate resins, urethane acrylate resins, and polyester acrylate resins can be preferably used. Since the ultraviolet curable resin can be suitably cured in a short time, it is preferable because a suitable smoothness can be easily obtained by a smoothing process such as a sanding process.

  As the extender used in the sealing layer, an air-permeable extender can be used, and examples thereof include calcium carbonate, talc, and silica. These extender pigments may be used alone or in combination. Among these, at least one of calcium carbonate and talc can be preferably used.

  The content of the extender pigment in the sealing layer is preferably 25 to 75% by mass and more preferably 30 to 65% by mass because it is easy to suppress suitable film formation and swelling of the decorative board. 40 to 60% by mass is particularly preferable.

  Further, in the coating material forming the sealing layer, a dispersant, an antifoaming agent, a polymerization inhibitor, a photoinitiator, and the like can be appropriately used as additives.

  In the present invention, by providing the sealing layer on the wood base material, prevention of elution of spider components such as lignin and tannin contained in the wood base material, prevention of penetration of the colored layer into the wood base material, Various functions such as improvement of the adhesion of the decorative layer, concealment of the color tone in the woody base material, and smoothing of the base before application of the colored layer can be realized.

  The sealing layer may be composed of only one layer or may be composed of two or more layers. The case where only one layer is used is preferable because the manufacturing process can be simplified and the manufacturing cost can be reduced. Further, in the case of being composed of two or more layers, it is preferable that the function of the sealing layer is shared and expressed by each layer, so that these functions are easily expressed suitably. In addition, by using two or more layers, the types of raw materials that can be used increase, and the range of designs using these increases. When the sealing layer is a multilayer of two or more layers, each layer is a sealing layer made of an ionizing radiation curable resin containing the extender pigment.

  The sealing layer can be formed by coating the coating material for the sealing layer with a natural roll coater, reverse roll coater, natural reverse roll coater, natural reverse squeeze coater, die coater, knife coater or the like.

About the application quantity of the coating material for sealing layers, it is preferable that it is 5-200 g / m < ² > at the time of drying, and it is especially preferable that it is 10-100 g / m < ² >. By setting it as the said range, the filling unevenness of the coating material to the recessed part to the wood type base material surface at the time of coating hardly arises, and it becomes easy to improve the smoothness of a coating surface.

  In the present invention, in order to improve the smoothness of the surface of the sealing layer, the surface of the sealing layer may be smoothed. As the said smoothing process, since it is easy to ensure adhesiveness with an adhesive agent and surface smoothness, the smoothing process by a sander process can be used preferably. As the sander method, a belt sander is preferably used, and any of a platen method, a drum method, and a combination method thereof can be used. Types of sandpaper include coarse (# 30-100), medium (# 100-200), fine (# 200-400), ultrafine (# 400-600), ultrafine (# 600 or more), etc. Any of these can be used, but it is preferable to use fine or very fine because smoothness can be easily obtained.

[adhesive]
In the present invention, a reactive hot-melt adhesive is used as an adhesive used for laminating a wooden base material having a sealing layer on the surface layer and a decorative sheet. By using the reactive hot-melt adhesive, a solvent impression process is unnecessary, and a high initial adhesive force can be realized. Therefore, a suitable specular decorative panel can be produced with high productivity. As the reactive hot melt adhesive, a PUR adhesive can be particularly preferably used.

  Examples of the polyol component that can be used in the PUR adhesive include polyester polyols such as polyester diol, polyether polyols such as polyether diol, and mixtures or copolymers thereof. Furthermore, acrylic polyol, polycarbonate polyol, polyolefin polyol, castor oil polyol, polyhydric alcohol and the like, or a mixture or copolymer thereof can be mentioned.

  Further, the polyisocyanate component is not particularly limited, but for example, aromatics such as phenylene diisocyanate, tolylene diisocyanate (TDI), 4,4′-diphenylmethane diisocyanate, 2,4-diphenylmethane diisocyanate, naphthalene diisocyanate, etc. Examples thereof include aliphatic or alicyclic diisocyanates such as diisocyanate, hexamethylene diisocyanate, lysine diisocyanate, cyclohexane diisocyanate, isophorone diisocyanate, dicyclohexylmethane diisocyanate, xylylene diisocyanate, and tetramethylxylylene isocyanate. Among these, it is preferable to use diphenylmethane diisocyanate (MDI) having a low vapor pressure during heating.

  As the PUR adhesive, those having a melting point of 90 to 130 ° C. and a viscosity of 1000 to 30000 mPa · s are preferable, and among them, a polyester polyol-based PUR adhesive is particularly preferable because of excellent initial adhesive strength. In particular, such a PUR adhesive is preferably obtained by using polyester polyol in combination with polyether polyol or other polyol, such as acrylic polyol.

  In addition, the polyurethane reactive hot melt can use what is marketed, for example, DIC Corporation make, Typhos FH-100, etc. can be used.

  The decorative sheet used in the present invention is a decorative sheet having at least one surface made of a resin film. When a decorative sheet having a resin film in the layer structure is laminated with a reactive hot-melt adhesive on the sealing layer using the ionizing radiation curable composition as described above, a mirror-coated decorative board is formed by a gas generated during the lamination. Although swelling and fluctuation are likely to occur on the surface, according to the configuration of the present invention, it is possible to obtain a highly specular decorative board with excellent sharpness.

  The configuration of the decorative sheet is not particularly limited as long as at least one surface layer is made of a resin film, and is coated with a clear paint having a colored layer on the resin film and forming a mirror surface on the colored layer. Configuration (transparent paint layer / colored layer / resin film layer), configuration having a colored layer on the back of the transparent resin film layer forming the mirror surface (transparent resin film layer / colored layer), and having a colored layer on the resin film The transparent resin film layer forming a mirror surface is laminated on the colored layer (transparent resin film layer / colored layer / resin film layer), and has a colored layer on the paper layer. A configuration in which a transparent resin film layer forming a mirror surface is laminated (transparent resin film layer / colored layer / paper quality layer) can be exemplified. Especially, the structure (transparent resin film layer / colored layer / resin film layer) in which a transparent resin film layer having a colored layer on the resin film and forming a mirror surface is laminated on the colored layer is sharp. It is preferable because excellent smoothness for realizing high specularity, concealability for realizing a suitable design, and particularly easy to realize. In addition, you may provide a primer layer, an adhesive bond layer, a masking layer, etc. suitably between these layers.

  The resin film used for the surface layer forming the mirror surface is biaxially stretched polyethylene terephthalate (O-PET), glycol-modified polyethylene terephthalate (PET-G), polycarbonate (PC), polyethylene (PE), polyvinyl chloride (PVC ), Acrylic (AC), stretched polypropylene (OPP), unstretched polypropylene (CPP), polyvinyl alcohol (PVS), and the like. Although it is arbitrary about thickness, 20 micrometers-300 micrometers are preferable, and 50 micrometers-200 micrometers are more preferable.

  The resin film used for the surface layer has a haze value of preferably 5% or less, more preferably 3% or less, and even more preferably 1% or less because high specularity is easily obtained. The resin film is also preferably subjected to a smoothing treatment with a smooth roll or a belt roll. Moreover, when forming a decorative sheet, the resin film surface may be smoothed by a press using a mirror surface roll or the like. Moreover, surface treatments, such as a primer process and a corona treatment for improving the adhesiveness with a coating material, may be given to the front and back of the said resin film. In addition, the surface layer of the resin film may be provided with a top coat for improving hardness and stain resistance.

  Examples of the resin film laminated with the substrate include glycol-modified ethylene terephthalate (PETG), polybutylene terephthalate (PBT), polyvinyl chloride (PVC), acrylonitrile butadiene styrene (ABS), polyethylene (PE), unstretched polypropylene ( Examples thereof include CPP) and polyvinyl alcohol (PVA).

  Since the resin film laminated with the base material is easy to obtain suitable design properties, the concealment ratio measured according to JIS K 5600-4-1 is preferably 70% or more, and 75% or more. Is more preferable, and it is further more preferable that it is 80% or more. It is preferable to use a colored resin film that is colored as such a resin film. In addition, a transparent resin film may be sufficient when concealment property is securable with other layers, such as a colored layer.

  The colored layer in the decorative sheet is a layer that imparts an arbitrary high design tone to the decorative sheet. The colored layer may be a single layer, or may be a colored layer in which a plurality of patterns or single color layers are stacked. The colored layer can be formed by applying or printing a colored paint containing a resin component and a coloring material.

  Examples of the resin used in the colored coating used in the colored layer include vinyl chloride acetate-vinyl copolymer resin, acrylic resin, urethane resin, acrylic urethane resin, nitrified cotton, polyvinyl alcohol, polyvinyl acetal, cellulose derivative, and polycarbonate resin. , Polyamide resins, polyester resins, butyral resins, and the like, or a mixture of two or more of them. In addition, these can also be made into what is called a two-component type using a hardening | curing agent. Of these, a two-component urethane resin is preferable, and examples thereof include a mixture of a polyol such as polyester, acrylic, acrylic alkyd and the like and an isocyanate.

  The colorant used for the color paint includes a colorant selected from organic pigments and inorganic pigments and extender pigments. As the inorganic pigment constituting the colorant, for example, titanium white, carbon black, chrome lead, cadmium yellow, cadmium red, petal, ultramarine, and aluminum white can be used. As organic pigments, quinacridone, lake red, benzicine yellow, isoindolinone, phthalocyanine blue, Sinclair red, etc. can be used, and any organic and inorganic pigments other than those described above are appropriately used according to the desired color tone. it can. Further, the extender pigment used as an aggregate is preferably an inorganic pigment, and particles such as calcium carbonate, clay, talc, barium sulfate, calcium sulfate, aluminum hydroxide, magnesium hydroxide, silica, and alumina can be used. .

  The colored paint may contain various additives as necessary. As the additive, for example, a leveling agent, a sedimentation stabilizer, an adhesion improver with a base or a top coat layer, or the like can be appropriately used.

  The coloring paint may be applied by a suitable method depending on the mode to be used, and examples thereof include a flow coater, a gravure coater, a roll coater, a comma coater, a die coater, an ink jet, and a screen.

The coating amount of the colored coating material, because it easy to obtain a suitable smoothness of the veneer, it is preferable that the 1 to 50 g / m ² on a dry coating, and more preferably to 3~40g / m ^2.

[Mirror surface veneer]
The mirror surface decorative board of the present invention is a decorative board in which a decorative sheet is laminated on a base material having the sealing layer via a reactive hot melt adhesive. With this configuration, even when an inexpensive wooden base material is used, it is possible to realize high specularity with excellent sharpness. In particular, a mirror surface decorative plate using a decorative sheet having a transparent resin film layer as the surface layer is preferable because it can realize high smoothness and easily obtain high mirror surface properties with excellent sharpness.

  The mirror surface decorative plate of the present invention preferably has a gloss value of 50 or more, more preferably 80 or more. Further, the haze value is preferably 5% or less, more preferably 3% or less, and even more preferably 1% or less.

  The mirror surface decorative plate of the present invention can easily achieve high smoothness and can stably realize extremely excellent mirror surface properties without causing swelling or the like. Since the mirror surface decorative plate can realize high-quality and excellent design at low cost, it can be usefully used for various applications such as kitchen members, storage members, door members, wall members, and other panel members.

Example 1
A 15-mm-thick cosmetic particle board with an acrylic UV-curable resin composition containing epoxy acrylate and trimethylolpropane EO-added triacrylate as the main components, and calcium carbonate and talc as body pigments A coating material (content of extender pigment in non-volatile content: 50% by mass) was applied at 66 g / m ² and cured with ultraviolet light, and then the surface was polished and smoothed. For the smooth surface, a PUR adhesive (FH100 made by DIC) was applied to the back surface of a mirror surface sheet having a thickness of 250 μm PET / color ink / PETG sheet with a die coater so that the coating amount was 45 μm. A decorative sheet was obtained by pressure bonding with a hot roll press. Then, it left still in the dryer set to 40 degreeC for 6 hours, and evaluated about the smoothness of the surface of a decorative board, and the swelling of a mirror surface sheet. In addition, the gloss value of the obtained decorative board surface was 110.

(Example 2)
A decorative board was obtained in the same manner as in Example 1 except that the content of the extender pigment in the nonvolatile content contained in the filler coating was 25% by mass. About the obtained decorative board, it carried out similarly to Example 1, and evaluated the smoothness of the decorative board surface and the swelling of a mirror surface sheet. In addition, the gloss value of the obtained decorative board surface was 110.

Example 3
A decorative board was obtained in the same manner as in Example 1 except that an ultraviolet curable paint in which the content of the extender in the nonvolatile content contained in the filler paint was 70% by mass was used. About the obtained decorative board, it carried out similarly to Example 1, and evaluated the smoothness of the decorative board surface and the swelling of a mirror surface sheet. In addition, the gloss value of the obtained decorative board surface was 110.

(Comparative Example 1)
A decorative board was obtained in the same manner as in Example 1 except that the extender pigment was not blended with the filler paint. About the obtained decorative board, it carried out similarly to Example 1, and evaluated the smoothness of the decorative board surface and the swelling of a mirror surface sheet.

(Comparative Example 2)
A decorative board was obtained in the same manner as in Example 1 except that the sealing paint was not used. About the obtained decorative board, it carried out similarly to Example 1, and evaluated the smoothness of the decorative board surface and the swelling of a mirror surface sheet.

<Surface smoothness evaluation>
A fluorescent lamp was projected on the surface of the obtained decorative board, and the distortion was visually observed. In addition, the photograph of the observation result of Example 1 and Comparative Example 2 is shown in FIG. 1 (Example 1) and FIG. 2 (Comparative Example 2).
○ The shape of the fluorescent lamp is clearly visible, and the side of the fluorescent lamp image is visually recognized in a straight line. △ A fluorescent lamp image with a substantially uniform thickness is shown, but distortion is confirmed in the linear shape of the side. The shape of the fluorescent lamp image is greatly distorted, and a fluorescent lamp image of uniform thickness is not confirmed, or the side of the fluorescent lamp image is greatly wavy

<Swelling evaluation>
The presence or absence of swelling of the mirror sheet on the surface of the obtained decorative plate was visually evaluated.
○ No swelling × With swelling

  As is clear from the above table, the mirror surface decorative plate of the present invention has a high specularity because the mirror surface sheet does not swell after the mirror sheet is laminated.

Claims (6)

A decorative sheet in which a decorative sheet is laminated via an adhesive on the sealing layer of a gas-permeable substrate having a sealing layer on the surface layer,
The adhesive is a reactive hot melt adhesive;
At least one surface of the decorative sheet is made of a resin film,
The specular decorative board, wherein the sealing layer is made of an ionizing radiation curable composition containing extender pigments.   The mirror surface decorative board according to claim 1, wherein the gloss value of the surface is 50 or more.   The mirror surface decorative board according to claim 1 or 2, wherein the base material is a woody base material.   The mirror surface decorative board according to any one of claims 1 to 3, wherein the content of the extender pigment in the sealing layer is 20 to 75 mass%.   The mirror surface decorative board according to any one of claims 1 to 4, wherein the surface of the decorative sheet laminated with the base material is a resin film on the other surface.   The mirror surface decorative board according to any one of claims 1 to 5, wherein the surface of the sealing layer is a sanded surface.