阅读说明：本技术 透明性树脂膜、装饰板和装饰板的制造方法 (Transparent resin film, decorative sheet, and method for producing decorative sheet ) 是由 古田哲 藤井亮 中岛智美 根津义昭 茅原利成 住田阳亮 于 2019-09-30 设计创作，主要内容包括：本发明提供即使为了赋予优异的外观设计性而在表面形成凹凸形状,也能够具有优异的耐候性能的透明性树脂膜、使用该透明性树脂膜得到的装饰板以及该装饰板的制造方法。本发明涉及用于保护在基材的一侧叠层的图案层的透明性树脂膜,透明性树脂膜的特征在于,上述透明性树脂膜至少叠层有表面保护层和透明性树脂层,在上述表面保护层一侧具有凹凸形状,上述透明性树脂膜的凹凸形状的凹部的厚度为100μm以上,上述透明性树脂膜含有紫外线吸收剂。(The invention provides a transparent resin film which can have excellent weather resistance even if the surface is provided with concave-convex shape for providing excellent appearance design, a decorative plate obtained by using the transparent resin film and a manufacturing method of the decorative plate. The present invention relates to a transparent resin film for protecting a pattern layer laminated on one side of a substrate, wherein the transparent resin film comprises at least a surface protective layer and a transparent resin layer laminated thereon, the surface protective layer has a concave-convex shape, the concave portion of the concave-convex shape of the transparent resin film has a thickness of 100 [ mu ] m or more, and the transparent resin film contains an ultraviolet absorber.)

1. A transparent resin film for protecting a pattern layer laminated on one side of a substrate, characterized in that,

the transparent resin film is formed by laminating at least a surface protective layer and a transparent resin layer,

the surface protective layer has a concavo-convex shape on one side,

the thickness of the concave and convex recesses of the transparent resin film is 100 [ mu ] m or more,

the transparent resin film contains an ultraviolet absorber.

2. The transparent resin film according to claim 1,

the ultraviolet absorber is contained in the surface protective layer and/or the transparent resin layer.

3. The transparent resin film according to claim 1 or 2,

the transparent resin layer has an adhesive primer layer on the side opposite to the surface protective layer side.

4. The transparent resin film according to claim 3,

the thickness of the adhesive primer layer is 0.5 to 10 [ mu ] m.

5. The transparent resin film according to claim 1, 2, 3 or 4,

the ultraviolet absorbent is triazine ultraviolet absorbent.

6. A decorative plate is characterized in that a decorative plate is provided,

a transparent resin film according to claim 1, 2, 3, 4 or 5, which comprises a substrate, a pattern layer and the resin film in this order in the thickness direction.

7. The trim panel of claim 6 wherein,

an adhesive layer is provided between the pattern layer laminated on one side of the base material and the transparent resin film.

8. A method for manufacturing a decorative sheet according to claim 6 or 7, the method comprising:

forming an adhesive layer on one surface of the transparent resin film on which the pattern layer is laminated; and

and a step of bonding the transparent resin film to the pattern layer via the adhesive layer.

Technical Field

The present invention relates to a transparent resin film, a decorative sheet obtained using the transparent resin film, and a method for producing the decorative sheet.

Background

In recent years, due to the widespread use of an ink jet printing method using an ink jet printer, decorative sheets used for building materials, decorative molded articles, and the like can be produced in a wide variety of types and in small quantities, and complicated patterns (characters, numerals, figures, and the like) can be printed as a pattern layer.

The inkjet printing method has an advantage that the substrate to be printed is not limited to a film, and can be printed on a flat plate or a substrate having an uneven or curved surface.

However, since the pattern layer printed by the inkjet printing method is usually located on the outermost surface of the substrate, surface properties such as scratch resistance, stain resistance, and weather resistance are insufficient, and a transparent resin film needs to be laminated on the surface of the pattern layer in order to protect the pattern layer.

As such a transparent resin film, for example, patent document 1 discloses a cover film in which a protective layer is provided on one surface of a transparent polypropylene containing a triazine-based ultraviolet absorber and a hindered amine-based light stabilizer, and an adhesive layer is provided on the other surface.

However, in the conventional transparent resin film, although the surface design is improved by the uneven shape, the weather resistance is uneven due to the difference in thickness caused by the uneven shape, and particularly, the weather resistance is poor in the thin film portion, so that there is room for improvement.

In particular, the tendency is more remarkable when various inks are used for the pattern layer to be printed by the inkjet printing method.

Documents of the prior art

Patent document

Patent document 1: japanese patent laid-open publication No. 2005-120255

Disclosure of Invention

Technical problem to be solved by the invention

The purpose of the present invention is to provide a transparent resin film that can have excellent weather resistance even when an uneven shape is formed on the surface in order to impart excellent design properties, a decorative sheet obtained using the transparent resin film, and a method for producing the decorative sheet.

Means for solving the problems

As a result of intensive studies to solve the above-mentioned problems, the inventors of the present invention have found that a transparent resin film having irregularities on the surface opposite to the side on which a pattern layer is laminated, wherein the irregularities of the transparent resin film formed by the irregularities have a predetermined thickness, and wherein the transparent resin film contains an ultraviolet absorber, can provide a transparent resin film having excellent weather resistance even when the irregularities are formed on the surface in order to impart excellent design properties to the transparent resin film, and have completed the present invention.

The present invention is a transparent resin film for protecting a pattern layer laminated on one side of a substrate, the transparent resin film being characterized in that the transparent resin film is laminated with at least a surface protection layer and a transparent resin layer, the surface protection layer has a concavo-convex shape, the thickness of a concave portion of the concavo-convex shape of the transparent resin film is 100 [ mu ] m or more, and the transparent resin film contains an ultraviolet absorber.

In the transparent resin film of the present invention, the ultraviolet absorber is preferably contained in the surface protective layer and/or the transparent resin layer.

The transparent resin film of the present invention preferably has an adhesion primer layer on the side of the transparent resin layer opposite to the surface protective layer side.

The adhesive primer layer preferably has a thickness of 0.5 to 10 μm.

Preferably, the ultraviolet absorber is a triazine-based ultraviolet absorber.

The present invention is also a decorative sheet comprising a base material, a pattern layer and the transparent resin film of the present invention in this order in the thickness direction.

The decorative sheet of the present invention preferably has an adhesive layer between the pattern layer laminated on one side of the base material and the transparent resin film.

The present invention is also a method for manufacturing a decorative sheet according to the present invention, including: forming an adhesive layer on one surface of the transparent resin film on which the pattern layer is laminated; and a step of bonding the transparent resin film to the pattern layer via the adhesive layer.

Effects of the invention

The invention provides a transparent resin film which can endow a decorative plate with excellent appearance design and weather resistance.

The decorative sheet of the present invention obtained using the transparent resin film of the present invention has excellent design properties and also has excellent weather resistance.

Drawings

Fig. 1 is a schematic view showing a cross section of one example of the transparent resin film of the present invention.

Fig. 2 is a schematic cross-sectional view showing a preferred example of the transparent resin film of the present invention.

Fig. 3 is a schematic cross-sectional view showing a preferred example of the decorative sheet of the present invention.

Detailed Description

The transparent resin film of the present invention will be explained.

The transparent resin film of the present invention comprises at least a surface protection layer and a transparent resin layer stacked on the surface protection layer, and has a concave-convex shape on the surface protection layer side, the thickness of a concave portion of the concave-convex shape is a predetermined value or more, and the transparent resin film contains an ultraviolet absorber.

In the conventional transparent resin film, the thickness varies due to the uneven shape, and the ultraviolet absorber is small in the portion where the film thickness is thin (concave portion of uneven shape), and sufficient weather resistance cannot be obtained.

However, in the transparent resin film of the present invention, since the thickness of the concave portions of the uneven shape can be sufficiently secured and the ultraviolet absorber is contained in the concave portions of the uneven shape, sufficient weather resistance can be obtained even in the thin film portion formed by the uneven shape.

In the present specification, the phrase "the concave portions of the uneven shape also contain an ultraviolet absorber" means that the ultraviolet absorber is present between the bottom surfaces of the concave portions of the uneven shape of the transparent resin film of the present invention and the surface of the transparent resin film on the side opposite to the surface protective layer in cross section. Specifically, the surface of the transparent resin film of the present invention on the surface-protecting layer side was cut to 10cm including concave and convex recesses²The area (b) of (a) is a region where a sample is prepared, the prepared sample is finely crushed using a freeze crusher, an ultraviolet absorber is extracted using THF (tetrahydrofuran), diluted using methanol, acetone, IPA, or the like, and then measured using liquid chromatography, whereby it can be determined whether or not the ultraviolet absorber is also present in the concave portions of the uneven shape.

A preferred example of the transparent resin film of the present invention will be described with reference to fig. 1.

As shown in fig. 1, the transparent resin film 10 of the present invention has a transparent resin layer 12, a surface protection layer 11 on one surface thereof, and a surface protection layer 11 having a concave-convex shape.

By providing such a surface protective layer 11, the transparent resin film 10 of the present invention is more excellent in durability (scratch resistance, stain resistance, weather resistance, etc.), and can suitably prevent a reduction in design properties due to scratches.

As shown in fig. 2, the transparent resin film 10 of the present invention preferably has an adhesive primer layer 13 on the surface of the transparent resin layer 12 opposite to the surface protection layer 11.

In the transparent resin film 10 of the present invention, it is preferable to provide an undercoat layer (not shown) between the transparent resin layer 12 and the surface protective layer 11, from the viewpoint of making the adhesion between the transparent resin layer 12 and the surface protective layer 11 stronger.

The respective configurations of the transparent resin film of the present invention will be explained below.

The transparent resin layer is a layer which is laminated on one surface of a substrate described later and functions as a protective pattern layer. The transparent resin layer may be transparent, and may be translucent or colored within a range where a pattern layer described later can be seen.

The transparent resin layer contains 1 or more of the following resins, preferably is composed of a thermoplastic resin, and examples of the thermoplastic resin include: olefin resins such as polyethylene, polypropylene, polybutene, polymethylpentene, and olefin-based thermoplastic elastomers; polyester resins such as polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, ethylene glycol-terephthalic acid-isophthalic acid copolymer, terephthalic acid-ethylene glycol-1, 4-cyclohexanedimethanol copolymer, and polyester thermoplastic elastomers; acrylic resins such as polymethyl (meth) acrylate, methyl (meth) acrylate-butyl (meth) acrylate copolymers, and methyl (meth) acrylate-styrene copolymers; polycarbonate resins, polyvinyl chloride, polystyrene, ionomers, and the like. Among them, polypropylene is preferably used from the viewpoint of high tensile strength, excellent chemical resistance and excellent production process.

Wherein, in the present specification, (meth) acrylate means acrylate or methacrylate.

The transparent resin layer may be an unstretched layer, or may be uniaxially or biaxially stretched as necessary.

The thickness of the transparent resin layer is not particularly limited, but is preferably 20 μm at the lower limit, more preferably 500 μm or less at the upper limit, even more preferably 60 μm at the lower limit, and even more preferably 420 μm or less at the upper limit. When the thickness of the transparent resin layer is less than 20 μm, the tensile strength may be insufficient to protect the surface of the pattern layer, and when it exceeds 500 μm, the transmittance of the transparent resin film of the present invention may be reduced, which may result in a reduction in the visibility of the pattern layer.

The transparent resin layer may be a laminate composed of 1 layer or 2 or more layers.

In the case where the transparent resin layer is a laminate composed of a plurality of layers, the types of resins constituting the layers to be formed may be the same or different, and the thicknesses of the plurality of layers composed of resins may be the same or different.

The method of laminating the transparent resin layer 2 or more is not limited as long as it is a usual method, and a dry lamination method, an extrusion heat lamination method, or the like can be mentioned.

By having the surface protective layer, the transparent resin film of the present invention has more excellent durability (scratch resistance, stain resistance, weather resistance, and the like), and the surface of the pattern layer can be protected more appropriately, and a decrease in design properties due to damage of the transparent resin film itself of the present invention can be prevented appropriately.

The surface protective layer may have a single-layer structure or a multi-layer structure formed of the same or different materials, and the following materials may be appropriately mixed.

The surface protective layer is not particularly limited, and examples thereof include a protective layer composed of a crosslinked cured product of a two-liquid curable resin or an ionizing radiation curable resin composition, and the crosslinked cured product is preferably transparent, may be translucent, and may be colored within a range in which a pattern layer described later can be seen.

As the above-mentioned two-liquid curable resin, a binder resin of an adhesion primer layer described later can be used.

As the ionizing radiation curable resin, for example, an oligomer having a radical polymerizable unsaturated bond or a cation polymerizable functional group in a molecule (hereinafter, also referred to as a prepolymer, a macromer, and the like) and/or a monomer having a radical polymerizable unsaturated bond or a cation polymerizable functional group in a molecule are preferably used. Here, the ionizing radiation means an electromagnetic wave or a charged particle having energy capable of polymerizing or crosslinking molecules, and is generally an Electron Beam (EB) or ultraviolet ray (UV).

Examples of the oligomer or monomer include compounds having a (meth) acryloyl group, a radical polymerizable unsaturated group such as a (meth) acryloyloxy group, and a cation polymerizable functional group such as an epoxy group in the molecule. These oligomers and monomers may be used alone or in combination. Wherein, in the present specification, the above (meth) acryloyl group means an acryloyl group or a methacryloyl group.

As the oligomer having a radical polymerizable unsaturated group in the molecule, for example, an oligomer such as urethane (meth) acrylate, polyester (meth) acrylate, epoxy (meth) acrylate, melamine (meth) acrylate, or triazine (meth) acrylate is preferably used, and a urethane (meth) acrylate oligomer is more preferably used. As the molecular weight, about 250 to 10 ten thousand is usually used.

The monomer having a radical polymerizable unsaturated group in the molecule is preferably a polyfunctional monomer, and more preferably a polyfunctional (meth) acrylate.

Examples of the polyfunctional (meth) acrylate include diethylene glycol di (meth) acrylate, propylene glycol di (meth) acrylate, bisphenol a ethylene oxide-modified di (meth) acrylate, trimethylolpropane tri (meth) acrylate, trimethylolpropane ethylene oxide tri (meth) acrylate, dipentaerythritol tetra (meth) acrylate, dipentaerythritol penta (meth) acrylate { 5-functional (meth) acrylate }, dipentaerythritol hexa (meth) acrylate { 6-functional (meth) acrylate }, and the like. Here, the polyfunctional monomer means a monomer having a plurality of radical polymerizable unsaturated groups.

In the present invention, the ionizing radiation-curable resin composition more preferably contains an ionizing radiation-curable resin component composed of a urethane acrylate oligomer and a polyfunctional monomer, and the ionizing radiation-curable resin component is particularly preferably a urethane acrylate oligomer/polyfunctional monomer (mass ratio) of 6/4 to 9/1. Within the range of the mass ratio, the scratch resistance is more excellent.

Further, if necessary, a monofunctional monomer may be suitably used in addition to the ionizing radiation-curable resin component described above within a range not departing from the object of the present invention.

Examples of the monofunctional monomer include methyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, and phenoxyethyl (meth) acrylate.

When the ionizing radiation-curable resin composition is crosslinked by ultraviolet rays, a photopolymerization initiator is preferably added to the ionizing radiation-curable resin composition.

When the ionizing radiation curable resin composition is a resin system having a radical polymerizable unsaturated group, the photopolymerization initiator may be acetophenone, benzophenone, thioxanthone, benzoin, or benzoin methyl ether, alone or in combination.

In the case where the ionizing radiation-curable resin composition is a resin system having a cationically polymerizable unsaturated group, the photopolymerization initiator may be an aromatic diazonium salt, an aromatic sulfonium salt, an aromatic iodonium salt, a metallocene compound, a benzoinsulfonic acid ester, or the like, used alone or as a mixture. The amount of the photopolymerization initiator is about 0.1 to 10 parts by mass per 100 parts by mass of the ionizing radiation-curable resin component.

Further, various additives may be further added to the ionizing radiation-curable resin composition as needed. Examples of such additives include: thermoplastic resins such as polyurethane resins, polyvinyl acetal resins, polyester resins, polyolefin resins, styrene resins, polyamide resins, polycarbonate resins, acetal resins, vinyl chloride-vinyl acetate copolymers, vinyl acetate resins, acrylic resins, and cellulose resins; lubricants such as silicone resins, waxes, fluorine-containing resins, and the like; ultraviolet absorbers such as benzotriazole, benzophenone, and triazine; light stabilizers such as hindered amine radical scavengers; colorants such as dyes and pigments.

Further, as the electron beam source of the ionizing radiation, for example, a source which irradiates electrons having an energy of 70 to 1000keV with various electron beam accelerators of the kochrowatt-walton type, van der graaff type, resonance transformer type, insulation core transformer type, linear type, high frequency high voltage type, high frequency type, and the like is used. The dose of the electron beam irradiation is preferably about 1 to 10Mrad, for example.

As the ultraviolet source of the ionizing radiation, for example, a light source such as an ultra-high pressure mercury lamp, a low pressure mercury lamp, a carbon arc lamp, a black light lamp, or a metal halide lamp can be used, and as the wavelength of the ultraviolet, a wavelength region of 190 to 380nm is mainly used.

The thickness of the surface protective layer is not particularly limited, but is preferably 0.1 μm at the lower limit and 50 μm at the upper limit, more preferably 1 μm at the lower limit and 30 μm at the upper limit. When the thickness of the surface protective layer is less than 0.1 μm, sufficient durability (scratch resistance, stain resistance, weather resistance, etc.) may not be imparted, and when it exceeds 50 μm, the transmittance of the transparent resin film of the present invention may be reduced, resulting in a decrease in visibility of the pattern layer.

The surface protective layer is a layer provided on the surface opposite to the surface on which the pattern layer described later is laminated, and is preferably bonded to the transparent resin layer through an undercoat layer. The adhesion between the surface protective layer and the transparent resin layer can be further strengthened by the primer layer.

As the primer layer, the same primer layer as the primer layer for adhesion described later is preferably used.

The transparent resin film of the present invention has a concavo-convex shape on the surface protective layer side.

The method for forming the above-mentioned uneven shape is not particularly limited, and examples thereof include embossing by heat, and a method of transferring an uneven shape by a shaping sheet.

As the embossing by heat, for example, a known method of embossing by a single sheet or a rotary embossing machine can be mentioned.

Examples of the embossed pattern include sand lines, hair lines, pear peel patterns, wood grain board guide grooves, stone board surface irregularities, cloth surface textures, and ruled line grooves.

The temperature at which the embossing is performed is not particularly limited, but is preferably a temperature at which so-called emboss recovery reduction, in which the uneven pattern disappears, is achieved during the heat pressure bonding molding.

The depth of the formed uneven shape is not particularly limited, but is preferably adjusted so that the center line average roughness Ra, which is defined in JIS B0601 (1982), falls within the range of 1 to 30 μm, for example.

The thickness of the transparent resin film of the present invention is not particularly limited, and the thickness of the concave and convex recesses is 100 μm or more. When the thickness of the concave portions of the uneven shape of the transparent resin film is less than 100 μm, sufficient durability (abrasion resistance and scratch resistance) cannot be imparted to the transparent resin film of the present invention, and the amount of the ultraviolet absorber contained in the concave portions of the uneven shape is insufficient, so that sufficient weather resistance cannot be obtained. The thickness of the concave portion of the above-described uneven shape is preferably 105 μm to 480 μm, and more preferably 110 μm to 300 μm.

The transparent resin film of the present invention contains an ultraviolet absorber in the concave portions of the uneven shape.

Here, the "concave portions having a concave-convex shape" refers to the portions of the transparent resin film of the present invention having the thinnest thickness, and as shown in fig. 1, the portions including the deepest concave portions having a concave-convex shape of the surface protection layer 11 can be confirmed by observing the cross section of the transparent resin film of the present invention with a microscope. The length from the bottom surface of the deepest recessed portion to the surface of the transparent resin layer 12 opposite to the surface protection layer 11 side is the "thickness of the recessed portion having the uneven shape".

The upper limit of the thickness of the recessed portions of the uneven shape of the transparent resin film is not particularly limited, and is preferably less than 500 μm, for example.

As shown in fig. 1, the length from the surface of the surface protection layer 11 to the surface of the transparent resin layer 12 opposite to the surface protection layer 11 side is the total thickness of the transparent resin film 10 of the present invention, and the total thickness preferably has a lower limit of more than 100 μm and an upper limit of 500 μm, more preferably has a lower limit of 140 μm and a more preferably upper limit of 460 μm.

The transparent resin film of the present invention contains an ultraviolet absorber.

As the ultraviolet absorber, for example, an organic or inorganic ultraviolet absorber can be used. Among them, organic ultraviolet absorbers having excellent transparency are suitably used.

Examples of the organic ultraviolet absorber include: 2 ' -hydroxyphenyl-5-chlorobenzotriazole ultraviolet absorbers such as 2- (2 ' -hydroxy-3 ', 5 ' -di-tert-butylphenyl) -5-chlorobenzotriazole, 2- (2 ' -hydroxy-3 ' -tert-butyl-5 ' -methylphenyl) -5-chlorobenzotriazole, 2- (2 ' -hydroxy-3 ' -tert-amyl-5 ' -methylphenyl) -5-chlorobenzotriazole, 2- (2 ' -hydroxy-3 ' -isobutyl-5 ' -propylphenyl) -5-chlorobenzotriazole and the like; benzotriazole-based ultraviolet absorbers such as 2 '-hydroxyphenylbenzotriazole-based ultraviolet absorbers (e.g., 2- (2' -hydroxy-3 ', 5' -di-tert-butylphenyl) benzotriazole and 2- (2 '-hydroxy-5' -methylphenyl) benzotriazole); benzophenone-based ultraviolet absorbers such as 2,2 '-dihydroxybenzophenone-based ultraviolet absorbers including 2, 2' -dihydroxy-4-methoxybenzophenone, 2 '-dihydroxy-4, 4' -dimethoxybenzophenone and 2,2 '-dihydroxy-4, 4' -tetrahydroxybenzophenone, and 2-hydroxybenzophenone-based ultraviolet absorbers including 2-hydroxy-4-methoxybenzophenone and 2, 4-dihydroxybenzophenone; salicylate-based ultraviolet absorbers such as phenyl salicylate and 4-tert-butylphenyl salicylate.

Among them, triazine-based ultraviolet absorbers are preferable from the viewpoint of appropriately imparting weather resistance, design properties, barrier properties, and the like.

Examples of the triazine-based ultraviolet absorber include 2, 4-bis (2, 4-dimethylphenyl) -6- (2-hydroxy-4-N-octyloxyphenyl) -1, 3, 5-triazine, 2- (2, 4-dihydroxyphenyl) -4, 6-bis (2, 4-dimethylphenyl) -1, 3, 5-triazine, 2- (2, 4-dihydroxyphenyl) -4, 6-diphenyl-1, 3, 5-triazine, 4 '- (1,3, 5-triazine-2, 4, 6-triyltrimethylamino) tribenzoic acid tris (2-ethylhexyl ester), 2- (2-hydroxy-4-methoxyphenyl) -4, 6-diphenyl-1, 3, 5-triazine, N' -tri-m-tolyl-1, 3, 5-triazine-2, 4, 6-triamine, 2,4, 6-tris (4-butoxy-2-hydroxyphenyl) -1, 3, 5-triazine, 2- (4, 6-diphenyl-1, 3, 5-triazin-2-yl) -5- [ 2- (2-ethylhexanoyloxy) ethoxy ] phenol, and the like.

In addition, a reactive ultraviolet absorber in which an acryloyl group or a methacryloyl group is introduced into a benzotriazole skeleton, or the like can be used. Alternatively, in the case where high transparency is not required, an inorganic ultraviolet absorber may be added. As the inorganic ultraviolet absorber, titanium oxide, cerium oxide, iron oxide, etc. having a particle size of 0.2 μm or less can also be used.

The content of the ultraviolet absorber may be determined appropriately according to the ultraviolet absorbing ability of the ultraviolet absorber used.

For example, when a triazine-based ultraviolet absorber is contained as the ultraviolet absorber in the transparent resin layer, the content of the triazine-based ultraviolet absorber in the transparent resin layer is preferably 1 mass% to 10 mass%.

When the content of the transparent resin layer is less than 1% by mass, weather resistance may not be sufficiently imparted, and when the content of the transparent resin layer exceeds 10% by mass, the transparency of the film may be impaired, and the design property may be lowered when a decorative sheet is produced, or the adhesion between the transparent resin film of the present invention and a pattern layer described later may not be sufficiently obtained, and the processability of the transparent resin film of the present invention may be lowered.

A more preferable lower limit of the content of the ultraviolet absorber is 2 mass%, and a more preferable upper limit is 7 mass%.

Since the transparent resin film of the present invention can be extremely excellent in weather resistance, it is preferable that the surface protective layer and/or the transparent resin layer contain the ultraviolet absorber.

In addition, in the conventional transparent resin film, when the layer having the uneven shape contains the ultraviolet absorber, there are portions where the amount of the ultraviolet absorber is small due to the difference in thickness, and therefore there are portions where sufficient weather resistance cannot be obtained, but in the transparent resin film of the present invention, the recessed portions of the uneven shape have a predetermined thickness as described above, and the recessed portions of the uneven shape also contain the ultraviolet absorber sufficiently, and therefore high weather resistance can be obtained.

In the case where the undercoat layer is provided between the transparent resin layer and the surface protective layer, the undercoat layer may contain an ultraviolet absorber.

As shown in fig. 2, the transparent resin film of the present invention preferably has an adhesion primer layer 13 on the surface of the transparent resin layer 12 opposite to the surface protection layer 11 side.

The adhesion primer layer is provided to enhance adhesion to a pattern layer described later.

Preferably, the adhesive primer layer contains a binder resin.

Examples of the binder resin include a urethane resin, an acrylic-urethane copolymer resin, a cellulose resin, a polyester resin, and a vinyl chloride-vinyl acetate copolymer. When the urethane acrylate oligomer is blended in the ionizing radiation curable resin composition for the surface protective layer, a urethane resin is preferable from the viewpoint of adhesiveness to the surface protective layer and efficiency in production.

The thickness of the adhesive primer layer is preferably 0.5 μm to 10 μm. When the thickness is 0.5 μm or more, the adhesion between the transparent resin film of the present invention and a substrate on which a pattern layer described later is laminated can be suitably ensured, and when the thickness is 10 μm or less, the transparent resin film of the present invention becomes too thick, sufficient transparency cannot be obtained, and the design of the decorative sheet can be suitably ensured.

The thickness of the adhesion primer layer is more preferably 0.8 μm or more and 6 μm or less.

The adhesive primer layer may contain inorganic fine particles such as silica.

In the present invention, the transparent resin layer may be subjected to a surface treatment such as a saponification treatment, a glow discharge treatment, a corona discharge treatment, a plasma treatment, an Ultraviolet (UV) treatment, or a flame treatment, within a range not departing from the gist of the present invention.

The transparent resin film of the present invention protects the pattern layer and has a surface having irregularities, and therefore, the decorative sheet having the transparent resin film of the present invention laminated thereon can be provided with excellent design.

Such a decorative sheet having a substrate, a pattern layer, and the transparent resin film of the present invention in this order in the thickness direction is also one embodiment of the present invention.

Next, a preferred example of the decorative sheet of the present invention will be described with reference to fig. 3.

The decorative sheet 20 of the present invention is formed by laminating a pattern layer 24 on one surface of a base material 25 and laminating a transparent resin film 10 of the present invention on the opposite side of the pattern layer 24 from the side having the base material 25.

In addition, the adhesive layer 23 is preferably provided from the viewpoint of making the adhesion between the pattern layer 24 and the transparent resin film 10 of the present invention stronger.

The following describes the respective configurations of the decorative sheet of the present invention.

The substrate is not particularly limited, and may be appropriately determined according to the use of the decorative sheet obtained by using the transparent resin film of the present invention.

The material constituting the base material is not particularly limited, and examples thereof include known materials such as resin materials, wood materials, and metal materials. Among them, as a material constituting the base material, a resin material or a wood material having rigidity and lightness is preferable. And may also be a composite thereof.

The resin material preferably contains a thermoplastic resin, for example.

As the thermoplastic resin, preferred are: examples of the thermoplastic resin include monomers and copolymers of a polyvinyl resin such as a polyvinyl chloride resin, a polyvinyl acetate resin, or a polyvinyl alcohol resin, a polyolefin resin such as polyethylene, polypropylene, polystyrene, an ethylene-vinyl acetate copolymer resin (EVA), or an ethylene- (meth) acrylic resin, a polyester resin such as a polyethylene terephthalate resin (PET resin), an acrylic resin, a polycarbonate resin, a polyurethane resin, an acrylonitrile-butadiene-styrene copolymer (ABS resin), or an acrylonitrile-styrene copolymer, or a mixed resin thereof. Among them, polyolefin resins, acrylonitrile-butadiene-styrene copolymers, polyvinyl chloride resins, ionomers, and the like are preferable. The resin material may be foamed.

Examples of the woody material include various raw materials such as fir, cypress, beech, pine, eucalyptus, teak, and horse chest wood. The core material may be any of a flat cut veneer, a wood plywood (including LVL), a particle board, a Medium Density Fiberboard (MDF), a High Density Fiberboard (HDF), a laminated material, and the like, which are made of these raw materials, and a laminated material obtained by laminating them.

Examples of the metal material include iron.

The base material may contain an inorganic compound.

In the case where the base material includes a base material made of a plurality of types of resins, the types of resins forming the base material made of the plurality of types of resins may be the same or different, and the thicknesses of the base materials made of the plurality of types of resins may be the same or different.

In the present invention, the base material may have a hollow structure, or a slit groove or a through hole may be formed in a part of the base material.

The thickness of the substrate is not particularly limited, and is preferably 0.01mm or more, and more preferably 0.1mm or more and 50mm or less, for example.

The substrate includes a substantially plate-shaped substrate other than a flat plate, and also includes a substrate having irregularities or curved surfaces.

The substrate is laminated with a pattern layer on one side.

The pattern layer is a layer for imparting decorativeness to the decorative sheet of the present invention obtained using the transparent resin film of the present invention, and may be, for example, a masking layer (entire surface printing layer) uniformly colored, a pattern layer formed by printing various patterns using ink and a printing machine, or a layer in which a masking layer and a pattern layer are combined (hereinafter referred to as a pattern layer).

By providing the shielding layer, when the base material is colored or uneven in color, the color of the surface can be adjusted by the intended coloring.

Further, by providing the pattern layer, it is possible to impart a pattern such as a wood grain pattern, a stone pattern simulating the surface of a rock such as a marble pattern (for example, a travertine marble pattern), a cloth pattern imitating a cloth pattern or a cloth-like pattern, a tiled pattern, a bricklaying pattern, or a wood chip parquet, a parquet, or the like obtained by combining and maintaining these patterns to the decorative sheet. These patterns can be formed by multicolor printing using ordinary process pigments of yellow, red, blue and black colors, or by multicolor printing of special colors by preparing plates of the respective colors constituting the patterns.

As the ink composition used for the pattern layer, a binder resin may be used in which a colorant such as a pigment or a dye, an extender pigment, a solvent, a stabilizer, a plasticizer, a catalyst, a curing agent, and the like are appropriately mixed. The binder resin is not particularly limited, and examples thereof include a urethane resin, an acrylic resin, a urethane-acrylic copolymer resin, a vinyl chloride/vinyl acetate/acrylic copolymer resin, an acrylic resin, a polyester resin, and a nitrocellulose resin. As the binder resin, any 1 of them may be used alone or 2 or more may be used in combination.

Further, as the colorant, carbon black (ink), inorganic pigments such as iron black, titanium white, antimony white, chrome yellow, titanium yellow, iron oxide red, cadmium red, ultramarine blue, cobalt blue, organic pigments or dyes such as quinacridone red, isoindolinone yellow, phthalocyanine blue, metal pigments composed of scaly foils such as aluminum and brass, and pearl (pearl) pigments composed of scaly foils such as titanium dioxide-coated mica and basic lead carbonate are preferably cited.

The thickness of the pattern layer is not particularly limited, and is, for example, preferably 0.1 μm or more, and more preferably 0.5 μm or more and 600 μm or less. When the thickness of the pattern layer is within the above range, the decorative sheet of the present invention can be provided with excellent design properties and can also be provided with a masking property.

However, when the base material itself has design properties in advance, such as a flat cut veneer, the pattern layer may not be provided.

The thickness of the decorative sheet of the present invention is not particularly limited, and is preferably 0.05mm or more, and more preferably 1mm or more and 50mm or less, for example.

The decorative sheet of the present invention preferably has an adhesive layer between the pattern layer and the transparent resin film of the present invention.

The adhesive layer is provided between the pattern layer and the base sheet of the transparent resin film of the present invention, and the adhesive layer can further enhance the adhesion between the pattern layer and the transparent resin film of the present invention.

Preferably, the adhesive layer contains a binder resin.

As the binder resin contained in the adhesive layer, the binder resin used in the adhesive primer layer is preferably used.

The method of adhering the adhesive layer is not particularly limited, and for example, the adhesive layer can be obtained by a heat-melting method or a heat-laminating method, or by laminating using an aqueous adhesive, a heat-sensitive adhesive, a pressure-sensitive adhesive, a hot-melt adhesive, or the like.

The method for producing the decorative sheet of the present invention includes a method of laminating the base material, the pattern layer, and the transparent resin film by using an adhesive or the like for forming the adhesive layer.

Preferably, the method of manufacturing a decorative sheet includes: forming an adhesive layer on one surface of the transparent resin film on which the pattern layer is laminated; and a step of bonding the transparent resin film to the pattern layer via the adhesive layer.

Such a method for manufacturing the decorative sheet of the present invention is also one embodiment of the present invention.

In the transparent resin film, the uneven shape is formed by embossing or the like when the uneven shape is provided on the surface-protecting layer side, but the uneven shape is slightly provided on the surface (the side on which the pattern layer is laminated) opposite to the surface on which the embossing is performed, following the uneven shape on the surface on which the embossing is performed. In this case, air enters the uneven shape on the side where the pattern layer is laminated, which is formed by the transparent resin film, so that so-called gas-trapping occurs, and the design may be degraded.

In the method for manufacturing a decorative sheet according to the present invention, since the step of forming the adhesive layer on the surface of the transparent resin film on the side where the pattern layer is laminated is included, the adhesive layer can be made to enter the concave portions of the uneven shape on the side where the pattern layer is laminated, the occurrence of the gas biting can be prevented, and the reduction in design can be suppressed.

Examples

The present invention will be described in more detail with reference to examples, but the present invention is not limited to these examples at all.

(example 1)

A transparent polypropylene film (thickness: 60 μm) containing 5 mass% of a triazine-based ultraviolet absorber (product name: ADK STAB LA-46, manufactured by ADEKA CORPORATION) was prepared, and an adhesive primer as a two-pack curable polyurethane resin was applied to one surface of the transparent polypropylene film using isocyanate as a curing agent to obtain an adhesive primer having a thickness of 2 μm.

Then, a transparent polypropylene resin (thickness: 80 μm) containing 5 mass% of a triazine-based ultraviolet absorber (product name: ADK STAB LA-46, manufactured by ADEKA CORPORATION) was melt-extruded on the other surface (surface opposite to the primer for adhesion) of the transparent polypropylene film, and these were laminated by a heat lamination method.

After the surface was corona-treated, a primer layer of a two-pack curable urethane resin containing isocyanate as a curing agent was applied to the surface so as to have a thickness of 2 μm.

The surface of this undercoat layer was coated with urethane (meth) acrylate as an ionizing radiation curable resin containing 5 mass% of a triazine-based ultraviolet absorber (product name: ADK STAB LA-46, manufactured by ADEKA CORPORATION) by a gravure coating method to a thickness of 15 μm, and then irradiated with electron beams under conditions of an accelerating voltage of 165keV and 5Mrad to form a surface protective layer.

The surface-protecting layer side was heated by an infrared non-contact heater, and immediately thereafter, embossing was performed by hot pressing to impart an uneven shape to the surface-protecting layer side, thereby producing a transparent resin film. The total thickness of the obtained transparent resin layer was 157 μm, and the thickness of the concave and convex recesses was 105 μm.

On the other hand, an HDF (high density fiberboard) (thickness: 3mm) was prepared, and a pattern layer was applied to one surface of the HDF by an ink jet printer to a thickness of 2 μm to prepare a base material.

The transparent resin film obtained was bonded by applying a two-pack curable polyester resin (thickness: 30 μm) containing isocyanate as a curing agent to the side of the primer layer for bonding the transparent resin film obtainedThe decorative sheet was produced by laminating the base layer side and the surface of the substrate having the pattern layer side in contact with each other. Thereafter, 10kg/m of²The pressure of (3) is maintained for 3 days in a normal temperature environment.

(example 2)

A transparent resin film was produced in the same manner as in example 1 except that a transparent polypropylene resin (thickness: 100 μm) containing 5 mass% of a triazine-based ultraviolet absorber (product name: ADK STAB LA-46, manufactured by ADEKA CORPORATION) was melt-extruded on the other surface (surface on the opposite side of the primer layer for adhesion), and these were laminated by a thermal lamination method to control the uneven shape to the content shown in table 1, thereby producing a decorative sheet.

(example 3)

A transparent resin film was produced in the same manner as in example 1 except that a transparent polypropylene resin (thickness: 200 μm) containing 5 mass% of a triazine-based ultraviolet absorber (product name: ADK STAB LA-46, manufactured by ADEKA CORPORATION) was melt-extruded on the other surface (surface on the opposite side of the primer layer for adhesion), and these were laminated by a thermal lamination method to control the uneven shape to the content shown in table 1, thereby producing a decorative sheet.

(example 4)

A transparent resin film was produced in the same manner as in example 1 except that a transparent polypropylene film (thickness: 80 μm) containing 5 mass% of a triazine-based ultraviolet absorber (product name: ADK STAB LA-46, manufactured by ADEKA CORPORATION) was used, a transparent polypropylene resin (thickness: 400 μm) containing 5 mass% of a triazine-based ultraviolet absorber (product name: ADK STAB LA-46, manufactured by ADEKA CORPORATION) was melt-extruded, and these were laminated by a heat lamination method to control the uneven shape to the content shown in Table 1, thereby producing a decorative sheet.

(example 5)

A transparent resin film was produced in the same manner as in example 1 except that a transparent polypropylene film (thickness: 60 μm) containing no ultraviolet absorber and a transparent polypropylene resin (thickness: 80 μm) containing 5 mass% of a triazine-based ultraviolet absorber (product name: ADK STAB LA-46, manufactured by ADEKA CORPORATION) were used, and the uneven shape was controlled to the content shown in Table 1, thereby producing a decorative sheet.

(example 6)

A transparent resin film was produced in the same manner as in example 1 except that the ultraviolet absorber contained in the transparent polypropylene film (thickness: 60 μm) and the transparent polypropylene resin (thickness: 80 μm) was changed to a benzotriazole-based ultraviolet absorber (product name: ADK STAB LA-36, manufactured by ADEKA CORPORATION), and a decorative sheet was further produced.

Comparative example 1

A transparent resin film was produced in the same manner as in example 1 except that a transparent polypropylene film (thickness: 60 μm) containing 5 mass% of a triazine-based ultraviolet absorber (product name: ADK STAB LA-46, manufactured by ADEKA CORPORATION) and a transparent polypropylene resin (thickness: 60 μm) containing 5 mass% of a triazine-based ultraviolet absorber (product name: ADK STAB LA-46, manufactured by ADEKA CORPORATION) were used, and the uneven shape was changed so that the uneven shape of the concave and convex portions of the transparent resin film became 90 μm, thereby producing a decorative sheet.

(evaluation method)

< design of appearance >

The decorative sheets obtained in examples and comparative examples were evaluated by visual inspection of the printed patterns according to the following criteria. The results are shown in table 1.

+++: the printed pattern is clearly visible

++: the printed pattern looks slightly blurred

+: the printed pattern appeared to be slightly yellowed

-: the printed pattern looks unclear

Color difference after weather resistance test

The decorative sheets obtained in examples and comparative examples were placed in an ultra accelerated weathering Tester (EYE Super UV Tester, manufactured by Kawasaki electric Co., Ltd.) set under the following conditions, irradiated for 20 hours and condensed for 4 hours for 1 cycle, and taken out after 17 cycles.

(accelerated test conditions)

Blackboard temperature: 63 deg.C

Humidity: 50% RH

Irradiation intensity: 60W/m²(365nm)

Then, the color difference conversion of the decorative sheet before and after the accelerated test was measured by a color difference meter (Minolta co., ltd., CR-300). That is, the L value, a value, and b value of the decorative sheet before and after the promotion test are measured, and the color difference change Δ E is calculated by the following equation 1, and evaluated according to the following criteria. The results are shown in table 1.

ΔE＝[(ΔL)²+(Δa)²+(Δb)²]^1/2Formula 1

++：ΔE＜1.0

+：1.0≤ΔE＜1.5

－：ΔE≥1.5

(Δ L) ═ L value (after weathering test) -L value (before weathering test) & gt

Δ a ═ a value (after weathering test) -a value (before weathering test) & gt

Δ b ═ a value (after weathering test) -a value (before weathering test) & gt

< abrasion resistance (テーバー abrasion test) >

For the decorative sheets obtained in examples and comparative examples, the decorative sheets were produced according to the japanese agro-forestry standards for flooring: the abrasion A test was carried out by using a Taber abrasion tester (manufactured by Kikugaku Kogyo Co., Ltd.) to abrade paper (S-42) under a load of 1kg, and the pattern left by the patterned layer was evaluated at 1500 times of rotation. The results are shown in table 1.

+++: leaving the pattern layer completely

++: leaving more than 8 patterned layers

+: more than half of the pattern layer is left and less than 8

-: less than half of the pattern layer is left

[ Table 1]

Industrial applicability

According to the present invention, a transparent resin film which imparts excellent appearance design and weather resistance to a decorative sheet can be provided. The decorative sheet of the present invention has excellent design properties and also excellent weather resistance, and is therefore suitable for use as a building material for interior decoration, such as a door, a floor material, a wall, a patio, and various decorative molded articles.

Description of the symbols

10: a transparent resin film; 11: a surface protection layer; 12: a transparent resin layer; 13: a primer layer for adhesion; 20: a decorative plate; 23: an adhesive layer; 24: a pattern layer; 25: a substrate.