JPH11254631A - Embossed decorative sheet and manufacture thereof - Google Patents

Abstract

(57) Abstract: An embossed decorative sheet and a method for producing the embossed decorative sheet, wherein the decorative sheet is an olefin-based resin sheet and has a lower surface hardness than a vinyl chloride resin sheet and is more easily scratched. Had the drawback. A printed pattern layer is provided on one side of a base sheet, and a protective sheet is provided on the printed pattern layer. The protective sheet is formed by extruding a molten polyethylene terephthalate resin or an eval resin, or by using an olefin resin. Polyethylene terephthalate resin or Eval resin coextruded, laminated and subjected to cold-pressure embossing.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an embossed embossed decorative sheet and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, decorative sheets have been used as decorative boards by bonding them to the surfaces of wooden boards, inorganic boards, metal plates and the like with an adhesive. As the decorative sheet, a vinyl chloride resin sheet is often used, and a 70-120 μm-thick colored vinyl chloride sheet on which an arbitrary pattern is printed and a 70-120 μm-thick protective sheet for protecting the printed pattern. By passing a 120 μm transparent vinyl chloride sheet between a heated embossing roll having an embossed pattern and a pressure roll attached to the embossing roll, lamination and embossing are simultaneously performed to prepare an embossed decorative sheet. I was However, it is said that the vinyl chloride resin generates hydrogen chloride gas during incineration and causes acid rain and dioxin. In recent years, a decorative sheet not using the vinyl chloride resin has been demanded from the viewpoint of environmental problems. In addition, embossing is applied by a heated embossing roll (hereinafter, referred to as a hot-press embossing treatment). After that, the embossing is applied during natural cooling or slow cooling. It returned to about 70% of the embossed version, and lacked sharpness.

For this reason, the present inventors have previously used an olefin resin as a protective sheet as a resin instead of a vinyl chloride resin, and extruded a molten olefin resin onto a cooling embossing roll having an embossed pattern. A method of embossing with a colored base material coated with a picture and embossing (the embossing with a cooling embossing roll is hereinafter referred to as a cold-pressure embossing process) has been proposed. As a result, a product having no emphasis on the environment and having good emboss reproducibility can be obtained.

However, in this method, the protective sheet of the decorative sheet is an olefin-based resin sheet, and has a drawback that the surface hardness is lower than that of the vinyl chloride resin sheet and the surface is easily damaged. For this reason, it was necessary to further apply a top coat layer to the olefin resin sheet by coating. This has the problem that the number of steps is increased by one, and that even if a top coat layer is applied, the scratch resistance is insufficient.

[0005]

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and an object thereof is to provide an embossed decorative sheet using a new resin sheet as a protective sheet, Another object of the present invention is to provide an embossed decorative sheet using a co-extruded sheet of an olefin resin sheet and this new resin sheet, and a method for producing the embossed decorative sheet.

[0006]

In order to solve the above problems, first, in claim 1, a base sheet, a print pattern layer provided on one surface of the base sheet, and a print pattern layer provided on the print pattern layer are provided. Wherein the protective sheet is an extruded sheet made of polyethylene terephthalate resin or ethylene vinyl alcohol resin, and the protective sheet is embossed. This is a decorative sheet.

According to a second aspect of the present invention, a printed pattern layer is provided on one side of the base sheet, and a molten polyethylene terephthalate resin or ethylene vinyl alcohol resin is extruded onto the printed pattern layer to form a sheet, laminated, and cooled. A method for producing an embossed decorative sheet, characterized in that the laminated sheet is provided with an embossed protective sheet.

According to a third aspect of the present invention, there is provided a laminated sheet comprising a base sheet, a printed pattern layer provided on one side of the base sheet, and a protective sheet provided on the printed pattern layer. The sheet is a co-extruded two-layer sheet of an olefin resin sheet and a polyethylene terephthalate resin or ethylene vinyl alcohol resin sheet provided with an olefin resin sheet on the printing pattern layer side, and the two-layer sheet is embossed. The embossed decorative sheet is characterized in that:

[0009] Further, in claim 4, a printed pattern layer is provided on one side of the base sheet, and an olefin resin is provided on the printed pattern layer side on the printed pattern layer. Alternatively, the present invention provides a method for producing an embossed decorative sheet, comprising coextruding an ethylene vinyl alcohol resin into a two-layer sheet, laminating the sheets, and performing a cold-pressure embossing treatment to form a laminated sheet provided with a protective sheet.

In the present invention, a sheet made of polyethylene terephthalate or ethylene vinyl alcohol resin, which is harder than an olefin resin sheet and has a hardness equivalent to a vinyl chloride resin sheet, is used on the outermost surface of the protective sheet. Further, the resin was melt-extruded to form a sheet, and at the same time, the printing sheet was subjected to lamination and cold-pressure embossing, thereby improving emboss reproducibility.

Hereinafter, the present invention will be described in detail with reference to the drawings. FIG. 1 is a cross-sectional view of an embossed decorative sheet 1 according to claim 1 of the present invention. The printed pattern layer 3 is provided on one surface of a base sheet 2 to form a printed sheet 4. A protective sheet 7 of polyethylene terephthalate 6 or ethylene vinyl alcohol resin 6 is provided by melt extrusion, and the protective sheet 7 is a laminated sheet provided with an emboss 8. FIG. 2 is a sectional view of the embossed decorative sheet 1 according to claim 3, wherein the protective sheet 7 in FIG. 1 is composed of an olefin resin 5 and a polyethylene terephthalate 6 or an ethylene vinyl alcohol resin 6.
And a co-extruded two-layer sheet. FIG. 3 shows an example of a method for producing the embossed decorative sheet 1,
The embossing roll 10 having the embossed pattern is cooled, and the pressing roll 9 is provided along with the embossing roll 10. An appropriate gap is provided between the embossing roll 10 and the pressing roll 9. In this gap, the molten resin is extruded from the extrusion head from one side (in the case of a two-layer sheet, the polyethylene terephthalate or ethylene vinyl alcohol resin fused with the olefin resin is extruded), and from the other side, the printed sheet is separately formed. 4 is fed out and merged with the molten resin, and the extruded molten resin is cooled and solidified to be formed into a sheet and embossed at the same time. The embossed sheet moves along the outer periphery of the embossing roll 10 and is peeled off by the peeling roll to obtain the embossed decorative sheet 1. Since the emboss 8 is forcibly cooled, the shape of the emboss 8 is maintained, and the emboss 8 is less likely to collapse.

[0012]

Embodiments of the present invention will be described below. The substrate sheet is not particularly limited as long as it does not generate chlorine gas or hydrogen chloride gas during combustion, and is specifically paper or a polyolefin-based sheet.

The printing pattern layer is provided on the base sheet by a usual printing method such as gravure printing.

The protection sheet is a single-layer or two-layer sheet. When used in a single layer, it is a sheet made of polyethylene terephthalate resin or ethylene vinyl alcohol resin, and this resin is not particularly limited.
A decorative sheet using this single-layered protective sheet is inexpensive, and is preferably used for applications that do not require bending and that can be applied to flat surface application. The two-layer sheet is a co-extruded sheet of an olefin resin sheet and a sheet made of a polyethylene terephthalate resin or an ethylene vinyl alcohol resin. The olefin resin is not particularly limited as long as it is a resin capable of obtaining the same or higher physical properties as the decorative sheet using the conventional vinyl chloride resin, but among the olefin resins, a composition mainly composed of a polypropylene resin is preferable. I understood. Furthermore, when heat resistance, impact resistance, low temperature processability, and the like are required for the obtained sheet, a homopolymer, a random copolymer, a block copolymer, or the like may be arbitrarily selected for the polypropylene used according to the requirement.
The decorative sheet using a two-layer sheet as this protective sheet is suitable for low-temperature bending and V-cut processing applications.
A product without cracking and whitening is obtained. The thickness of the polyethylene terephthalate resin or ethylene vinyl alcohol resin sheet is preferably about 5 to 15 μm, and the thickness of the olefin resin layer as the stress relaxation layer during bending is preferably about 50 to 80 μm. Since the outermost layer of the embossed decorative sheet is not an olefin-based resin sheet, there is no need to apply a top coat for surface protection as in the conventional case, so it has become possible to eliminate steps such as corona treatment and top coat step.

Further, an antioxidant may be appropriately added for extruding the sheet and for preventing thermal oxidation of the obtained product, and a light stabilizer for preventing deterioration due to ultraviolet rays. The type and amount of these additives are not particularly limited, but a combination of those generally used for olefin-based resins is sufficient.

[0016] If necessary, an anchor coat layer may be provided on the printed pattern layer to improve the adhesiveness with the protective sheet. Specifically, it is a urethane resin paint,
Provided by printing and coating means.

[0017]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the drawings. <Embodiment 1> This will be described with reference to FIGS. Base sheet 2
The printing sheet 4 was prepared by printing a wood pattern as a printing pattern layer 3 by a gravure printing method using a urethane-based ink using a polyethylene resin sheet. On the print pattern layer 3 of the print sheet 4, a urethane-based anchor coat agent was applied by about 1 μm by a gravure printing method to provide an anchor coat layer (not shown). As shown in FIG. 3, the print sheet 4 having the anchor coat layer was passed between a pressure roll 9 and an emboss roll 10. Meanwhile, the protective sheet 7
15% by weight of hydrogenated styrene and butadiene rubber as a thermoplastic elastomer in a random polymerization type polypropylene, 0.2% by weight of a phenolic antioxidant, and 0.3% of a hindered amine light stabilizer. Embossing roll having a tubular embossed pattern from an extruder head (T-die) 11 using a polyethylene terephthalate resin 6 and a polyethylene terephthalate resin 6. 10 (cooled by circulating water) and pressure roll 9
(The printing sheet 4 is passed through the pressure roll 9 side) and the molten resin was co-extruded. In this way, the extruded resin is formed into a sheet and laminated with the printing sheet 4 to form a laminated sheet. At the same time, the embossing 8 is applied to the protective sheet 7, and the embossed decorative sheet 1 having the embossing 8 and a total thickness of 180 μm is formed. Created.

<Embodiment 2> A description will be given with reference to FIGS.
Using a polyethylene resin sheet as the base sheet 2 and a wood pattern as a print pattern layer 3 by gravure printing using a urethane-based ink, a print sheet 4 was prepared. On the printed pattern 3 of the printed sheet 4, a urethane-based anchor coating agent was applied by about 1 μm by a gravure printing method to provide an anchor coat layer (not shown). As shown in FIG. 3, the print sheet 4 having the anchor coat layer was passed between a pressure roll 9 and an emboss roll 10. on the other hand,
Polyethylene terephthalate resin 6 as protective sheet 7
Extruder head using 0.2% by weight of phenolic antioxidant, 0.3% by weight of hindered amine light stabilizer and 0.5% by weight of benzotriazole ultraviolet absorber (T die) 11 melts between the embossing roll 10 (cooled by circulating water) having a tubular embossing pattern and the pressing roll 9 (the printing sheet 4 is passed through the pressing roll 9 side). The resin was extruded. In this way, the extruded resin is formed into a sheet, and is laminated with the print sheet 4 to form a laminated sheet, and at the same time, the protective sheet 7 is embossed 8 with a total thickness of 150.
A μm embossed decorative sheet 1 was prepared.

<Comparative Example 1> A print sheet was prepared by printing a wood pattern as a print pattern layer by a gravure printing method using a urethane-based ink using a polyethylene resin sheet as a base sheet. On the printed pattern layer of the printed sheet, a urethane-based anchor coating agent is applied for about 1 by a gravure printing method.
μm was applied to form an anchor coat layer. The printing sheet having the anchor coat layer was passed between a pressure roll and an emboss roll. On the other hand, as a protective sheet, a polypropylene resin (styrene which is hydrogenated as a thermoplastic elastomer to polypropylene of random polymerization type,
15% by weight of butadiene rubber, 0.2% by weight of phenolic antioxidant, 0.3% of hindered amine light stabilizer
Embossing roll (cooled by circulating water) having a tubular embossed pattern from an extruder head (T-die) using an extruder head (T die). The molten resin was extruded between a pressure roll (a printing sheet is passed through the pressure roll side). In this way, the extruded resin was formed into a sheet, laminated with a print sheet to form a laminated sheet, and at the same time, the protective sheet was embossed to prepare an embossed embossed sheet.
Next, a corona treatment was applied to the polypropylene resin sheet as a protective sheet of the embossed decorative sheet, and the surface was treated with a corona.
After adjusting the thickness to dyn / cm, a urethane top coat resin was applied by about 9 μm by a gravure method to obtain an embossed decorative sheet having a 180 μm total thickness top coat layer.

<Comparative Example 2> A wood pattern was printed as a print pattern layer on a colored vinyl chloride resin sheet as a substrate sheet by using a vinegar-based vinyl chloride ink by a gravure method to prepare a printed sheet. An embossed decorative sheet having an emboss was formed on the printed pattern layer of the printed base sheet by heating a transparent vinyl chloride sheet and embossing simultaneously with lamination (doubling embossing method). At this time, embossing was performed at the same time as lamination by heat to obtain an embossed sheet. Thus, the thickness 18
A 0 μm embossed decorative sheet was prepared.

<Physical Properties Test> Physical properties tests were performed on the embossed decorative sheets prepared in Examples 1 and 2 and Comparative Examples 1 and 2. Physical property test items include emboss reproducibility test (measure the emboss depth with a surface roughness meter and evaluate how much the emboss plate depth is reproduced) and V-cut suitability test (base material of embossed decorative sheet) After applying a urethane-based primer to the sheet side at about 1 μm, the urethane-based primer is bonded to a wooden base material using a vinyl acetate-based aqueous emulsion adhesive, subjected to V-cut processing, and bent at 90 ° C. in an environment of 20 ° C. and 0 ° C. Observation of the degree of whitening at the edges) and pencil hardness test (JIS K5)
400 (measured surface hardness). Table 1 shows the results.
Shown in (The cost comparison is also described.)

[0022]

[Table 1]

As is clear from Table 1, the embossed decorative sheet 1 produced according to the present invention had good reproducibility of the embossed applied and the surface hardness was equivalent to that of the vinyl chloride decorative sheet. Further, the decorative board using the embossed decorative sheet prepared in Example 1 has V-cut processing suitability, which indicates that it is suitable for applications including bending. The embossed decorative sheet of Example 2 is inexpensive and may be used for applications that do not require V-cutting or bending. In Comparative Example 1, since the olefin resin was used, the reproducibility of embossing was excellent, but the surface protective layer was a top coat resin layer, and the surface hardness was lower than that of a vinyl chloride decorative sheet. The decorative vinyl chloride sheet in Comparative Example 2 has a problem in emboss reproduction ratio.

[0024]

Since the present invention has the above-described configuration,
There are the following effects. That is, according to claim 1,
A surface hardness equivalent to that of a vinyl chloride resin is obtained, and an inexpensive embossed decorative sheet is obtained. According to the second aspect, the method for producing an embossed decorative sheet according to the first aspect is excellent in emboss reproducibility since it is a cold pressure embossing method. According to the third aspect, the same surface hardness as that of the vinyl chloride resin is obtained, the emboss reproducibility is good, and it is suitable for use in bending and V-cut processing. According to a fourth aspect of the present invention, there is provided the method for producing an embossed decorative sheet according to the third aspect. Therefore, it exhibits an excellent practical effect as an embossed decorative sheet for a decorative plate.

[Detailed description of drawings]

FIG. 1 is a sectional view of an embossed decorative sheet of Example 2 according to the present invention.

FIG. 2 is a cross-sectional view of the embossed decorative sheet of Example 1 according to the present invention.

FIG. 3 is a schematic view showing one embodiment of a method for manufacturing a decorative sheet according to the present invention.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Embossed decorative sheet 2 ... Base sheet 3 ... Print pattern layer 4 ... Printed sheet 5 ... Olefin resin 6 ... Polyethylene terephthalate resin or ethylene vinyl alcohol resin 7 ... Protective sheet 8 ... Embossed 9 ... Pressure roll 10 ... Embossed roll (Cooling) 11 ... Extrusion head

 ──────────────────────────────────────────────────続 き Continuation of the front page (72) Inventor Masahiro Yamazoe 1-5-1, Taito, Taito-ku, Tokyo Letterpress Printing Co., Ltd.

Claims (4)

[Claims] 1. A laminated sheet comprising a base sheet, a printed pattern layer provided on one side of the base sheet, and a protective sheet provided on the printed pattern layer, wherein the protective sheet is a polyethylene terephthalate resin. Alternatively, an embossed decorative sheet is an extruded sheet made of an ethylene vinyl alcohol resin, and the protective sheet is embossed. 2. A printed pattern layer is provided on one side of a substrate sheet, and a molten polyethylene terephthalate resin or ethylene vinyl alcohol resin is extruded on the printed pattern layer to form a sheet, laminated, and subjected to a cold press embossing treatment. A method for producing an embossed decorative sheet, comprising a laminated sheet provided with a protective sheet. 3. A laminated sheet comprising a base sheet, a printed pattern layer provided on one side of the base sheet, and a protective sheet provided on the printed pattern layer, wherein the protective sheet is an olefin resin. The sheet is a co-extruded two-layer sheet of an olefin resin sheet and a polyethylene terephthalate resin or ethylene vinyl alcohol resin sheet provided on the printing pattern layer side, and the two-layer sheet is embossed. Embossed decorative sheet. 4. A printed pattern layer is provided on one side of a substrate sheet, and an olefin resin is provided on the printed pattern layer side on a printed pattern layer side with a molten olefin resin and a polyethylene terephthalate resin or an ethylene vinyl alcohol resin. A co-extruded two-layer sheet and laminating the same, and applying a cold-pressure embossing treatment to obtain a laminated sheet provided with a protective sheet.