JPS6044140B2 - Method for manufacturing decorative sheets - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a synthetic resin foam laminate for decorative and cushioning purposes.

The present invention can be used for interior materials of automobiles and cases, interior decoration materials such as wall materials and furniture, cushion materials, surface decoration materials such as albums, decoration materials for bags and bags, etc.
The present invention provides an aesthetically and substantially useful material that has excellent three-dimensional effect, surface strength, and texture. Traditionally, materials used for this type of use include fabric, PVC leather, and synthetic leather, but these are just surface materials, and when making cushioning materials, these materials are sewn into bags. death,
A method such as inserting cotton, polyurethane foam, etc. into this as a cushion member is used.

Furthermore, PVC leather used as a vehicle interior material is often not pasted directly, but overlaid with polyurethane foam or the like. The disadvantages of these materials are that it takes a long time to sew and is difficult to work with, and when materials such as leather alone require decorative uneven patterns on the surface, it is necessary to use new materials such as button diaphragms. In addition, products such as leather that combine raw cloth and a resin layer are layered with polyurethane foam as cushioning material, which ultimately increases the cost. With the aim of developing a skinned polyurethane foam laminate, the present inventors initially investigated a method of transferring a polyurethane film layer on a releasable support provided with a crest pattern to a polyurethane foam.

However, this method of printing crests had the disadvantage that the types of diaphragms were limited and it was difficult to express originality. In addition, in this polyurethane foam laminate with a skin, a plastic film is formed directly on the polyurethane foam layer, so when this laminate is adhered to a wall or album as a decorative material, the solvent contained in the adhesive will be removed from the polyurethane foam layer. It directly affects the plastic and, in severe cases, may cause the plastic film to swell and dissolve, causing problems in appearance and practical use. Furthermore, there was a strong demand for the development of decorative sheets that could be embossed using an embossing device. In view of the above, the present inventors have carried out extensive research in order to obtain a decorative sheet that provides a stable concavo-convex drawing pattern using a heating embossing device and is less susceptible to the effects of adhesives, and has developed a film layer made of a specific synthetic resin. The present inventors have discovered that this object can be achieved by using the following.

That is, in the method for producing a decorative sheet of the present invention, the polyurethane foam layer is made of polyurethane having a softening point of 60'C or higher,
Polyurethane film layer is 100%, modulus is 30-25
0k91cr1 and a polyurethane having a softening point higher than that of the polyurethane foam layer, the synthetic resin crosslinked foam has a thickness of 0.5 to 100 Tnm, and has a melting point or decomposition point higher than the softening point of the polyurethane foam layer. A composite sheet is formed from a synthetic resin having a polyurethane adhesive layer, a polyurethane foam layer, and a polyurethane film layer are laminated and integrated on the surface of a crosslinked synthetic resin foam in order. The composite sheet is heated and pressed to compress the polyurethane film layer and the polyurethane foam layer. The method is characterized in that the synthetic resin crosslinked foam is fixed, and the heat and pressure is released to restore the synthetic resin crosslinked foam to the state before the heat and pressure was applied. The present invention will be explained in detail below.

The crosslinked synthetic resin foam used in the present invention needs to have a melting point or decomposition point higher than the softening point of the polyurethane foam layer.

For example, crosslinked elastomers such as polyurethane, natural goss and styrene-butadiene copolymers, acrylonitrile, butadiene copolymers, neoprene, etc. are used;
Among them, polyurethane foam is common. The polyurethane resin forming the polyurethane film layer and the polyurethane foam layer is a polyether polyol such as polytetramethylene glycol or polypropylene glycol, a polycarbonate polyester, a hydroxyl compound such as ethylene glycol or 1,4-butanediol, and a dibasic acid, such as A polyester obtained by reacting a polyester obtained by reacting with adipic acid or an ε-caprolactone polyester as a polyol component with an isocyanate such as diphenylmethane diisocyanate or tolylene diisocyanate, and a low molecular weight glycol or diamine. or polyester-based polyurethane. In the present invention, the polyurethane film layer has a 100% modulus of 30 to 250k91cT.
i.

If it is less than 30k91cF1f, it is too weak to be used as a practical decorative sheet, and if it exceeds 250k91cIL, the texture becomes too hard, which is not preferable.

The polyurethane film layer is formed of polyurethane whose softening point is higher than that of the polyurethane foam layer, and is generally 100°C or higher, preferably 130°C or higher.
Those having a softening point of ~300°C are suitable. 100
If it is below 300°C, the resin will stick to the mold or the film will break when heated and pressurized, and if it exceeds 300°C, the resin will not stick to the mold when heated and pressurized, but the degree of softening will be small, so the concave and convex drawing pattern will be clear. This is not preferable because it makes it difficult to attach.

The polyurethane foam layer needs to have a softening point of 60°C or higher, preferably 80 to 250°C.

If it is less than 60°C, it is not preferable because the foam layer will be severely softened when heated and pressed, and the foam layer will be destroyed or the resin will adhere to the mold.

On the other hand, if the temperature exceeds 250°C, it is necessary to increase the temperature during heating and pressing, which is unsuitable for economically forming a concavo-convex pattern in a short period of time, which is not preferable. The polyurethane resin forming the polyurethane adhesive layer is a polyether polyol such as polytetramethylene glycol or polypropylene glycol, or a polycarbonate polyester, or a hydroxyl compound such as ethylene glycol, 1.
A polyester obtained by reacting 4-butanediol etc. with a dibasic acid such as adipic acid or an ε-caprolactone polyester is used as the polyol component, and isocyanates such as tolylene diisocyanate and diphenylmethane diisocyanate and low molecular weight glycols are used. Alternatively, it is formed from polyether-based or polyester-based polyurethane obtained by reacting with diamine or the like.

For the polyurethane adhesive layer, either one-component type or two-component type polyurethane resin can be used. By forming a polyurethane adhesive layer, the effect of the solvent contained in the adhesive on the polyurethane film layer when adhering the decorative sheet to a wall, the ceiling of a car, etc. is reduced by forming a polyurethane foam layer on the synthetic resin crosslinked foam. It is significantly reduced in combination with the solvent resistance of

Furthermore, the method of the present invention is superior in surface smoothness compared to the case where a polyurethane foam layer is adhered to a synthetic resin crosslinked foam without using an adhesive. Although the decorative sheet of the present invention can be used for various purposes, it is particularly suitable for use as an interior material for automobiles and cases, an interior decoration material for walls and furniture, and a surface decoration material for albums, etc. A decorative sheet with a stable concavo-convex pattern can be easily obtained. Furthermore, a synthetic resin layer such as amino acid, nylon, or acrylic resin may be further provided on the polyurethane film layer within a range that does not impair heat-embossability. Examples of the present invention will be shown below based on the drawings, but the present invention is not limited to these examples.

Example 1 As shown in Fig. 1, a polyester-based polyurethane resin solution was applied to a flat silicone vapor surface 1 to a dry thickness of 20μ, and this was dried by heating to form a polyurethane film layer 2. I forced it.

This layer coating had a 100% modulus of 90k91cr1 and a softening point of 160 layer C. On this polyurethane film layer 2, a foamable urethane elastomer compound mainly composed of a polypropylene glycol-based isocyanate-terminated polyurethane prepolymer is applied at a basis weight of 170y1d,
This was heated in a heating machine at a temperature of 110°C for 3 minutes under humidification to foam and harden it, resulting in a thickness of 400μ and a density of 0.47y1cIL.
A polyurethane foam layer 3 having a softening point of 140°C was obtained. Next, a glycol di-liquid type polyurethane adhesive 4 was applied on the polyurethane foam layer at a basis weight of 100yI, and then the density was 20k917TI1, the softening point was 205°C, and the thickness was 3? After bonding the flexible polyurethane foam (synthetic resin crosslinked foam) 5 together and heating it at 100'C for 8 minutes to reaction cure the adhesive 4, the silicone vapor 1 was peeled off to obtain a composite sheet for embossing. .

This composite sheet is placed in a heated embossing machine and heat-embossed with a diamond pattern design mold to clearly reveal the diamond pattern concavo-convex pattern, suitable for album surface decoration material as shown in Figure 2. A decorative sheet was obtained. Example 2 As shown in Fig. 1, a polytetramethylene glycol polyurethane resin solution was applied to the surface 1 of the squeezed silicone vapor to a dry thickness of 15 mm.
The polyurethane film layer 2 was formed by applying the film to a thickness of μ and drying it by heating.

The coating of this layer has a 100% modulus of 100k91cI.
It had a t1 softening point of 180°C. On this polyurethane film layer 2, a foamable urethane elastomer compound mainly composed of ε-caprolactone polyester-based isocyanate-terminated polyurethane prepolymer is applied in a basis weight of 160qIrd.
, and heated this in a heating machine at a temperature of 120°C for 4 minutes under humidification to foam and harden it, resulting in a thickness of 350μ and a density of 0.
．． A polyurethane foam layer 3 having a softening point of 55fIcr1 of 125°C was obtained. Next, a polyester-based two-component polyurethane adhesive 4 is applied on the polyurethane foam layer 3 at a basis weight of 110 fI, and then a chloroprene foam (synthetic resin crosslinked foam) 5 with a density of 100 kg 1 d 1 and a thickness of 5 gourds is laminated at 80°C. After the adhesive 4 was reacted and cured by heating, the silicone vapor 1 was peeled off to obtain a composite sheet for embossing.

This composite sheet was placed in a heating embossing machine and heated and pressed with a striped design mold to obtain a decorative sheet suitable for wall materials as shown in FIG. 2 having a clear concavo-convex drawing pattern. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a sectional view showing one embodiment of the decorative sheet of the present invention, and FIG. 2 is a sectional view showing an embodiment in which a concave-convex pattern is applied to a synthetic resin laminate.

DESCRIPTION OF SYMBOLS 1...Silicone vapor, 2...Polyurethane film) layer, 3...Polyurethane foam layer, 4...Polyurethane adhesive layer, 5...Synthetic resin crosslinked foam.

Claims (1)

[Claims] 1 The polyurethane foam layer is made of polyurethane with a softening point of 60°C or higher, and the polyurethane film layer is made of polyurethane with a 100% modulus of 30 to 250 kg/cm^2 and a higher softening point than the polyurethane foam layer, and is made of synthetic resin crosslinked foam. The body is made of a synthetic resin having a melting point or decomposition point higher than the softening point of the polyurethane foam layer, and has a thickness of 0.5 to 100 mm, and a polyurethane adhesive layer is sequentially applied to the surface of the synthetic resin crosslinked foam. A composite sheet in which a polyurethane foam layer and a polyurethane film layer are laminated and integrated is heated and pressurized to compress and fix the polyurethane film layer and polyurethane foam layer, and the heating and pressure is released to substantially heat the synthetic resin crosslinked foam. A method for producing a decorative sheet, characterized by restoring it to its state before pressurization.