Stock material or miscellaneous articles – Structurally defined web or sheet – Continuous and nonuniform or irregular surface on layer or...
Reexamination Certificate
1998-04-23
2001-02-06
Thibodeau, Paul (Department: 1773)
Stock material or miscellaneous articles
Structurally defined web or sheet
Continuous and nonuniform or irregular surface on layer or...
C428S142000, C428S195100, C428S321300, C428S480000, C428S483000, C428S518000, C428S520000, C428S913300, C428S914000
Reexamination Certificate
active
06183842
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a decorative laminated sheet, particularly to a decorative laminated sheet having excellent moldability, a low temperature impact resistance, surface smoothness, colorless transparency and other various properties; the decorative laminated sheet resists becoming cloudy or opaque when embossing or heat sealing. The decorative laminated sheet of the present invention is particularly suitable for vacuum press molding, pneumatic press molding and membrane press molding.
2. Description of the Related Art
Conventionally, decorative laminated sheets have been widely used or laminated on metallic or wooden materials such as furniture, cabinets, fittings, desks and cupboards. The decorative laminated sheets have been laminated and sealed tightly on adherends having complex contours by the membrane press molding.
For example, Japanese Patent Publication No. 7-39170 discloses a decorative laminated sheet composed of a substrate layer of a polyvinyl chloride sheet and a transfer film laminated thereon using a laminating method of so-called doubling embossing. According to Japanese Patent Publication No. 7-39170, a decorative laminated sheet having stain resistance, scratch resistance and high gloss is provided.
Japanese Patent Laid-Open No. 7-24979 discloses a decorative laminated sheet composed of an opaque polyolefin type resin film and an amorphous polyethylene terephthalate resin film. The amorphous film used for the sheet described in Japanese Patent Laid-Open NO. 7-24979 is partially crystalline. According to Japanese Patent Laid-Open NO. 7-24979 a decorative laminated sheet having excellent moldability, transparency, weather resistance, stain resistance or the like can be obtained.
However, when the above-mentioned decorative laminated sheets are molded by membrane press molding, vacuum press molding, or pneumatic press molding, the sheet may become cloudy or opaque when embossing or heat sealing.
When membrane press molding, a thermoplastic decorative sheet, which is colored or surface-printed with a desired color and a desired thickness, is heated to approximately the softening point thereof, placed on an adherend having a complex contour such as a door of a kitchen unit, covered with, for example, a rubber sheet and then air or liquid pressure is applied to stick the decorative sheet to the contour. Vacuum press molding and pneumatic press molding are based on a same principle of the membrane press molding. The former is a molding method with a vacuum pressure using no membrane rubber, and the latter is a molding method utilizing an air pressure.
The decorative laminated sheet is generally manufactured by a calendar roll method. During the manufacture, irregularities, so-called bank marks, are partially produced caused by a nonuniform flow of a peculiarity of the resin on a calendar sheet. The irregularities do not cause adverse affects on a practical use, however, they affect the smoothness of the surface, resulting in a damaged appearance. In addition, if the line speed is increased when doubling embossing, the bank mark becomes more prominent, thereby reducing productivity.
Moreover, the decorative laminated sheet tends to crack easily at a low temperature. The sheet can crack when handling it in winter.
Furthermore, the sheet composed of the substrate layer of polyvinyl chloride disclosed in the Japanese Patent Publication No. 7-39170 is colored at an early stage, and, due to thermal degradation, is not an especially excellent transparency.
An object of the present invention is to provide a decorative laminated sheet having excellent moldability, a low temperature impact resistance, surface smoothness, colorless transparency and other various properties; the decorative laminated sheet resists becoming cloudy or opaque when embossing or heat sealing, and is particularly suitable for vacuum press molding, pneumatic press molding and membrane press molding.
SUMMARY OF THE INVENTION
Through intense studies of the present inventors, the above-mentioned problems are solved.
The present invention provides a decorative laminated sheet sequentially comprising:
(A) a completely amorphous polyester type resin layer, and
(B) a substrate layer composed of a material selected from the group consisting of a polyolefin type resin, a polyvinyl chloride type resin, an acrylonitrile-butadiene-styrene type resin, an acrylonitrile-styrene-crylic acid ester type resin, an acrylonitrile-ethylene propylene-styrene type resin, a methyl methacrylate-butadiene-styrene type resin, a polyethylene terephthalate and a completely amorphous polyester type resin.
According to the decorative laminated sheet of the present invention, the (A) completely amorphous polyester type resin layer is composed of two or more of diol components.
According to the decorative laminated sheet of the present invention, a transfer foil is formed on the (A) completely amorphous polyester type resin layer.
According to the decorative laminated sheet of the present invention, a transfer foil is formed on the (B) substrate layer composed of a completely amorphous polyester type resin.
According to the decorative laminated sheet of the present invention, the transfer foil is formed on the (B) substrate layer composed of the material of the completely amorphous polyester type resin and the completely amorphous polyester type resin is composed of the two or more of diol components.
According to the present invention, a laminated sheet molded by a membrane press molding is composed of the above-mentioned decorative laminated sheet.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be described below in detail. The (B) substrate layer of the present invention is composed of a material selected from the group consisting of a polyolefin type resin, a polyvinyl chloride type resin, an acrylonitrile-butadiene-styrene type resin, an acrylonitrile-styrene-acrylic acid ester type resin, an acrylonitrile-ethylene propylene-styrene type resin, a methyl methacrylate-butadiene-styrene type resin, a polyethylene terephthalate or a completely amorphous polyester type resin.
Examples of the polyolefin type resin include a polypropylene type resin, a polyethylene type resin, and a copolymer thereof (for example, an ethylene vinyl acetate copolymer). MFR (measurement conditions of polypropylene: JIS K7210, 23° C., 2.16 kgf, measurement conditions of polyethylene: JIS K7210, 190° C., 2.16 kgf) of these resins may be 0.3 to 30 g/10 minutes, preferably 0.3 to 10 g/minutes. In case of using the ethylene vinyl acetate copolymer, the content of ethylene is preferably 70 to 95% by weight, and a saponified substance thereof can also be used. The polyvinyl chloride type resin preferably has a polymerization degree of 400 to 1500, and more preferably 700 to 1300. Copolymers other than the polymer of single polyvinyl chloride resin can also be used therewith.
Plasticizers, stabilizers, lubricants and fillers can be blended in the polyvinyl chloride type resin as required.
Examples of the plasticizer include a phthalic acid ester type compound, an adipic acid ester type compound, a sebacic acid ester type compound, an azelaic acid ester type compound, a trimellitic acid ester type compound, a phosphoric ester type compound, a polyester type compound, an epoxy type compound, a paraffin chloride, an aromatic hydrocarbon type compound, an oil type hydrocarbon compound or the like.
Examples of the stabilizer include a metallic soap (a calcium soap, a barium soap, a zinc soap, a cadmium soap, a lead soap, a lead salt stabilizer), a metallic liquid stabilizer (a metallic salt of branched aliphatic acid (2-ethyl hexoin acid, isodecane acid or the like), unsaturated aliphatic acid (oleic acid, ricinoleic acid, linoleic acid or the like) and aromatic acid (carbolic acid, benzoic acid, salicylic acid and derivatives thereof) with barium, calcium, zinc, tin, magnesium, sodium or potassium), organic tin stabilizer or the like.
Examples of the lubricant include a hydrocarbon
Shimizu Motohiro
Tokunaga Yasushi
Riken Vinyl Industry Co., Ltd.
Sughrue Mion Zinn Macpeak & Seas, PLLC
Thibodeau Paul
Zacharia Ramsey
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