Stock material or miscellaneous articles – Web or sheet containing structurally defined element or... – Including a second component containing structurally defined...
Patent
1996-08-29
1999-07-27
Thibodeau, Paul
Stock material or miscellaneous articles
Web or sheet containing structurally defined element or...
Including a second component containing structurally defined...
4284231, 4289088, B32B 516, B32B 2700
Patent
active
059287780
DESCRIPTION:
BRIEF SUMMARY
TECHNICAL FIELD
The present invention relates to a decorative material whose surface is excellent in scratch resistance. More specifically, the present invention relates to a decorative laminate obtainable by covering the surface of paper or plastic sheet or film, or the printed surface thereof, with a coating layer excellent in both abrasion resistance and flexibility.
BACKGROUND OF THE INVENTION
Heretofore, reactive resins such as thermosetting resins or ionizing-radiation-curing resins have been used as overcoat materials to cover the surface of paper or plastic sheet or film, or the printed surface thereof so as to protect such a material from damage by abrasion or scratch.
In order to successfully protect the above-described materials from damage by abrasion or scratch, it is necessary to make a resin to be used for coating the materials harder. In order to attain this, it has been necessary to lower the average molecular weight of crosslinked molecules of the resin. Consequently, however, the flexibility of the resin itself is lowered, so that the resin layer tends to be cracked when the substrate is bent.
DISCLOSURE OF THE INVENTION
We studied overcoat materials capable of forming films which are hardly damaged by scratch and which have flexibility. As a result, it was found that although a coating layer formed by using a composition containing reactive resins to which a predetermined amount of spherical particles having a specific average particle diameter are added can show the desired effects to a certain extent, such a coating layer is still unsatisfactory. It was also found that it is necessary to further specify the relationship between the average thickness of the coating layer and the average particle diameter of the spherical particles and that a decorative laminate excellent in both flexibility and abrasion resistance can be obtained by strictly controlling this relationship. The present invention has been accomplished on the basis of the above findings.
Namely, a decorative material according to the present invention comprises a substrate and an abrasion-resistant coating layer formed thereon, and is characterized in that the abrasion-resistant coating layer comprises spherical particles (A) having an average particle diameter of 3 to 50 micrometers, and a binder (B) comprising crosslinkable resins, that the amount of the spherical particles (A) is from 5% to 50% by weight of the total amount of the components (A) and (B), that the hardness of the spherical particles (A) is higher than that of the binder (B), and that the average particle diameter d (micrometers) of the spherical particles (A) fulfills the following inequality (1):
BEST MODE FOR CARRYING OUT THE INVENTION Substrate
In the present invention, paper, plastic film or sheet, metallic foil or plate, or the like can be used as the substrate depending on the purpose. Although either a sheet-like material such as paper, plastic sheet or nonwoven fabric, or a board-like material such as metallic plate, woodboard or plastic board can be used as the substrate, it is preferable to use a sheet of a flexible material. This is because it is possible to continuously produce a decorative material when a roll of such a substrate sheet is used in the production process.
In general, in the case where a sheet-like material is used as the substrate, the thickness thereof is preferably from 5 to 200 micrometers. Further, it is also possible to use, as the substrate, a sheet having a rough surface or a three-dimensional pattern.
Specific examples of the paper which can be used as the substrate include tissue, craft paper, titanium paper, linter paper, cardboard, plasterboard paper, raw fabric of so-called vinyl wall paper obtained by applying polyvinyl chloride resin to paper by means of sol coating or dry lamination, high-grade paper, coated paper, art paper, vegetable parchment, glassine paper, animal parchment, paraffin paper and Japanese paper. In addition, a paper-like sheet can also be used as the substrate. Examples of the paper-
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Kobayashi Toshitake
Matano Takashi
Ono Haruo
Takahashi Kazuhiro
Takemoto Masataka
Dai Nippon Printing Co. Ltd.
Rickman Holly C.
Thibodeau Paul
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