Melamine resin decorative sheet and method of refurbishing finished surface

Patent metadata

Field	Value
Publication number	US-9707740-B2
Application number	US-201314382719-A
Country	US
Kind code	B2
Filing date	Mar 6, 2013
Priority date	Mar 7, 2012
Publication date	Jul 18, 2017
Grant date	Jul 18, 2017

Abstract

A melamine resin decorative sheet of the present invention includes a laminate structure of a surface layer and a core layer, in which the surface layer is configured of a surface layer material composed of a surface layer base material which carries a resin containing a melamine resin on a first surface side that serves as a design surface and which carries a solid content of a thermoplastic emulsion resin on a second surface side that contacts with the core layer, and in which the core layer is configured of a heat dissipative material layer.

First claim

The invention claimed is:

1. A melamine resin decorative sheet comprising:
a laminate structure of a surface layer and a core layer, and an adhesive layer between the surface layer and the core layer,
wherein the surface layer is configured of a surface layer material composed of a surface layer base material which carries a resin containing a melamine resin on a first surface side that serves as a design surface and which carries a solid content of a thermoplastic emulsion resin on a second surface side that contacts with the core layer,
wherein the core layer is configured of a heat dissipative material layer, and
wherein the adhesive layer is configured of an adhesive layer base material that carries a solid content of a thermosetting resin.

2. The melamine resin decorative sheet according to claim 1 ,
wherein the heat dissipative material layer is a metallic layer.

3. The melamine resin decorative sheet according to claim 2 ,
wherein the metallic layer is an aluminum layer.

4. The melamine resin decorative sheet according to claim 1 ,
wherein the adhesive layer base material is a glass cloth.

5. The melamine resin decorative sheet according to claim 1 ,
wherein the solid content of the thermoplastic emulsion resin includes emulsion resin particles having an average particle diameter of 30 nm to 100 nm.

6. The melamine resin decorative sheet according to claim 1 ,
wherein the solid content of the thermoplastic emulsion resin is water-insoluble.

7. The melamine resin decorative sheet according to claim 1 ,
wherein the solid content of the thermoplastic emulsion resin includes urethane acrylic composite particles having a hetero-phase structure including an acrylic resin and an urethane resin in a single particle.

8. The melamine resin decorative sheet according to claim 7 ,
wherein the urethane acrylic composite particles are an aqueous clear type having a core-shell structure in which an acrylic component is set to a core and an urethane component is set to a shell.

9. The melamine resin decorative sheet according to claim 1 which has bending workability in which a minimum bending radius is 15 mm or less at normal temperature from 20° C. to 30° C.

10. The melamine resin decorative sheet according to claim 9 which has bending workability in which a minimum bending radius is 10 mm or less at normal temperature from 20° C. to 30° C.

11. A method of refurbishing a finished surface which makes a new decoration by laminating a melamine resin decorative sheet on an existing finished surface,
wherein the melamine resin decorative sheet includes a laminate structure of a surface layer and a core layer, and an adhesive layer between the surface layer and the core layer,
wherein the surface layer is configured of a surface layer material composed of a surface layer base material which carries a resin containing a melamine resin on a first surface side that serves as a design surface and which carries a solid content of a thermoplastic emulsion resin on a second surface side that contacts with the core layer,
wherein the core layer is configured of a heat dissipative material layer, and wherein the adhesive layer is configured of an adhesive layer base material that carries a solid content of a thermosetting resin.

12. The method of refurbishing a finished surface according to claim 11 ,
wherein the melamine resin decorative sheet is provided in advance with a sticking layer on a back surface.

13. The method of refurbishing a finished surface according to claim 11 ,
wherein the finished surface is a finished surface of an interior material or an exterior material of a vehicle or a ship.

14. A method of refurbishing a finished surface which makes a new decoration by laminating a melamine resin decorative sheet on an existing finished surface,
wherein the melamine resin decorative sheet includes a laminate structure of a surface layer and a core layer, and an adhesive layer between the surface layer and the core layer,
wherein the surface layer is configured of a surface layer material composed of a surface layer base material which carries a resin containing a melamine resin on a first surface side that serves as a design surface and which carries a solid content of a thermoplastic emulsion resin on a second surface side that contacts with the core layer,
wherein the core layer is configured of a heat dissipative material layer, wherein the adhesive layer is configured of an adhesive layer base material that carries a solid content of a thermosetting resin, and
wherein the melamine resin decorative sheet according to claim 1 is subjected to a defoaming treatment.

15. The method of refurbishing a finished surface according to claim 14 ,
wherein a defoaming treatment is performed by one of pressurizing the finished surface using a roll after molding the melamine resin decorative sheet, and pressurizing, heating or thermally compressing the melamine resin decorative sheet after laminating the melamine resin decorative sheet on the finished surface.

Assignees

• Sumitomo Bakelite Co

Inventors

• Arai Kousuke

Classifications

• B32B43/00

  Operations specially adapted for layered products and not otherwise provided for, e.g. repairing; Apparatus therefor · CPC title

• Y10T428/249921

  Web or sheet containing structurally defined element or component · CPC title

• B32B2264/025

  Acrylic resin particles, e.g. polymethyl methacrylate or ethylene-acrylate copolymers · CPC title

• B32B2605/12

  Ships · CPC title

• B60R13/00

  Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes · CPC title