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KR-102963633-B1 - EMBOSSED POLYMER SHEET AND MENUFACTURING METHOD FOR THE SAME

KR102963633B1KR 102963633 B1KR102963633 B1KR 102963633B1KR-102963633-B1

Abstract

An embossed sheet with excellent depth, transparency, and interfacial adhesion is disclosed. The embossed sheet according to the present invention is characterized by comprising: a substrate layer having a polymer resin and an embossing pattern formed thereon; a functional layer disposed on one side of the substrate layer; a thermosetting primer layer disposed between the substrate layer and the functional layer; and a colored layer disposed on the other side of the substrate layer.

Inventors

  • 조애리
  • 이승훈
  • 이성영

Assignees

  • (주)엘엑스하우시스

Dates

Publication Date
20260511
Application Date
20231221

Claims (10)

  1. delete
  2. A substrate layer containing a polymer resin and having an embossed pattern formed thereon; A functional layer disposed on one surface of the above-mentioned substrate layer; A thermosetting primer layer disposed between the above substrate layer and the above functional layer; and A colored layer disposed on the other side of the above-mentioned substrate layer; comprising The above substrate layer is PMMA (polymethyl methacrylate), and An embossed sheet characterized by the glass transition temperature (Tg) of the above PMMA being 106℃, which is 20 to 40℃ lower than the embossed sheet forming process temperature.
  3. A substrate layer containing a polymer resin and having an embossed pattern formed thereon; A functional layer disposed on one surface of the above-mentioned substrate layer; A thermosetting primer layer disposed between the above substrate layer and the above functional layer; and A colored layer disposed on the other side of the above-mentioned substrate layer; comprising The above substrate layer is PC (polycarbonate), and An embossed sheet characterized by the glass transition temperature (Tg) of the above PC being 15 to 25°C lower than the embossing sheet forming process temperature.
  4. In paragraph 2 or 3, An embossed sheet having an adhesion strength of 4B or higher to the substrate layer and/or functional layer of the above-mentioned thermosetting primer layer when measured according to ASTM D3359.
  5. In paragraph 2 or 3, The above functional layer is an embossed sheet having an equal correspondence with the uneven pattern of the above substrate layer.
  6. Step of preparing polymer sheets and release sheets; A pressing and transfer step of pressing the polymer sheet and the release sheet into an embossing pattern while transferring the functional layer of the release sheet to the substrate layer of the polymer sheet; The method includes the step of removing the aforementioned release sheet, The above substrate layer is PMMA, and The glass transition temperature (Tg) of the above PMMA is 106℃, which is 20~40℃ lower than the process temperature of the above press and transfer steps. Method for manufacturing embossed sheets.
  7. Step of preparing polymer sheets and release sheets; A pressing and transfer step of pressing the polymer sheet and the release sheet into an embossing pattern while transferring the functional layer of the release sheet to the substrate layer of the polymer sheet; The method includes the step of removing the aforementioned release sheet, The above substrate layer is PC, and The glass transition temperature (Tg) of the above PC is 146℃, which is 15~25℃ lower than the process temperature of the above press and transfer steps. Method for manufacturing embossed sheets.
  8. In paragraph 6 or 7, The above substrate layer is PMMA, and The polymer sheet comprises a substrate layer and a colored layer located on the opposite side of the surface where the substrate layer faces the release sheet. Method for manufacturing embossed sheets.
  9. delete
  10. In paragraph 6 or 7, The above release sheet comprises a thermosetting primer layer located on the surface facing the polymer sheet, A functional layer located on the above-mentioned thermosetting primer layer, UV mold layer located on the above functional layer, A base layer located on the above UV mold layer, comprising Method for manufacturing embossed sheets.

Description

Embossed Polymer Sheet and Manufacturing Method for the Same The present invention relates to a polymer sheet having an embossed surface (hereinafter referred to as the "embossed sheet") and a method for manufacturing the same. To create various surface textures on interior materials or furniture of buildings, methods such as paint coating, sheet bonding, and glass placement can be utilized. Among these, glass is used as a high-end decorative material due to its transparency, high surface hardness, excellent flatness, and sense of depth. However, glass has disadvantages such as being difficult to handle, brittle, and heavier than plastic. Meanwhile, plastic substitute materials such as PVC and PET are used in sheets to produce a glass-like texture. When PVC or PET is used in sheets, transparency can be achieved, but it is difficult to manufacture them with a thick substrate, so they are unsuitable as materials for producing a sense of depth. An acrylic functional layer is formed on the top surface of the sheet to improve appearance characteristics such as surface hardness and scratch resistance; however, due to low adhesion to the substrate, the functional layer peels off easily, resulting in poor appearance. In addition, to express color in the sheet, a colored acrylic layer is attached to the bottom of the sheet, allowing it to be applied to furniture surfaces such as MDF (Medium Density Fiberboard). However, the acrylic colored layer has the disadvantage of low adhesion to MDF and high cost. In order to improve upon the aforementioned drawbacks, attempts were made to apply polymer sheets using polymers that exhibit depth and transparency instead of glass, while also possessing excellent interlayer interface adhesion and adhesion to furniture. However, as mentioned above, the thickness of the polymer sheet must be increased to maintain depth. On the other hand, thick polymer sheets make it difficult to apply the roll-to-roll process, causing problems in terms of productivity. In other words, there is a trade-off between depth and productivity. In particular, when an embossing process is applied to the surface of a polymer sheet to provide aesthetic appeal, the embossed polymer sheet (embossed sheet) presents a problem in that it is difficult to uniformly apply a functional layer, such as a hard functional layer for improving surface hardness and scratch resistance, due to surface irregularities. Furthermore, as the embossing process and the subsequent process for forming the functional layer are carried out as separate processes, a decrease in productivity occurs. FIG. 1 is a cross-sectional view of an embossed sheet according to one embodiment of the present invention. Figure 2 is a flowchart of a conventional manufacturing method for manufacturing the embossed sheet of Figure 1. FIG. 3 is a schematic diagram of a manufacturing method according to one embodiment of the present invention for manufacturing the embossed sheet of FIG. 1. Figure 4 is a photograph of the embossed pattern of the defective part in the specimen evaluated as NG or Poor in Experimental Examples 1 and 2 above. Figure 5 is a photograph of the embossed pattern of the specimen evaluated as Very Good in Experimental Examples 1 and 2 above. Figure 6 is a photograph of the embossed pattern of the specimen evaluated as NG* in Experimental Examples 1 and 2 above. The aforementioned objectives, features, and advantages are described in detail below with reference to the attached drawings, thereby enabling those skilled in the art to easily implement the technical concept of the present invention. In describing the present invention, detailed descriptions of known technologies related to the present invention are omitted if it is determined that such descriptions would unnecessarily obscure the essence of the invention. Hereinafter, preferred embodiments according to the present invention will be described in detail with reference to the attached drawings. In the drawings, the same reference numerals are used to indicate the same or similar components. In the following, the statement that any configuration is placed on the "upper (or lower)" of a component or on the "upper (or lower)" of a component may mean not only that any configuration is placed in contact with the upper (or lower) surface of said component, but also that another configuration may be interposed between said component and any configuration placed on (or below) said component. In addition, where it is stated that one component is "connected," "combined," or "connected" to another component, it should be understood that while the components may be directly connected or connected to each other, another component may be "interposed" between each component, or each component may be "connected," "combined," or "connected" through another component. Hereinafter, an embossed sheet according to some embodiments of the present invention will be described. PVC and PET sheets are used