Decorative material having abrasion resistance

• US 5,928,778 A
• Filed: 08/29/1996
• Issued: 07/27/1999
• Est. Priority Date: 10/31/1994
• Status: Expired due to Term

• Current Assignee: Dai Nippon Printing Company Limited
• Original Assignee: Dai Nippon Printing Company Limited
• Inventors: Kobayashi, Toshitake, Takahashi, Kazuhiro, Takemoto, Masataka, Ono, Haruo, Matano, Takashi
• Primary Examiner(s): Thibodeau, Paul
• Assistant Examiner(s): Rickman, Holly C.
• Application Number:
  US08/666,407
• Time in Patent Office: 1,062 Days
• Field of Search: 428/329, 428/328, 428/327, 428/908.8, 428/323, 428/141, 428/143, 428/423.1
• US Class Current: 428/323
• CPC Class Codes: B44C 5/04 Ornamental plaques, e.g. decorative panels, decorative veneers
• CPC Class Codes: B44C 5/0476 with abrasion resistant properties
• CPC Class Codes: C08K 3/22 of metals
• CPC Class Codes: C08K 7/18 inorganic
• CPC Class Codes: C09D 7/61 inorganic
• CPC Class Codes: C09D 7/69 Particle size larger than 1000 nm
• CPC Class Codes: C09D 7/70 characterised by shape, e.g. fibres, flakes or microspheres
• CPC Class Codes: Y10T 428/25 Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/257 Iron oxide or aluminum oxide
• CPC Class Codes: Y10T 428/31551 Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]

Abstract

A decorative material including a substrate and an abrasion-resistant coating layer formed thereon. The abrasion-resistant coating layer includes spherical particles (A) having an average particle diameter of 3 to 50 micrometers, and a binder (B) including crosslinkable resins. The amount of the spherical particles (A) is from 5% to 50% by weight of the total amount of the components (A) and (B). The hardness of the spherical particles (A) is higher than that of the binder (B). The average particle diameter d (micrometers) of the spherical particles (A) fulfills the following inequality (1):

0.3t≦d≦3.0t                                  (1)

wherein "t" is an average thickness (micrometers) of the coating layer. Thus, the relationship between the average thickness of the coating layer and the average particle diameter of the spherical particles is strictly controlled so that a decorative material which is excellent in both flexibility and abrasion resistance (scratch resistance) can be successfully obtained.

Claims

1. A decorative material comprising:

a substrate; and

an abrasion-resistant coating layer formed on said substrate, said abrasion-resistant coating layer comprising spherical inorganic particles (A) having an average particle diameter of 3 to 50 micrometers and a Knoop hardness of at least 1,300 kg/mm², and a binder (B) comprising a crosslinkable resin comprising at least 10% by weight of a polyether urethane (meth) acrylate represented by the following general formula (2);

space="preserve" listing-type="equation">CH.sub.2 ═

C(R.sup.1)--COOCH.sub.2 CH.sub.2 --OCONH--X--NHCOO-- --CH(R.sup.2)--(CH.sub.2).sub.n --O--!.sub.m --CONH--X--NHCOO--CH.sub.2 CH.sub.2 OCOC(R.sup.1)═

CH.sub.2(

     2)

wherein R¹ and R² each represent hydrogen or a methyl group, X is a diisocyanate radical, n is an integer of 1 to 3, and m is an integer of 6 to 60, the average molecular weight of crosslinked molecules of said binder (B) after curing being from 200 to 800, the amount of said spherical particles (A) being from 5% to 50% by weight of the total amount of the components (A) and (B), the hardness of said spherical particles (A) being higher than that of said binder (B), the average particle diameter d, in micrometers, of said spherical particles (A) fulfilling the following inequality (1);

space="preserve" listing-type="equation">0.3t≦

d≦

3.0t (1)

wherein t is an average thickness, in micrometers, of said coating layer.