JPH07285139A - Decorative laminated sheet having uneven pattern in inside, and production thereof - Google Patents

Abstract

PURPOSE:To provide a method for producing a decorative laminated sheet efficiently at a low cost in which the physical property of a coating film on the surface is excellent and an uneven pattern exists in the inside and a three- dimensional sense and profundness are imparted and design property is excellent. CONSTITUTION:A sheet 4 for decoration in which a pattern printing layer 3 is applied to the top surface is laminated on the base material 6 for a decorative laminated sheet through a thermosetting resin layer 5. Furthermore, a transfer sheet 10 consisting of the base material sheet and an ionization radiation curing resin layer 2 having unevennesses on the surface is placed on the top surface thereof, so that the even surface touches the sheet 4 for decoration. The transfer sheet 10 is heated and pressed. Thereafter the decorative laminated sheet having an uneven pattern in the inside is produced by peeling the base material sheet of the transfer sheet 10.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative board having excellent three-dimensional appearance and deep design, which is suitable for various furniture surface materials and interior materials for building materials, and a manufacturing method thereof.

[0002]

2. Description of the Related Art Conventionally, as a decorative plate having a three-dimensional pattern, there is a transparent surface layer having an uneven pattern (that is, embossing). Since the surface is smooth, but the internal pattern is not flat, it is used as a high-grade decorative board with a deep aesthetic appearance.

As such a decorative board, (i) a decorative sheet in which a transparent sheet is thermocompressively laminated on a sheet having an embossed upper surface is stuck on a substrate, (ii) printing Emboss the surface of the substrate with paper attached, and then apply a transparent UV-curable resin or thermosetting resin on it.
Hardened decorative boards and the like are known.

However, in the former method, in order to prevent the embossing from being destroyed by heat and pressure, it is difficult to use a transparent upper layer sheet as a surface layer, which is hard to use, and is rather softer than the lower layer sheet. Since it had to be used, it had extremely weak surface properties such as abrasion resistance, solvent resistance, and stain resistance. Also, in the latter method, since a transparent UV-curable resin or thermosetting resin is used as the surface coating film, it has excellent surface physical properties, but the embossing process, the surface coating process ,
There is a drawback that the manufacturing cost is high due to various processing steps such as curing step.

[0005]

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and an object of the present invention is to provide an inner surface with an uneven pattern having excellent coating film physical properties. An object of the present invention is to provide a method for efficiently and inexpensively manufacturing a decorative board having a three-dimensional effect and a deep design.

[0006]

In order to achieve the above object, a method of manufacturing a decorative board having an uneven pattern inside according to the present invention comprises a base material for a decorative board and an upper surface via a thermosetting resin layer. On top of that, a decorative sheet having a pattern printed layer is laminated, and a transfer sheet comprising a base material sheet and an ionizing radiation curable resin layer having irregularities on the surface is further arranged so that the irregular surface contacts the cosmetic sheet. Place it on the table and heat and pressure it,
After that, the base sheet of the transfer sheet is peeled off.

Then, a decorative sheet having a pattern printing layer and a thermoplastic resin layer formed on the upper surface of the decorative sheet base material via a thermosetting resin layer is laminated, and the base material sheet is further formed on the upper surface of the decorative sheet. And a transfer sheet composed of an ionizing radiation curable resin layer having unevenness on the surface is placed such that the uneven surface is in contact with the cosmetic sheet, heat-pressed, and then the base sheet of the transfer sheet is peeled off. Is a preferred method.

In the decorative board having an uneven pattern in the present invention, a decorative board substrate, a thermosetting resin layer, a decorative sheet, a pattern printing layer and an ionizing radiation curable resin layer are laminated in this order from the bottom. In the decorative board thus constructed, the ionizing radiation-curable resin layer is characterized by being provided with an uneven pattern on the side in contact with the pattern printing layer.

Further, it is preferable that a thermoplastic resin layer is provided on the side of the pattern printing layer which is in contact with the ionizing radiation curable resin layer.

[0010]

In the present invention, as described above, a transfer sheet having an ionizing radiation curable resin layer having an uneven pattern formed at the time of heating and pressing in the manufacturing process of a decorative plate is stacked on the uppermost layer and heated and pressed. Transcribe. As a result, it is possible to easily obtain a decorative board having a smooth top surface, a three-dimensional appearance having an uneven pattern on the inner surface, and a deep design, and excellent physical and chemical properties.

Further, by providing a thermoplastic resin layer on the upper surface of the pattern printing layer in contact with the ionizing radiation curable resin layer,
The adhesiveness between the ionizing radiation curable resin layer and the pattern printing layer can be further enhanced.

[0012]

Embodiments of the present invention will now be described in detail with reference to the drawings. FIG. 1 is a cross-sectional view showing an embodiment of a decorative plate having an uneven pattern inside the present invention, and FIG. 2 is an explanatory view showing steps of one embodiment of a method for manufacturing a decorative plate having an uneven pattern inside the present invention. FIG. 3 is a cross-sectional view showing another embodiment of a decorative plate having an uneven pattern in the present invention, 1 is a decorative plate having an uneven pattern inside, 2 is an ionizing radiation curable resin layer, 3 is a pattern Printed layer, 4 is a cosmetic sheet, 5 is a thermosetting resin layer, 6
Is a base material for a decorative plate, 7 is a base material sheet, 8 is a thermoplastic resin layer, 9 is a shaping mold, 10 is a transfer sheet, 11 is ionizing radiation, 12 is a heating plate, and 13 is an uneven pattern.

As shown in FIG. 1, a decorative board 1 having an uneven pattern inside according to the present invention comprises a thermosetting resin layer 5, a cosmetic sheet 4, and a pattern on a decorative board substrate 6 in this order from the bottom. Print layer 3
And an ionizing radiation curable resin layer 2 which is the main constituent of the composition. As shown in FIG. 3, a thermoplastic resin layer 8 may be provided between the pattern printing layer 3 and the ionizing radiation curable resin layer 2.

Decorative plate 1 having an uneven pattern inside according to the present invention
As shown in FIG. 1 or FIG. 3, the feature is that an uneven shaped pattern 1 made of an ionizing radiation curable resin layer 2 is formed on the inner surface of the uppermost layer surface.
3 has the shape 3 of the unevenness, and
It is formed by the transfer sheet 10 as shown in (b).

Next, a method for manufacturing a decorative board having an uneven pattern inside the above structure will be described. First, in the manufacturing method of the present invention, as shown in FIG. 2 (a), an ionizing radiation curable resin 2 is applied to a concavo-convex mold 9 for shaping having an irregular shape on the surface, and the surface is ionized by the ionizing radiation. A base sheet 7 having releasability is superposed on the curable resin 2, and ionizing radiation 11 is irradiated from the side of the base sheet 7 to cure the ionizing radiation curable resin 2. Thereafter, the base sheet 7 is peeled off from the shaping mold 9 to obtain a transfer sheet 10 having an uneven pattern 13 formed by the ionizing radiation curable resin 2 on the surface of the base sheet 7 [FIG. 2 (b)]. ].

Next, as shown in FIG. 2 (c), a decorative sheet 4 having a pattern printing layer 3 provided on a decorative plate substrate 6 having an uncured thermosetting resin 5 applied to the surface thereof, And a transfer sheet 10 in which the concavo-convex pattern 13 made of the ionizing radiation curable resin 2 is formed on the surface of the base material sheet 7 is sequentially superposed and inserted between the pair of heating plates 12 and 12,
The upper and lower heating plates 12 are heated and pressed to laminate the decorative plate base material 6, the decorative sheet 4, and the ionizing radiation curable resin 2 into a close contact. That is, the thermosetting resin 5 is permeated into the cosmetic sheet 4 by being heated and clamped by the upper and lower heating plates 12, and further permeates to be adhered to the ionizing radiation curable resin 2 on the upper side. Conditions such as the hot plate temperature, the pressing pressure, and the heating time for the heating and pressing are appropriately determined according to the selected base material, the type of thermosetting resin, the coating amount, the coating viscosity, and the like. 120-150 ° C, 5-15
It is produced by heating it under a condition of kg / cm ² for about 30 seconds to 5 minutes, but the ionizing radiation-curable resin layer 2 is not destroyed,
The temperature and pressure may be sufficient to form sufficient irregularities on the cosmetic sheet 4 and the thermosetting resin layer 5, and the application amount of the thermosetting resin 5 is preferably 10 to 50 μm (wet state).

Next, as shown in FIG. 2 (d), the base sheet 7 of the transfer sheet 10 is peeled off, and as shown in FIG.
A decorative plate 1 having an ionizing radiation curable resin layer having a smooth surface and an uneven surface on the inner surface as a surface protective layer can be obtained. Furthermore,
As shown in FIG. 3, by providing the thermoplastic resin layer 8 between the pattern printing layer 3 and the ionizing radiation curable resin layer 2, the interlayer adhesive strength of the decorative plate can be stably increased. .

The decorative substrate 6 used in the present invention includes wood-based substrates such as wood, plywood, particle boards, hard boards, and insulation boards, gypsum boards,
Asbestos perlite plate, calcium silicate plate, inorganic base material such as glass wool, iron plate, zinc plated plate, metal plate such as aluminum plate and stainless plate, phenol plate, melamine plate, polyester plate, acrylic plate, vinyl chloride plate, etc. A synthetic resin base material or the like can be used alone or as a composite material in which they are appropriately combined.

As the decorative sheet 4, base paper used for ordinary decorative paper, for example, thin paper, high-quality paper, Japanese paper, non-woven fabric, kraft paper, etc. is used, but the decorative plate is heated and pressed by the upper and lower heating plates 12. The thermosetting resin 5 applied on the base material 6 for penetration penetrates into the cosmetic sheet 4 and further penetrates to adhere well to the ionizing radiation curable resin 2 on the upper part, improving the interlayer adhesive strength of the decorative plate 1. For this purpose, a non-sized paper having a basis weight of 100 g / m ² or less or a low-sized paper is preferable, and a non-sized paper having a basis weight of 20 to 65 g / m ² is desirable.

Examples of the thermosetting resin 5 used in the decorative board of the present invention include amino resins, phenol resins, xylene resins, epoxy resins, polyisocyanate resins,
An unsaturated polyester resin, a thermosetting acrylic resin, a urea resin, a melamine resin or the like is used alone or as a mixture of two or more kinds thereof. Especially, an adhesive layer made of a two-component curing type urea resin penetrates into the cosmetic sheet 4. It has good properties and exhibits excellent interlayer adhesive strength by hot pressing. The coating amount of the thermosetting resin 5 is preferably selected usually in the range of 10 to 50 μm (wet state). When the coating amount of the thermosetting resin 5 is less than 10 μm, the amount of penetration into the decorative sheet 4 is small, the adhesiveness with the ionizing radiation curable resin 2 passes through the pattern printing layer 3 is insufficient, and when it exceeds 50 μm When coated on the plate base material 6, it overflows from the base material surface, stains the conveyor, lowers productivity, and increases cost.

The thermoplastic resin layer 8 is provided in order to further enhance and stabilize the adhesion between the ionizing radiation curable resin layer 2 and the pattern printing layer 3 on the upper surface of the cosmetic sheet 4, and is a normal thermoplastic resin. , An adhesive that develops adhesiveness by heating an ionomer or the like, and as the resin, for example, a cellulose derivative such as ethyl cellulose, cellulose nitrate, cellulose acetate, ethyl hydroxyethyl cellulose, cellulose acetate propionate, polystyrene, or poly α-methyl. Styrene resin such as styrene or styrene copolymer, acrylic resin such as polymethylmethacrylate, polyethylmethacrylate, polyethylacrylate, polybutylacrylate, polyvinyl chloride, polyvinyl acetate, vinyl chloride / vinyl acetate copolymer Coalesced, ethylene / vinyl alcohol copolymer, Vinyl polymers such as polyvinyl butyral, polyurethane resin, polyisoprene rubber, polyisobutylene rubber, styrene-butadiene rubber, butadiene rubber resin acrylonitrile rubber, can be various ionomers are used, in particular a polyurethane resin. As a method of providing, the gravure printing method is performed at the same time when the pattern print layer 3 is formed.

The base sheet 7 used in the present invention is, for example, an acrylic resin such as polyethylene terephthalate, polypropylene, or polymethylmethacrylate,
About 10 to 100 μm of a plastic film made of polyvinyl chloride, a fluororesin, cellophane, etc., or a single piece made of paper or a composite of these,
Preferably, those having a thickness of about 25 to 50 μm can be used. A release layer may be provided if necessary, but the adhesive force between the base material sheet 7 and the ionizing radiation curable resin 2 is better than the adhesive force between the ionizing radiation curable resin 2 and the shaping mold 9. big,
In addition, the adhesiveness between the ionizing radiation curable resin 2 and the thermosetting resin 5 or the thermoplastic resin layer 8 of the transferred substrate must be smaller than that. Further, the smoothness of the surface is arbitrary, that is, if a film having high gloss is used, the high gloss surface is transferred to the ionizing radiation curable resin 2 and the mat shaping film is used for finishing the matte finish. You can use it.

As the ionizing radiation curable resin 2, a conventionally known resin which is cured by ionizing radiation such as ultraviolet rays or electron beams is used. For example, a prepolymer having a polymerizable unsaturated bond or an epoxy group in the molecule. It is possible to use a composition in which an oligomer, an oligomer, and / or a monomer are appropriately mixed. In addition, it is possible to obtain a complete cured resin layer that has a faithful convex shape corresponding to the shape of the concave portion with respect to the concave-convex type having a minute and complicated concave portion, and does not have air bubbles mixed therein. For this purpose, it is preferable to use a resin having a relatively low viscosity when the ionizing radiation curable resin is applied to the recesses. It can be a resin. However, since there is an appropriate range for the viscosity at the time when the ionizing radiation curable resin is applied to the recesses and the hardness of the resulting cured resin, the ratio of the monomer to the prepolymer (or oligomer) and the The number of functional groups of the monomer or prepolymer (or oligomer) must be selected according to the application of the decorative board.

The thickness of the ionizing radiation curable resin 2 depends on the depth of the unevenness of the uneven type, but if it is 10 to 150 μm and is thicker than this, cracks tend to occur during resin hardening. Further, since this ionizing radiation curable resin 2 becomes a surface protective layer of a decorative plate by transfer, it is preferably a substance having scratch resistance, chemical resistance and stain resistance, such as polyester acrylate, epoxy acrylate, Silicone acrylate,
It is convenient to use a high cross-linking density type resin mainly composed of a polyfunctional monomer such as siloxane.

The concavo-convex pattern of the shaping mold 9 may be, for example, the surface of various wood grain boards (fine concavities and convexities such as a fine fiber bundle structure), conduit grooves, and annual rings (alternate autumn and spring materials). (Laminate), cross-sectional pattern, etc., the surface of stone plates such as granite, travertine, etc., the surface irregularities of natural products such as the surface of woven fabric, knitted fabric, leather, etc., line-shaped irregularities, metal Partially corroded patterns on the surface of the plate, artificial fine uneven shapes such as hairline processing, spin processing, etc. are used.

The concave portion on the surface of the shaping die 9 is formed by utilizing, for example, electroforming, corrosion, mechanical cutting or the like. The best way to faithfully reproduce the surface shape of an original document such as a wood grain board as a concave portion of a concave-convex surface is to pour a liquid resin such as silicone on the surface of the original object, cure it, and then peel it off. An electroforming method in which a mother die is created by using the mother die and metal plating is performed based on the mother die is most suitable. The uneven surface is plated with chrome if necessary.

Example 1 A UV-curable resin was coated on an embossing cylinder for embossing, a polyester film having a thickness of 38 μm was overlaid, and the UV-curable resin was cured by an UV lamp of 80 w / cm 4 to emboss it. The transfer film was made into a continuous sheet. Separately, a 10-mm thick particle board is coated with a two-component curing type urea resin in a wet state to a thickness of 20 μm, and a 30 g / m ² thin paper is gravure-printed on the coated surface to make a non-printing makeup sheet. A transfer base material was prepared so that the surface was in contact with the resin-coated surface. Then 130
℃ Place the transfer substrate between heated upper and lower heating plate to its cosmetic picture-printed surface sheet side and the uneven pattern surface of the ultraviolet curable resin stacked transfer sheet so that the contact of 5 kg / cm ² Pressing was carried out for 30 seconds under pressure to integrate pressure. After cooling to room temperature, the polyester film was peeled off to obtain a decorative board having an uneven pattern inside.

Example 2 A sheet of a decorative sheet obtained by gravure-printing a thin paper of 30 g / m ² on which a pattern is printed by gravure printing and a polyurethane-based thermoplastic resin layer is provided thereon by a solid plate. In the same manner as in Example 1 except that was used, a decorative plate having an uneven pattern inside was obtained.

[0029]

INDUSTRIAL APPLICABILITY In the method for producing a decorative plate having an uneven pattern inside according to the present invention, a transfer sheet having an ionizing radiation curable resin layer having an uneven pattern formed at the time of heating and pressing is stacked on the uppermost layer, Since the ionizing radiation curable resin is transferred and laminated by heating and pressing, the production process is simplified, and the production cost can be reduced because the production can be efficiently performed in a short time.

Further, as described above, a transfer sheet having an ionizing radiation curable resin layer that is unevenly shaped at the time of heating and pressing in the manufacturing process of a decorative board is used, and the unevenness-shaped surface is laminated on the uppermost layer as an inner surface. And transcrib. As a result, the physical and chemical properties of the ionizing radiation curable resin transferred to the uppermost layer can be effectively imparted to the decorative board, and it has excellent properties such as abrasion resistance and solvent resistance. A decorative board is obtained.

Further, by providing the thermoplastic resin layer on the upper surface of the pattern printing layer which is in contact with the ionizing radiation curable resin layer, the adhesion between the ionizing radiation curable resin layer and the pattern printing layer could be improved.

Further, since the uneven surface is made of the ionizing radiation-curable resin, it becomes possible to shape the uneven pattern up to the lower cosmetic sheet layer by heating and pressing, resulting in an extremely three-dimensional and depth feeling. A veneer was obtained.

[Brief description of drawings]

FIG. 1 is a vertical cross-sectional view showing an embodiment of a decorative plate having an uneven pattern inside according to the present invention.

FIG. 2 is an explanatory view showing a process of one example of a method for producing a decorative board having an uneven pattern inside according to the present invention.

FIG. 3 is a vertical cross-sectional view showing another embodiment of a decorative board having an uneven pattern inside according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Decorative plate having an uneven pattern inside 2 Ionizing radiation curable resin layer 3 Pattern printing layer 4 Decorative sheet 5 Thermosetting resin layer 6 Decorative plate base material 7 Base material sheet 8 Thermoplastic resin layer 9 Imprinting mold 10 Transfer Sheet 11 Ionizing Radiation 12 Hot Plate 13 Uneven Pattern

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Claims (4)

[Claims] 1. A decorative sheet having a pattern printing layer on the upper surface thereof is laminated on a decorative plate base material via a thermosetting resin layer,
Further, a transfer sheet composed of a base material sheet and an ionizing radiation curable resin layer having unevenness on the upper surface thereof is placed so that the uneven surface is in contact with the cosmetic sheet, and heat-pressed, and then the transfer is performed. A method for producing a decorative board having an uneven pattern inside, characterized in that a base material sheet of the sheet is peeled off. 2. A decorative sheet on which a pattern printing layer and a thermoplastic resin layer are sequentially provided on the upper surface of a base material for a decorative plate via a thermosetting resin layer, and the base material sheet on the upper surface. And a transfer sheet composed of an ionizing radiation curable resin layer having unevenness on the surface is placed such that the uneven surface is in contact with the cosmetic sheet, heat-pressed, and then the base sheet of the transfer sheet is peeled off. A method for manufacturing a decorative board having an uneven pattern inside. 3. A decorative board comprising a base material for a decorative board, a thermosetting resin layer, a decorative sheet, a pattern printing layer, and an ionizing radiation curable resin layer, which are laminated in this order from the bottom. The decorative layer having an uneven pattern inside, wherein the resin layer is provided with an uneven pattern on the side in contact with the pattern print layer. 4. The decorative board having an uneven pattern inside, wherein a thermoplastic resin layer is provided on a side of the pattern printing layer which is in contact with the ionizing radiation curable resin layer.