JP2000177087A - Manufacture of decoration board - Google Patents

Abstract

PROBLEM TO BE SOLVED: To render a decoration board with a high designing property manufacturable in a few processes by forming a clear layer on a separation film in use of clear paint, and thereafter forming a pattern layer on the clear, and further sticking a decoration board pattern sheet on a base material after providing an adhesive layer on the pattern layer. SOLUTION: When a decoration board is manufactured, after a UV ray curable resin-containing clear paint is applied on a transparent PET film 1 fed from a PET film roll 1a by the use of a die-coater 2; then it is dried in a hot air drying furnace 3, thereby forming a clear layer on the PET film 1. Next, pattern-formed transfer foil 4a is placed on the PET film 1, and the pattern is transferred on the clear layer by a transfer roll 4 in order to form a pattern layer. Furthermore, after a polyurethane resin adhesive is applied by a die coater 5 thereon, it is dried in a hot air drying furnace 6 so as to obtain a decoration pattern sheet. Also, an adhesive layer surface of the pattern sheet is superimposed on a slate board 9 to next be stuck by a laminator 7 before finishing goods.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a decorative board which can be used as an interior material and an outer wall material of a building, and more particularly to a method of manufacturing a decorative board which does not require formation of a base layer.

[0002]

2. Description of the Related Art In recent years, as interior and exterior wall materials of buildings such as houses and buildings, many using decorative panels such as tiles and panels have been used.

[0003] Such a decorative board is generally made by smoothing the surface of a base material such as plywood, steel plate, gypsum board, calcium silicate plate and slate plate, and then forming a pattern thereon via a base layer. It is manufactured by printing by a method such as screen printing or offset printing to impart designability, and then forming a clear layer thereon. However, in this method, since a pattern is formed by printing, a large-scale manufacturing facility is required, and there is a problem that it is difficult to form a clear and delicate pattern pattern due to unevenness of a printing surface. .

As a method for solving such a problem, Japanese Patent Laid-Open Publication No. HEI 8-11278 discloses a method for transferring a design. In this method, a base layer made of a polyol-curable urethane resin paint is provided on a base material, a pattern is formed on the base layer by transfer, and a top coat layer made of a polyol-curable urethane resin paint is further formed thereon. To produce a decorative board laminated with However, in this method, a coating film is formed using a paint, so that a step of applying and drying the paint is required. Further, if the size or shape of the base material changes, it is necessary to change the manufacturing process accordingly.

[0005]

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a method for producing a decorative plate having a high designability in a small number of steps.

[0006]

According to the present invention, there are provided a step (1) of producing a decorative sheet for decorative board using a film having releasability and a step of providing the decorative sheet for decorative board on a substrate (2). ), Wherein the step (1) of producing the decorative sheet for decorative panel comprises: (1-a) using a clear coating composed of a radiation-curable resin on a film having releasability. (1-b) Step of forming a design layer on the clear layer obtained in the above step (1-a) (1-c) Obtained in the above step (1-b) Forming an adhesive layer using an adhesive on the design layer, wherein the step (2) of providing the decorative sheet for a decorative sheet on a base material comprises the step of (2-a) A step of attaching the adhesive layer surface to the base material (2-b); An object of the present invention is to provide a method for manufacturing a decorative board, comprising a step of irradiating a radiation to the above-mentioned releasable film surface side of the decorative sheet for decorative board to cure the clear layer.

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION The method for producing a decorative board according to the present invention comprises a step (1) of producing a decorative sheet for decorative board using a film having releasability, and placing the decorative sheet for decorative board on a substrate. Providing a decorative board comprising the step of providing a decorative sheet, wherein the step (1) of manufacturing the decorative sheet for decorative board comprises:
(1-a) a step of forming a clear layer on a film having releasability by using a clear coating made of a radiation-curable resin; (1-b) a step of forming a clear layer on the clear layer obtained in the above step (1-a) Forming a symbol layer on the (1-c) step (1)
-B) a step of forming an adhesive layer using an adhesive on the pattern layer obtained in (b), and the step (2) of providing the decorative sheet for decorative board on a base material comprises the step of (2-a) A) attaching the adhesive layer surface of the decorative sheet for decorative board to the base material;
(2-b) a step of irradiating radiation to the film surface having the releasability of the design sheet for decorative board to which the base material has been adhered, thereby curing the clear layer. It is a manufacturing method.

(1) Step of manufacturing decorative sheet for decorative sheet (1-a) Step of forming clear layer The first step in the method of manufacturing a decorative sheet of the present invention is a step of forming a decorative sheet using a film having releasability. In the step of manufacturing a sheet, this is a step of forming a clear layer made of a radiation curable resin on a film having releasability. The film having releasability used in the method for producing a decorative board in the present invention is a film having a releasability as a support film for a decorative sheet for a decorative board, in which a clear layer formed in the next step is cured. The material is not particularly limited as long as it can transmit radiation. For example, a film formed of various synthetic resins such as polyethylene terephthalate (PET) resin, polyethylene resin, polypropylene resin, and surface treatment of synthetic paper and the like Papers. From the viewpoints of transparency and strength, the film having releasability is preferably a PET resin film.

The thickness of the releasable film in the present invention is not particularly limited, but is generally 10
To 200 μm, more preferably about 25 to 100 μm. The thickness of the film having the peelability is 10
When the thickness is smaller than μm, the strength of the film becomes insufficient,
After the decorative board is manufactured, the film may be broken when the film is peeled off during use. Further, when the thickness of the film having the releasability is greater than 200 μm, it is not economical because an effect proportional thereto cannot be obtained, and
When the clear layer is irradiated with radiation and cured, the amount of radiation reaching the clear layer may be reduced and curing may be insufficient.

In the case of forming a matte decorative sheet for a decorative sheet by forming irregularities on the surface of the clear layer, the above-mentioned film having an irregular surface formed by embossing or the like on the surface in contact with the clear layer Can be used as a film having releasability.

Although the thickness of the clear layer in the present invention is not particularly limited, it is generally used as a dry coating film.
The thickness is set to 10 to 100 μm, preferably 20 to 100 μm, and more preferably 30 to 50 μm. When the thickness of the clear layer is thinner than 10 μm, a sense of depth in appearance is reduced, and a sense of quality as a design may be lost.
On the other hand, if the thickness of the clear layer is more than 100 μm, an effect proportional to the thickness cannot be obtained, which is not economical, and cracks or the like may be generated in the formed clear layer due to internal stress.

The clear layer in the present invention is formed by applying a clear paint. Examples of the method for applying the clear paint include, for example, brush coating, dip coating, spray coating, roll coating, and curtain flow coating.However, from the viewpoint of economy and mass production stability of the obtained clear layer appearance, roll coating is preferred. Coatings are preferred. The film on which the clear layer has been formed in this way is dried at 50 to 130 ° C. for 2 to 3 minutes. By this drying, the solvent component remaining in the clear layer is removed, and in the subsequent step, the clear layer and the design layer are sufficiently bonded.

The clear paint for forming the clear layer in the present invention is made of a radiation-curable resin. As the radiation-curable resin, for example, an ethylenically unsaturated double bond is included in a molecule.
A single substance or a mixture of compounds having one or more cationically polymerizable groups in a molecule, a single substance or a mixture of compounds having one or more cationically polymerizable groups in a molecule, and the like are given. Specifically, unsaturated polyester resin, polyester polyacrylate resin, polyester polymethacrylate resin, epoxy polymethacrylate resin, epoxy polyacrylate resin, polyester polymethacrylate resin, urethane polyacrylate resin, urethane polymethacrylate resin, acrylic polyacrylate resin, Acrylic polymethacrylate resin and the like can be mentioned. For these resins, for the purpose of reducing the adhesiveness, for example, saturated acrylic resin, saturated polyester resin, polyurethane resin, polyallyl phthalate resin, cellulose resin, butyral resin, synthetic rubber, polystyrene resin, styrene-maleic Acid resin,
An ethylene-vinyl acetate copolymer resin or the like may be included.

When the radiation-curable resin is used as an ultraviolet-curable resin, the clear coating generally contains a photopolymerization initiator. As the photopolymerization initiator, a known photopolymerization initiator that is generally used for an ultraviolet curable resin can be used. In addition, when a photopolymerization initiator is not blended, it can be generally used as an electron beam curable resin because it can be crosslinked by irradiation with an electron beam.

The clear coating material for forming the clear layer in the present invention is not particularly limited as long as it is a coating material which can be generally formed as a coating film by coating, and may be any of an organic solvent type, an aqueous type and an emulsion type. Paint form.

The clear layer in the present invention is generally formed as a colorless layer, but may be colored if necessary. In addition, from the viewpoint of design, it may have stains.

(1-b) Pattern Layer Forming Step The second step in the method for manufacturing a decorative sheet of the present invention is the first step in the step of manufacturing a decorative sheet for a decorative sheet using a film having releasability. This is a step of forming a pattern layer for giving a desired pattern to the pattern sheet for decorative board, on the clear layer of the film obtained in the step. The thickness of the design layer in the present invention is not particularly limited, but is generally set to 0.1 to 5 μm. When the thickness of the above-mentioned design layer is thinner than 0.1 μm, the design itself becomes unclear and the design property is deteriorated. When the thickness of the design layer is more than 5 μm, the unevenness due to the design layer becomes conspicuous, and the smoothness of the finally obtained decorative board may be reduced.

The design layer in the present invention can be formed by a method such as transfer or printing. The transfer is performed by printing a desired pattern on a base material such as a film or paper coated with a release resin by a printing method such as gravure printing, offset printing, screen printing, etc. to produce a transfer foil. It can be performed by placing on the above-mentioned clear layer with the design facing down and heating or pressing. In this way, a pattern layer having a clear and delicate pattern pattern can be formed by transfer.

Also, a pattern layer can be formed by directly printing a desired pattern on the clear layer by a printing method such as screen printing or an ink jet method.

The above-mentioned design layer is generally formed as a discontinuous layer on the clear layer of the film obtained in the first step, but may be a continuous design layer covering the entire surface as required. There may be. When the above-mentioned design layer is discontinuous, an adhesive layer formed thereon in the next step serves as a base for the design, and these two layers as a whole provide high decorativeness to the finally obtained decorative board. Is given.

(1-c) Step of Forming Adhesive Layer The third step in the method for producing a decorative sheet of the present invention is the first step in the step of producing a decorative sheet for a decorative sheet using a film having releasability. In this step, an adhesive layer made of an adhesive is further formed on the pattern layer of the film obtained in the first step and the second step.

The thickness of the adhesive layer in the present invention is not particularly limited.
It is set to 5 to 100 μm. The thickness of the adhesive layer is 5
If the thickness is smaller than μm, the effect as an adhesive cannot be sufficiently obtained. On the other hand, if the thickness of the adhesive layer is more than 100 μm, an effect proportional to the thickness cannot be obtained, so that it is not economical and it may take time to dry the formed adhesive layer.

The adhesive layer in the present invention is formed by applying an adhesive on the clear layer formed in the first step. Examples of the method for applying the adhesive include brush coating, dip coating, spray coating, roll coating, and curtain flow coating.However, from the viewpoint of economic efficiency and mass production stability of the obtained adhesive layer appearance, Roll coating is preferred. The film on which the adhesive layer has been formed in this manner remains in the adhesive layer in the subsequent step in order to sufficiently adhere the decorative design sheet obtained in the third step and the substrate. It is dried so that the solvent component is removed. This drying does not cure, and the drying temperature and the drying time are appropriately determined depending on the type of the adhesive and the thickness of the adhesive layer.

The adhesive for forming the adhesive layer in the present invention preferably contains a coloring component from the viewpoint of the concealing property and the design of the decorative sheet for decorative board. As the coloring component, specifically, various dyes, titanium dioxide, red iron oxide, yellow iron oxide, carbon black, phthalocyanine blue, phthalocyanine green, quinacridone pigment,
Examples include coloring pigments such as azo pigments and extenders such as talc, silica, calcium carbonate, and precipitated barium sulfate. The content of the coloring component is preferably 1 to 70% by weight based on the solid content of the adhesive, from the viewpoint of the effect as an adhesive and the pot life of the adhesive.
More preferably, it is 1 to 60% by weight.

The adhesive forming the adhesive layer in the present invention is not particularly limited, but preferably contains a thermosetting resin component from the viewpoint of adhesiveness. Such a thermosetting resin component comprises a thermosetting resin and a curing agent. However, when the thermosetting resin alone has curability, a curing agent may not be necessary as a thermosetting resin component.

The type of the thermosetting resin is not particularly limited, but specific examples include an acrylic resin having a curable functional group, a saturated or unsaturated polyester resin, an alkyd resin, an epoxy resin, and a urethane resin. be able to.

Examples of the acrylic resin having a curable functional group include those obtained by copolymerizing an ethylenically unsaturated group-containing monomer by an ordinary method. Such an ethylenically unsaturated group-containing monomer is not particularly limited, and examples thereof include 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate,
-Hydroxybutyl acrylate, Plaxel FM series (trade name, adduct of 2-hydroxyethyl (meth) acrylate and polycaprolactone, manufactured by Daicel Chemical Industries, Ltd.), hydroxyl group-containing monomers such as polyalkylene glycol mono (meth) acrylates Body, glycidyl acrylate, glycidyl methacrylate, epoxy group-containing monomers such as 2-methylglycidyl methacrylate, dimethylaminoethyl (meth) acrylate, amino group-containing monomers such as diethylaminoethyl (meth) acrylate, (meth) acrylamide, Acrylamide monomers such as N-methyl (meth) acrylamide, N-butoxymethyl (meth) acrylamide, N-methylacrylamide and the like can be mentioned. In addition, as other monomers, acrylonitrile, vinyl acetate, acrylic acid, methacrylic acid, methyl (meth) acrylate, ethyl (meth) acrylate, n-butyl (meth) acrylate, iso- (meth) acrylate Butyl, tert-butyl (meth) acrylate, styrene, vinyltoluene,
For example, p-chlorostyrene can be used. These may be used alone or in combination of two or more.

As the above-mentioned saturated polyester resin having a curable functional group, polycondensation is carried out by an ordinary method using an acid component mainly composed of a polycarboxylic acid and an alcohol component mainly composed of a polyhydric alcohol as raw materials. Can be obtained. The acid component is not particularly limited,
For example, terephthalic acid, isophthalic acid, phthalic acid and anhydrides thereof, 2,6-naphthalenedicarboxylic acid,
Aromatic dicarboxylic acids such as 2,7-naphthalenedicarboxylic acid and their anhydrides, succinic acid, adipic acid, azelaic acid, sebacic acid, dodecanedicarboxylic acid,
Saturated aliphatic dicarboxylic acids such as 4-cyclohexanedicarboxylic acid and anhydrides thereof, γ-butyrolactone,
Examples thereof include lactones such as ε-caprolactone, aromatic oxymonocarboxylic acids such as p-oxyethoxybenzoic acid, and corresponding hydroxycarboxylic acids. These may be used alone or in combination of two or more.

The alcohol component is not particularly restricted but includes, for example, ethylene glycol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,5-hexanediol, diethylene glycol, triethylene glycol, Ethylene glycol, 1,4-cyclohexanediol, 1,4-cyclohexanedimethanol,
Bisphenol A alkylene oxide adduct, bisphenol S alkylene oxide adduct, 1,2-propanediol, neopentyl glycol, 1,2-butanediol, 1,3-butanediol, 1,2-pentanediol, 2,3- Pentanediol, 1,4-pentanediol, 1,4-hexanediol, 2,5-hexanediol, 3-methyl-1,5-pentanediol,
Examples thereof include aliphatic glycols having a side chain such as 1,2-dodecanediol and 1,2-octadecanediol, and trihydric or higher polyhydric alcohols such as trimethylolpropane, glycerin and pentaerythritol.
These may be used alone or in combination of two or more.

The unsaturated polyester resin having a curable functional group can be obtained in the same manner as the saturated polyester resin except that an aliphatic unsaturated dicarboxylic acid is further used as a raw acid component. In particular, when the unsaturated polyester resin is obtained by mixing the aliphatic unsaturated dicarboxylic acid with the acid component described in the saturated polyester resin, the aliphatic unsaturated dicarboxylic acid and the saturated polyester resin are used. It has to be obtained by polycondensation under the condition that the above-mentioned acid component does not polymerize. As the aliphatic unsaturated dicarboxylic acid,
Specifically, those having a radical polymerizable double bond in the molecule can be mentioned. For example, maleic acid, fumaric acid, itaconic acid, citraconic acid and the like can be used.

As the alkyd resin having a curable functional group, in addition to an acid component and an alcohol component used in the production of the saturated polyester resin, a monovalent long-chain alcohol component is used to reduce the alkyd resin by an ordinary method. It can be obtained by polymerization. The monovalent long-chain alcohol component is not particularly limited, and examples thereof include soybean oil, safflower oil, coconut oil, castor oil and the like.
As the adhesive for forming the adhesive layer in the present invention, from the viewpoint of the storage stability of the adhesive and the weather resistance of the obtained adhesive layer, the alkyd resin is a short oil having an oil length of 30% or less or an oil having an oil length of 30% or less. It is preferred to use short oil alkyd resins.

As the epoxy resin having a curable functional group, for example, a compound having two or more glycidyl groups (including oxirane) in one molecule is preferably used. Specifically, glycidyl ester resin, bisphenol A condensation reaction product of A with epichlorohydrin, a glycidyl ether-type resin such as a condensation reaction product of bisphenol F with epichlorohydrin, an alicyclic epoxy resin, a flocculent aliphatic epoxy resin, a bromide-containing epoxy resin, A phenol novolak type epoxy resin, a cresol novolak type epoxy resin, or the like can be used.

Further, the urethane resin having a curable functional group is not particularly limited as long as it is a resin having a chain extended by a urethane bond. From the viewpoint of curability, two or more urethane resins per molecule are preferable. Those having a hydroxyl group are preferred. Specifically, the urethane resin can be obtained from a polyisocyanate compound having two or more isocyanate groups in one molecule and a polyol compound having two or more hydroxyl groups in one molecule. Specific examples of the isocyanate compound include diisocyanate compounds: aliphatic diisocyanate compounds such as hexamethylene diisocyanate and trimethylhexamethylene diisocyanate, alicyclic diisocyanate compounds such as isophorone diisocyanate, and tolylene diisocyanate.
Examples thereof include aromatic diisocyanate compounds such as 4,4-diphenylmethane diisocyanate, dimer acid diisocyanate, hydrogenated diisocyanates, dimers and trimers of these diisocyanate compounds, and high molecular weight polyisocyanate compounds. These may be used alone or as a mixture of two or more.

Specific examples of the polyol compound include diol compounds: polyether diol, polyester diol, and polycarbonate diol. Examples thereof include alkylene oxides such as ethylene oxide, propylene oxide, and methylene oxide, and polyethylene glycol. Polypropylene glycol, polyethylene propylene glycol, polytetramethylene ether glycol, polyhexamethylene ether glycol, those obtained by polymerizing or copolymerizing a heterocyclic ether such as tetrahydrofuran such as polyoctamethylene ether glycol, polyethylene adipate, polybutylene adipate, Polyhexamethylene adipate, polyneopentyl adipate, poly-3-methylpentyl adipate , Polyethylene / butylene adipate, polyneopentyl / hexyl adipate; may be mentioned polycaprolactone diol, a polylactone diol of poly-3-methyl-valerolactone diol. These may be used alone or as a mixture of two or more. The method for producing the urethane resin is not particularly limited, and using the polyisocyanate compound and the polyol compound as raw materials,
It can be obtained by methods well known by those skilled in the art.

As the curing agent, various ones well known by those skilled in the art can be selected according to the curable functional group of the thermosetting resin. For example, when the thermosetting resin has a hydroxyl group as a curable functional group, those usable as a curing agent include an amino resin, a blocked isocyanate compound, an aliphatic polycarboxylic acid and its anhydride, and an epoxy resin. Resins can be mentioned. These may be used alone, or two or more of different types or the same type may be used in combination as long as no problem occurs in curability.

Examples of the amino resin include a melamine resin, a benzoguanamine resin, a urea resin and a glycoluril resin. Further, examples of the melamine resin include melamine and alkyl etherified melamine substituted with an alkyl ether group. As the alkyl ether group, a methoxy group and a butoxy group are preferable.

As the blocked isocyanate compound,
What blocked the polyisocyanate compound with the blocking agent can be used. Examples of the polyisocyanate compound include those described above for the urethane resin, and adducts thereof with a polyhydric alcohol such as trimethylolpropane or a low molecular weight polyester resin. These may be used alone or in combination of two or more. The blocking agent is not particularly limited, for example, oximes such as methyl ethyl ketoxime, acetoxime, cyclohexanone oxime, acetophenone oxime, benzophenone oxime, phenols such as m-cresol, xylenol, methanol, ethanol, butanol, 2-ethylhexanol , Cyclohexanol, alcohols such as ethylene glycol monomethyl ether, lactams such as ε-caprolactam, diethyl malonate, diketones such as acetoacetate, mercaptans such as thiophenol, ureas such as thiourea, imidazoles, And carbamic acids.

Examples of the aliphatic polycarboxylic acids include the aliphatic dicarboxylic acids described above for the saturated polyester resin having a curable functional group.

Further, examples of the epoxy resin include the epoxy resin having a curable functional group and the polyepoxy compound such as triglycidyl isocyanurate described above for the thermosetting resin.

On the other hand, when the thermosetting resin has an acid group as a curable functional group, the above-mentioned epoxy resin is usually used, and polyhydroxy compounds and hydroxyalkylamides can also be used.

When the thermosetting resin has an epoxy group as a curable functional group, the above-mentioned aliphatic polycarboxylic acid is usually used, an anhydride thereof, and an alkyd resin having the curable functional group. And acrylic resins having a carboxylic acid group among the above-mentioned acrylic resins having a curable functional group.

The adhesive forming the adhesive layer in the present invention may contain a thermoplastic resin composition as a binder in addition to the thermosetting resin component. Examples of the thermoplastic resin composition include urethane resins, saturated polyester resins, and vinyl polymers such as ethylene-vinyl alcohol polymers.

Further, the thermosetting resin component may include a carbodiimide compound. In particular, when the thermosetting resin component contains a group capable of reacting with a carbodiimide group, for example, a carboxylic acid group, an amino group, an isocyanate group, a hydroxyl group, or the like, further containing a carbodiimide compound, The water resistance of the resulting decorative board is increased. In particular, when a blocked isocyanate is contained as the thermosetting resin component, the effect is high.

The carbodiimide compound is not particularly limited as long as it contains at least one structure represented by -N = C = N-, and specific examples thereof include dicyclohexylcarbodiimide, diisopropylcarbodiimide and the like. Dimethylcarbodiimide, diisobutylcarbodiimide, dioctylcarbodiimide, t-butylisopropylcarbodiimide, diphenylcarbodiimide, di-t-butylcarbodiimide, di-β-naphthylcarbodiimide and the like. It can also be obtained by carbodiimidization using a diisocyanate compound as a raw material.

Examples of the diisocyanate compound include the diisocyanate compounds described above for the polyisocyanate compound of the urethane resin. further,
By using an isocyanate blocking agent in the raw material, the degree of polymerization of the obtained compound having a carbodiimide group can be controlled. As the isocyanate sealing agent, specifically, phenyl isocyanate, tolyl isocyanate, dimethylphenyl isocyanate,
Examples thereof include monoisocyanate compounds such as cyclohexyl isocyanate, butyl isocyanate, and naphthyl isocyanate, and the above-mentioned blocking agents for the above-mentioned blocked isocyanate compounds.

The method for obtaining the carbodiimide compound is not particularly limited, and a conventional method for producing a polycarbodiimide (see, for example, US Pat. No. 2,941,956 and Japanese Patent Publication No.
No. 7-33279, J.P. Org. Chem. , 2
8, 2069-2075 (1963), Chemica
1 Review 1981, Vol. 81, No. 4,6
19-621) and the like, using a carbodiimidization catalyst.

The content of the carbodiimide compound contained in the thermosetting resin component is 10% by weight or less, preferably 6% by weight or less, more preferably 0.5 to 5% by weight, based on the solid content of the thermosetting resin component. 3% by weight. When the content of the carbodiimide compound is more than 10% by weight, it may affect the curing shrinkage at the time of forming the adhesive layer, causing cracks to occur, or shortening the pot life of the adhesive.

Further, the adhesive layer in the present invention may contain various components for increasing the viscosity, increasing the amount, and improving the flame retardancy and the adhesion.

The curing temperature of the adhesive forming the adhesive layer in the present invention is determined by the type of the above-mentioned adhesive. From the viewpoint of energy saving and resource saving and from the viewpoint of the heat resistance of the clear layer and the design layer, The temperature is preferably from 60 to 150 ° C. These adhesives can be selected according to the required performance as a decorative board. For example, when a decorative board is used for a bathroom wall material, a water-resistant adhesive is preferable, and when it is used for a kitchen wall material, a heat-resistant adhesive is preferable.

As described above, the adhesive layer in the present invention comprises:
In addition to the performance as a normal adhesive, it has a hiding effect on the base such as unevenness and color of the base material when the obtained decorative sheet for decorative board is provided on the base material, and furthermore has a design property by including a pigment Can be increased.

The above (1-a), (1-b) and (1)
The decorative sheet for decorative board is formed by the step of -c).

(2) A decorative sheet for decorative board is provided on a base material.
Kicking step (2-a) a fourth step in the method of manufacturing decorative board of attaching process present invention to a sheet of base material, among the steps of providing a pattern sheet for decorative plate onto a substrate, the above-mentioned ( This is a step of pasting the decorative sheet for decorative board obtained by the steps 1-a), (1-b) and (1-c) on a base material.

The substrate in the present invention is not particularly limited, and includes, for example, substrates used for interior materials and outer wall materials in buildings such as houses and buildings. Specifically, gypsum-based substrates such as gypsum board, fiber cement boards such as pulp cement board and wood chip cement board, concrete, metal sheets such as iron and aluminum, paper such as paperboard and gypsum board paper And various resin films such as polyethylene film and polypropylene film, and woody base materials such as wood and plywood. These substrates may be plate-shaped or may be formed into an arbitrary shape. Further, in the case of a base material such as a gypsum board, a calcium silicate plate, a slate plate, etc., a base treatment such as application of a generally applied sealer material or application of a siding sealer material and surface smoothing is performed. Is also good.

In the method for producing a decorative board of the present invention, the decorative sheet for decorative board is attached to the base material on the surface of the adhesive layer formed in the third step. In this step, a method of laminating is generally performed. This is a method in which a decorative sheet for a decorative board and a substrate are integrated while being bonded through a gap between a pair of rollers called a laminator. The material of the roller is preferably one in which one of the two is made of rubber and the other is made of steel in consideration of the material and thickness of the base material. The lamination is preferably performed at a pressure of ^{2 to} 6 kg / cm ² . Furthermore, from the viewpoint of adhesiveness, 80 to 150 ° C.
It is more preferable to carry out while heating.

(2-b) Clear Layer Curing Step The fifth step in the method for manufacturing a decorative sheet of the present invention is obtained in the fourth step of the step of providing a decorative sheet for a decorative sheet on a base material. This is a step of irradiating radiation to the releasable film surface side of the substrate on which the decorative sheet for decorative board is stuck to cure the clear layer.

The radiation used for curing the clear layer in the present invention is an ultraviolet ray or an electron beam, and is used for curing the above-mentioned radiation-curable resin of the clear layer.

The irradiation time of the radiation used for curing the clear layer in the present invention is appropriately set depending on the type of the radiation-curable resin used and the intensity of the irradiated radiation. It is not always necessary to completely cure the radiation-curable resin by irradiation with radiation, and it is sufficient that the radiation-curable resin has sufficient strength to peel off a film having releasability. In that case, the complete curing can be performed appropriately after peeling off the film having releasability.

The above (1-a), (1-b), (1-
A decorative board is manufactured by the steps c), (2-a) and (2-b).

The film having the releasability on the surface of the decorative board can be peeled off when used. The peeling can be performed by a method well known to those skilled in the art.

[0060]

EXAMPLES Preparation Example 1 Preparation of Clear Coating Containing Ultraviolet Curable Resin 67 parts by weight of an acrylic polymer (manufactured by Nippon Synthetic Chemical Industry Co., Ltd., trade name "Corponyl 1355"), urethane acrylate (manufactured by Shin-Nakamura Chemical Co., trade name " NK ester A-
6HA "), 60 parts by weight of toluene, 50 parts by weight of ethyl acetate, and 5 parts by weight of a photopolymerization initiator (trade name" Irgacure 184 "manufactured by Ciba Geigy Co., Ltd.), and the solid content is 40% by weight. Was obtained.

Production Example 2 Polyurethane Resin Adhesive (1)
Preparation of hydroxyl-containing polyurethane resin (manufactured by Hitachi Chemical Polymer,
100 parts by weight of trade name "Hypon 7662"), 5 parts by weight of isocyanate hardener (manufactured by Sumitomo Bayer, trade name "Desmodur R"), 30 parts by weight of titanium dioxide (manufactured by Ishihara Sangyo Co., Ltd., trade name "CR-97") The parts were uniformly mixed to obtain a polyurethane resin adhesive (1).

Production Example 3 Polyurethane resin adhesive (2)
Preparation of Polyurethane Resin Adhesive (2) was obtained in the same manner as in Production Example 2 except that 3 parts by weight of a polycarbodiimide-based resin (trade name “Carbodilite V-03” manufactured by Nisshinbo Industries) was uniformly mixed. .

Embodiment 1 An embodiment of the present invention will be described below in detail with reference to the drawings. FIG. 1 shows an outline of a method for manufacturing a decorative board according to the present invention.

FIG. 1 shows a transparent PET film 1 which is a film having releasability, a die coater 2 for applying a clear paint, a hot air drying furnace 3 for drying the applied clear paint, a transfer roll 4 for transferring a pattern, and an adhesive for applying an adhesive. The outline of a method of manufacturing a decorative board including a die coater 5, a hot-air drying furnace 6 for drying an adhesive, a laminator 7 for attaching a sheet to a substrate, and a high-pressure mercury lamp 8 for curing a clear layer is shown.

After applying the ultraviolet curable resin-containing clear paint obtained in Production Example 1 on a transparent PET film 1 (thickness: 50 μm) supplied from a PET film roll 1 a by a clear paint application die coater 2. , Dried at 80 ° C. for 3 minutes in a hot air drying oven 3 for drying clear paint,
An uncured clear layer having a thickness of μm was formed on the PET film 1. Next, a transfer foil 4a on which a design is formed is placed on the PET film on which the clear layer is formed so that the design is overlapped on the clear layer, and the transfer roll 4 is set to 80 ° C and 4 ° C.
The design was transferred onto the clear layer at Kg / cm ² to form a design layer. Here, the thickness of the design layer was 1 μm. Further, the polyurethane resin adhesive (1) obtained in Production Example 2 was applied thereon by a die coater 5 for applying an adhesive so as to have a dry film thickness of 20 μm, and a hot air drying oven for drying the adhesive at 80 ° C. for 3 minutes. 6 to obtain a decorative sheet for decorative board. The adhesive layer surface of the obtained decorative sheet for a decorative board is superimposed on the slate board 9, and a laminator 7 of a roller pair of a rubber roller and a steel roller is used to apply 4 kg / l.
It was affixed under the conditions of cm ² and 80 ° C. PET film 1 of a slate plate provided with the obtained decorative sheet design sheet
By passing the side surface under a 120 W / cm high-pressure mercury lamp 8 using a condensing reflector at a speed of 10 m / min to cure the clear layer, and for a decorative board without a slate board attached The decorative sheet (1) was obtained by separating the pattern sheet portion with a cutter knife or the like. In addition, the PET film 1 on the surface of the decorative plate can be easily peeled off by hand.

Example 2 The procedure of Example 1 was repeated, except that the polyurethane resin adhesive (2) obtained in Production Example 3 was used instead of the polyurethane resin adhesive (1) obtained in Production Example 2. Thus, a decorative plate (2) was obtained.

Evaluation of the obtained decorative board After the decorative boards obtained in Examples 1 and 2 were cut into a size of 100 × 300 cm by a cutting machine, water resistance was applied to prevent water from entering the cut surface. A hot water resistance test and a boiling water resistance test were performed on the test plate prepared by applying the tape. Table 1 shows the obtained results.

Warm water resistance test In the test plate, the initial interlayer adhesion between the adhesive layer and the clear layer before the test was measured by using a cutter knife to make five parallel lines at 4 mm intervals so as to intersect the vertical direction and perpendicular to it. A cut was made in the direction, and cellophane tape was firmly adhered on the obtained 16 squares, and then it was confirmed by suddenly pulling it forward. After applying a water-resistant tape so that water did not enter where the cuts were made, after immersion in a thermostatic water bath set at 60 ° C. for 10 days, the interlayer adhesion between the adhesive layer and the clear layer was similarly evaluated. . The evaluation criteria were as follows. ◎: No peeling ○: Slight peeling

Boiling Water Resistance Test In the test plate, the initial interlayer adhesion between the adhesive layer and the clear layer before the test was confirmed in the same manner as in the hot water resistance test.
Immerse in a constant temperature water bath set at 100 to 95 ° C for 4 hours,
After drying at 0 ° C. for 2 hours, interlayer adhesion was evaluated in the same manner. The evaluation criteria were as follows. ◎: No peeling ○: Slight peeling

[0070]

[Table 1]

[0071]

The method for manufacturing a decorative board according to the present invention does not require the formation of a base layer in the method for manufacturing a decorative board using a decorative sheet for decorative board. Therefore, a decorative board with high designability can be manufactured in a small number of steps.

Further, the adhesive for forming the adhesive layer in the present invention contains a compound having a carbodiimide group, and particularly when the adhesive is a blocked isocyanate-curable adhesive, Water resistance is significantly improved. This is considered to be because the water resistance of the adhesive layer is improved by increasing the hydrophobicity of the uretonimine group which is considered to be formed by the isocyanate group and the carbodiimide group contained in the adhesive.

[Brief description of the drawings]

FIG. 1 is a process diagram showing one embodiment of an outline of a method for producing a decorative board of the present invention.

FIG. 2 is a view showing a cross section of a decorative board of the present invention manufactured by providing the decorative sheet for decorative board of the embodiment shown in FIG. 1 on a slate board.

FIG. 3 is a view showing a cross section of one obtained by peeling a PET film 1 from the decorative board of FIG. 2;

[Explanation of symbols]

 Reference Signs List 1 PET film 1a PET film roll 2 Die coater for applying clear paint 3 Hot air drying oven for drying clear paint 4 Transfer roll 4a Transfer foil 5 Die coater for applying adhesive 6 Hot air drying oven for drying adhesive 7 Laminator 8 High pressure mercury lamp 9 Slate plate 10 Clear layer 11 Pattern layer 12 Adhesive layer

Continued on the front page F term (reference) 2E110 AA57 AB04 AB22 AB23 BA03 BA11 BB02 BB23 EA09 GA05W GA32W GA33X GB01X GB02X GB06X GB16X GB23X GB52W GB54W 3B005 EB09 FA03 FA08 FB13 FC08Y FC09Y FF08 4F100 AH03G01 KA01BA01BAK CA13G EA021 EH461 EJ08 EJ082 EJ182 EJ52 EJ522 EK082 GB07 HB00 HB00B JB13G JB14B JB141 JL02 JL14C JN01B

Claims (7)

[Claims] 1. A decorative board manufacturing method comprising the steps of: (1) manufacturing a decorative sheet for decorative board using a film having releasability; and (2) providing the decorative sheet for decorative board on a substrate. In the method, the step (1) of producing the decorative sheet for decorative board includes: (1-a) a step of forming a clear layer on a film having releasability by using a clear paint made of a radiation-curable resin ( 1-b) Step of forming a pattern layer on the clear layer obtained in the step (1-a) (1-c) Applying an adhesive on the pattern layer obtained in the step (1-b) Forming an adhesive layer by using the above, and providing the pattern sheet for decorative board on a base material (2).
(2-a) a step of attaching an adhesive layer surface of the decorative sheet for decorative board to the base material; (2-b) a film surface having the releasability of the decorative sheet for decorative board to which the base material is attached; Irradiating radiation to the side and curing the clear layer. 2. The method for manufacturing a decorative board according to claim 1, wherein the adhesive forming the adhesive layer contains a coloring component. 3. The method for manufacturing a decorative board according to claim 1, wherein the adhesive forming the adhesive layer contains a thermosetting resin component. 4. The method according to claim 3, wherein the thermosetting resin component contains a carbodiimide compound. 5. The method for producing a decorative board according to claim 3, wherein the thermosetting resin component contains a blocked isocyanate compound. 6. The method according to claim 1, wherein said adhesive layer has a thickness of 5 to 100 μm. 7. A decorative board manufactured by the method according to claim 1.