JP2001010009A - Decorative sheet excellent in cubic effect and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorative sheet excellent in cubic effects and design properties with depth, and provide further a manufacturing method of the decorative sheet by a method wherein a printed designed layer is provided at an underlayer and a shape having a good uneven pattern over the whole printed designed layer is provided. SOLUTION: In a decorative sheet, which is produced by laminating a sealer layer 3, an adhesive layer 4, a paper base material sheet 5, a design printed layer 7 and an uneven pattern layer 8 on the top surface of a base material in the order named, a primer layer 6 is provided between the paper base material sheet 5 and the design printed layer 7. In addition, the uneven pattern layer 8 is formed by applying and hardening a liquid-repellent-including coating.

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 a three-dimensional appearance, having a picture pattern layer and a thick film uneven pattern layer, which is suitable for various furniture surface materials and building interior materials, and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, as a decorative material having an uneven pattern on its surface, (1) a decorative material on which a pattern of an uneven pattern or a cissing pattern is printed, and (2) embossing by embossing with an embossing roll, an embossing template or the like. Known cosmetic materials are known. However, the decorative material of the above (1) has a poor three-dimensional effect because the pattern is only formed by printing, and the decorative material of (2) has a fine and complicated shape on an embossing roll or an embossed template. Since it is difficult to express the mold, the resulting cosmetic material tends to have a relatively simple uneven pattern, and it is not suitable for the production of small quantities of many kinds, and the production efficiency is poor due to the additional steps. there were.

In order to solve the above-mentioned drawbacks, decorative paper having a printed pattern formed thereon is adhered to a substrate such as plywood, MDF, calcium silicate plate, asbestos slate plate, cement slate plate and the like. A paint containing a liquid-repellent agent is applied from above, and a pattern provided with a concavo-convex pattern on the surface, or using a transfer sheet, transfer a picture pattern to the substrate surface, and also contain a liquid-repellent agent from above the printed pattern There have been proposed coatings coated with a paint and provided with an uneven pattern on the surface, but all have a shallow surface uneven pattern and poor three-dimensional appearance.

[0004]

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and has as its object to provide a print pattern layer as a lower layer and to provide a good print pattern layer over the entire surface of the print pattern layer. It is an object of the present invention to provide a decorative board having a three-dimensional appearance and a deep design property having a shape composed of various uneven patterns, and a method of manufacturing the decorative board.

[0005]

Means for Solving the Problems To achieve the above object, a solution of the present invention is to provide a sealer layer, an adhesive layer, a paper-based substrate sheet, a pattern printing layer, and a concavo-convex pattern layer on an upper surface of a substrate. In the laminated decorative board, a primer layer was provided between the paper-based substrate sheet layer and the pattern printing layer, and the uneven pattern layer was formed by applying and curing a paint containing a liquid repellent. A decorative plate excellent in three-dimensional appearance characterized by the above. With this configuration, the paper-based substrate sheet does not absorb the paint containing the pattern printing ink and the liquid repellent, so that a fine pattern printed layer can be formed, and the liquid repellent effect is large. Expresses a design with excellent three-dimensional appearance.

The average period of the unevenness of the uneven pattern layer is 0.5 to 5 mm, and the average height of the unevenness is 30 to 150 mm.
By forming it as μm, it is possible to obtain a decorative plate having an excellent design, which has a three-dimensional effect and is hardly conspicuous by dirt such as fine foreign substances due to irregular reflection on the surface.

[0007] The invention is also characterized in that the uneven pattern layer made of a paint containing a liquid repellent is mixed with a pigment having glitter. By doing so, it is possible to exhibit a superior effect for the appearance of a three-dimensional effect, and to obtain a decorative plate having more excellent design.

Further, by providing a transparent resin layer between the pattern printing layer and the uneven pattern layer, a paint containing a liquid repellent is applied to the surface of the transparent resin layer. The property is increased and the uneven shape is emphasized. Further, the abrasion resistance of the pattern due to the friction in the concave portions of the uneven pattern layer formed by the paint containing the liquid repellent is improved, and a decorative plate having excellent surface properties can be obtained.

A step of preparing a paper-based decorative sheet in which a picture print layer is laminated on one side via a primer layer, wherein the pattern print layer of the paper-based decorative sheet is not provided with an adhesive applied to the surface of the substrate; A step of placing and adhering a surface so as to be in contact with the adhesive layer surface, and a step of forming an uneven pattern on the surface by coating and curing a paint containing a liquid repellent agent on the surface of the pattern printing layer. By using the method for producing a decorative board excellent in three-dimensional effect described above, a decorative board excellent in three-dimensional effect having the above-described effects can be easily and reliably manufactured.

In the step of applying a coating material containing a liquid repellent to the surface of the pattern printing layer to form a concavo-convex pattern, the coating material containing the liquid repellent is applied by a sponge roll coater to provide a large amount of repellent. Since the paint containing the liquid agent can be stably and uniformly applied, the difference in the unevenness can be increased, and the uneven pattern having a more excellent three-dimensional appearance can be reliably manufactured.

[0011]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, specific embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a sectional view showing a laminated structure of an embodiment of a decorative board excellent in three-dimensional appearance according to the present invention,
FIG. 2 is a cross-sectional view showing a laminated structure of another embodiment of a decorative board having an excellent three-dimensional effect according to the present invention, and FIG. 3 is an explanatory view showing steps of a method of manufacturing a decorative board having an excellent three-dimensional effect according to the present invention.
1, 1 'is a decorative board excellent in three-dimensional appearance, 2 is a substrate, 3 is a sealer layer, 4 is an adhesive layer, 5 is a paper base sheet layer, 6 is a primer layer, 7 is a picture printing layer, and 71 is concealment. Solid layer, 7
2 is a picture pattern layer, 8 is an uneven pattern layer, 9 is a transparent resin layer, 1
0 represents a paper-based decorative sheet.

As shown in FIG. 1, the decorative board 1 of the present invention having excellent three-dimensional appearance has a sheet-like base material sheet 5 on a sealer layer 3 provided on the upper surface of a substrate 2 via an adhesive layer 4. Primer layer 6, concealed solid layer 71 and printed pattern layer 7
Paper-based decorative sheet 10 provided with a pattern print layer 7 composed of
And a concavo-convex pattern layer 8 formed of a coating material containing a liquid repellent is laminated thereon, and is provided thereon by a primer layer 6 provided on the upper surface of the paper base sheet 5. Preventing the paint containing the picture printing ink and the liquid repellent from being absorbed into the paper base sheet 5,
An uneven pattern layer 8 having excellent design is provided on the upper surface of the picture print layer 7.

Next, an example of a method of manufacturing the decorative board 1 having a three-dimensional appearance having an uneven pattern on the surface according to the present invention will be described with reference to the drawings. First, as shown in FIG. 3A, a paper-based decorative sheet 10 in which a primer layer 6, a concealed solid layer 71, and a pattern printing layer 7 composed of a pattern layer 72 are provided on the upper surface of a paper-based substrate sheet 5 is prepared. prepare. Next, FIG.
As shown in FIG. 1, a sealer layer 3 is provided on the surface of a substrate 2.
Next, as shown in FIG.
The paper-based decorative sheet 10 is adhered to the surface via the adhesive layer 4. Further, as shown in FIG. 3D, a decorative sheet 1 having an uneven pattern layer 8 having a three-dimensional appearance is obtained by applying and curing a paint containing a liquid repellent on the upper surface of the picture print layer 7. Can be

As the substrate 2 used for the decorative panel 1 having excellent three-dimensional effect of the present invention, wood board, wood board such as wood veneer, wood plywood, particle board, MDF, hard board, gypsum board,
Plaster-based plates such as gypsum slag plates, calcium silicate plates, asbestos slate plates, lightweight foam concrete plates, inorganic plates such as asbestos cement plates, iron plates, galvanized steel plates, aluminum plates,
A metal plate such as a copper plate is exemplified.

The sealer layer 3 is used, for example, to prevent the elution of the alkali component from the inorganic substrate, to prevent the adhesive from being sucked into the wooden substrate surface, and to improve the adhesion between the paper-based decorative sheet 10 and each substrate 2. The sealer layer 3 made of a curable resin such as a polyisocyanate-based resin, a moisture-curable urethane-based resin, or a styrene-acrylate copolymer resin is preferable as a method for improving the quality performance. .

The configuration of the paper-based decorative sheet 10 for forming the pattern print layer 7 on the decorative plate 1 having excellent three-dimensional appearance includes:
As shown in FIG. 3 (a), a paper-based substrate sheet 5 is provided with a primer layer 6 and a pattern printing layer 7 composed of a concealed solid layer 71 and a pattern layer 72 on one surface thereof. Examples of the paper base sheet 5 include a printing paper for building materials weighing 23 to 65 g / m ² , pure white paper, or a thin paper (so-called reinforced printing paper) in which a thermoplastic synthetic resin is mixed to enhance the inter-paper strength. used. In addition, the primer layer 6
In order to prevent the absorption of the paint containing the picture printing ink and the liquid repellent on which the paper base sheet 5 is provided,
And is provided for the purpose of improving the inter-sheet strength of the paper-based substrate sheet, as the resin used, urethane-based resin, acrylic resin, urea resin, melamine resin, etc. is applied by a known gravure printing method Depending on the type of the base material used at this time, the coating amount is 30 to 60 g /
m ² is suitable, and as the resin to be used, a two-component curable acrylic polyol resin is preferable.

Further, as the picture printing layer 7, a picture pattern layer 72 for expressing, for example, a stone pattern, a cloth pattern, a surface pattern of natural leather, an abstract pattern, etc., may be provided on the concealed solid layer 71 of solid printing. . When the pattern layer 72 is provided on the concealed solid layer 71 as the print layer 7, the concealed solid layer 71 is configured to include only the color pigment and not the glitter pigment, and The concealed solid layer 71 can also contain a brilliant pigment together with the coloring pigment. When the pattern pigment layer 72 contains a glitter pigment, it is possible to make the glitter pigments of the pattern layer 72 and the resin layer 8 containing the liquid repellent different from each other. By making them different from each other and relating them to each other, a special visual effect and a three-dimensional effect can be created.

A coating material containing a liquid repellent for forming a coating layer having a desired concavo-convex pattern is prepared by adding a liquid repellent to an ordinary resin varnish made of a thermoplastic resin, a thermosetting resin, an ionizing radiation-curable resin, or the like. If necessary, other additives, for example, a colorant such as a pigment or a dye, an extender pigment, a solvent, a stabilizer, a plasticizer, a curing agent, and the like can be appropriately mixed. A resin varnish mixed with an acrylic polyol-based resin and a non-yellowing type isocyanate cross-linking agent is preferable as a resin having a good liquid repellency and good design.

As the liquid repellent used in the liquid repellent paint, known ones, for example, silicone, polyethylene wax,
Liquid repellent substances such as paraffin wax, amide wax, wax wax, and vinyl fluoride compound can be used, and silicone is preferable. It is preferable that the amount added be 0.1 to 2.0% by weight based on the composition in the coating composition. The silicone as the liquid repellent substance will be described in more detail. Examples of the silicone include a silicon atom such as a methyl group, a propyl group, a phenyl group, an alkoxy group, a hydroxyl group, an acetoxy group, a halogen atom, and a metal salt. It has a linear, side chain or cyclic structure in which groups are arbitrarily bonded.

As a coating method, known coating means such as a gravure printing method, a roll coating method, and a reverse roll coating method can be used. However, as in the present invention, a concavo-convex pattern excellent in three-dimensional appearance is formed. For example, as a method of uniformly applying a high-viscosity paint having a paint viscosity of 50 to 60 seconds at 25 ° C. (measured with a No. 4 Hodcup viscometer), a natural method using a sponge roll coater is used. It is preferable to coat. The coating amount is 20 to 100 g / m ² (wet state), and preferably 30 to 60 g / m ² (wet state). When the coating amount is as small as less than 20 g / m ² , it is difficult to form coating unevenness or a liquid-repellent portion as a concave portion, resulting in poor design. Conversely, if the coating amount is too large, such as 100 g / m ² or more, the coating of the liquid-repellent portion is repelled and the concave portion is not sufficiently formed.
In addition, the layer is formed thicker than necessary, which is not only disadvantageous in terms of cost, but also makes the underlying pattern printing layer 7 difficult to see and is inferior in design.

As the pigment added to the paint containing the liquid repellent, commonly used organic or inorganic pigments and brilliant pigments can be used. For example, typical pigments include silica, extender pigments, polyazo pigments, isoindolinone pigments, perylene pigments, carbon black and the like. Then, in order to further show a three-dimensional effect, it is preferable to use a glitter pigment. As the glitter pigment, for example, a pigment called a pearl pigment, specifically, a crushed shell or pearl, a mica fine particle baked with titanium oxide or iron oxide, a metal powder (eg, copper, aluminum, Fine particles of preferably 1 to 120 μm of brass, bronze, gold, silver, etc., and pieces of deposited plastic, for example, polyethylene terephthalate film obtained by depositing the above metal (usually aluminum) and pulverizing (silver powder) ),
After the vapor deposition, a transparent yellow paint is applied and pulverized (golden powder). The amount of the pigment having glitter added to the coating material containing the liquid repellent is preferably 1 to 10% by weight.
Conversely, if the amount of the pigment added is too small as 1% or less, the appearance of a three-dimensional effect is insufficient and the design is inferior.

FIG. 2 is a cross-sectional view showing another embodiment of the decorative plate according to the present invention which is excellent in three-dimensional appearance. A picture printing layer 7 of the decorative plate 1 shown in FIG. 1 and a concavo-convex pattern layer 8 made of a paint containing a liquid repellent agent
And a transparent resin layer 9 made of a curable resin is provided between the transparent resin layer 9 and the surface on which the transparent resin layer 9 is provided. It is emphasized, and has a more deep and three-dimensional appearance on the design side, and has improved abrasion resistance and scratch resistance on the performance side.

The resin used for the transparent resin layer 9 includes
Curable synthetic resins such as urethane resins, acrylic resins, and polyester resins are suitable, and two-component curable acrylic urethane resins are particularly preferably used. The thickness is preferably 5 μm or more from the viewpoint of preventing the pattern of the pattern printing layer 7 from disappearing due to friction in the concave portions of the concave and convex pattern layer 9. It is also possible to add a glitter pigment to the transparent resin layer 9 to make the color tone of the pattern printing layer 7 and the color of the uneven pattern layer 8 different from each other. , Can create a three-dimensional effect.

Example 1 A primer layer was formed on thin paper having a weight of 30 g / m ² using an ink composed of a two-component curable acrylic polyol resin, and a nitrocellulose resin was added with an isocyanate curing agent on the primer layer. The solid print layer and the desired pattern ink layer were printed to produce a paper-based decorative sheet. Separately, 30 g / m ² of a polyisocyanate resin paint was applied as a sealer layer to a 5 mm thick calcium silicate plate,
It was prepared by drying at 0 ° C. for 20 minutes. Then, after the vinyl acetate-based adhesive is roll-coated on the surface of the sealer layer of the calcium silicate plate, the paper-based decorative sheet obtained above is laminated and bonded so that the non-printed surface is in contact with the adhesive surface, and then the printing is performed. A two-component curable acrylic urethane resin paint (NO.220 Brighton Silver, manufactured by Osaka Varnish Co., Ltd.) containing a liquid repellent is applied to the layer surface under the conditions of a viscosity of 50 to 60 seconds / NO. 40 g / m ² (wet)
Apply using a sponge roll coater so that
It was cured by heating at 80 ° C. for 20 minutes to obtain a decorative plate having a pattern pattern layer on a lower pattern and having a three-dimensional appearance having glitter and unevenness.

[0025]

As described above, the decorative plate having excellent three-dimensional effect of the present invention has a structure in which a primer layer is provided between a paper-based substrate sheet and a pattern printing layer, thereby providing a paper-based substrate. Since the sheet does not absorb the paint containing the pattern printing ink and the liquid repellent, a fine pattern printing layer can be formed, and the liquid repellent effect is large and the design with excellent three-dimensional appearance can be exhibited. Also, by using a paint containing a brilliant pigment in a paint containing a liquid repellent, it is possible to further enhance the contrast of the concavo-convex pattern and to obtain a sufficient depth, thereby further imparting a sense of quality. it can. Furthermore, since a transparent resin layer is provided between the pattern printing layer and the uneven pattern layer, a coating containing a liquid repellent is applied to the surface of the transparent resin layer, thereby increasing the liquid repellency. This enhances the uneven shape, improves the abrasion resistance of the pattern due to friction in the concave portions of the uneven pattern layer made of the paint containing the liquid repellent agent, and makes it possible to provide a decorative board having excellent surface physical properties.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing a laminated structure of an embodiment of a decorative board excellent in three-dimensional effect according to the present invention.

FIG. 2 is a cross-sectional view showing a laminated structure of another embodiment of a decorative board excellent in three-dimensional effect according to the present invention.

FIG. 3 is an explanatory view showing steps of a method for producing a decorative board excellent in three-dimensional appearance according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1, 1 'Decorative board excellent in three-dimensional appearance 2 Base material 3 Sealer layer 4 Adhesive layer 5 Paper-type base material sheet 6 Primer layer 7 Picture printing layer 71 Concealing solid layer 72 Picture pattern layer 8 Uneven pattern layer 9 Transparent resin layer 10 Paper type decorative sheet

Continued on the front page F-term (reference) 4F100 AA03 AE01 AE06 AJ11 AK01E AK22G AK25 AK36 AK51 AK52 AP01 AP02 AP03 AR00B AR00D AT00A BA05 BA07 BA10A BA10E CA13E CA30E CB00 CC00E DG10C EC182 EH082 EHB EJHB2 EHB2 EHB2 EHB2 EHB2 EHB2 EHB2 EHB2EH462 JL11B JN01E JN21E YY00E

Claims (6)

[Claims] 1. A sealer layer, an adhesive layer,
In a decorative sheet in which a paper-based substrate sheet, a pattern printing layer, and an embossed pattern layer are sequentially laminated, a primer layer is provided between the paper-based base sheet layer and the picture printed layer, and the embossed pattern layer is repelled. A decorative plate excellent in three-dimensional appearance, formed by applying and curing a coating material containing a liquid agent. 2. The irregular pattern layer has an average period of irregularities of 0.5 to 5 mm and an average height of irregularities of 30 to 150 mm.
A decorative plate with excellent three-dimensional effect characterized by a thickness of μm. 3. The decorative plate excellent in three-dimensional appearance according to claim 1, wherein the uneven pattern layer made of a coating material containing the liquid repellent agent is mixed with a pigment having glitter. 4. A transparent resin layer is provided between the pattern printing layer and the uneven pattern layer.
The decorative board excellent in three-dimensional effect according to any one of Items 1 to 3. 5. A step of preparing a paper-based decorative sheet in which a picture print layer is laminated on one side via a primer layer, wherein the pattern print layer of the paper-based decorative sheet is coated with an adhesive applied to the substrate surface. A step of placing and adhering the surface having no surface in contact with the surface of the adhesive layer, and a step of forming an uneven pattern on the surface by coating and curing a paint containing a liquid repellent on the surface of the pattern printing layer. A method for producing a decorative board having an excellent three-dimensional appearance. 6. The step of applying a coating material containing a liquid repellent to the surface of the picture printing layer to form an uneven pattern, wherein the coating material containing the liquid repellent is applied by a sponge roll coater. Item 6. The method for producing a decorative board excellent in three-dimensional effect according to Item 5.