JP2001182276A - Mirror surface decorated plate, and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorated plate which is incombustible, heat-resistant, cleaning-resistance, and excellent in design, in particular, in mirror finish, and a manufacturing method which can provide the decorated plate with high productivity. SOLUTION: In the mirror-finished decorated plate with an adhesive layer, a metal foil layer, a decorated layer, and a transparent or translucent resin layer laminated on at least one surface of an inorganic substrate, the difference in the center line mean roughness between a case of 2.5 mm in cut-off of the surface of the decorated layer and a case, of 0.8 mm in cut-off is <=0.15 μm, and the center line mean roughness is <=0.15 μm in a case of 2.5 mm in cut-off of the surface of the transparent or translucent resin layer. This decorated plate is obtained by providing the adhesive layer on the surface of the inorganic substrate 51, adhering the metal foil layer 21 on the adhesive layer by the steel belt press method, and providing the decorated layer and the transparent or translucent resin layer.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a specular decorative board excellent in mirror properties and excellent in fire resistance, nonflammability, workability and the like, and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, tiles are excellent in nonflammability, high hardness, durability, heat resistance, washing resistance, and the like.
It is often used around kitchen stoves. However, a cement-based material, which is a porous material, is usually used for joints of tiles, and mold and the like are easy to grow, and it is difficult to wash the joints. Therefore, there is a drawback that the cleanliness after long-term use is very poor. In addition, although the tile has the original aesthetic appearance in terms of design, it lacks design variations. Also on the machined surface, there are disadvantages such as difficulty in cutting, so that it is difficult to unitize, requires a long construction period, and the cost of the tile itself is high, resulting in a high total cost.

[0003] In addition, decorative plates in which a metal foil such as stainless steel is adhered to a calcium silicate plate or a wood-based material are also used. For example, the surface is polished to reduce the gloss, and even if scratches or the like occur, they are less noticeable. However, by performing such a treatment, the mirror finish is naturally reduced, and oil stains and the like are easily adhered.

[0004] In view of the above-mentioned problems, a decorative plate used as an inorganic substrate such as a cement plate or a calcium silicate plate has been proposed for the purpose of shortening the construction period and improving the workability of the decorative plate. And since such decorative panels are required to have easy-to-clean from the viewpoint of performance, as well as specularity, high designability, and workability that make it easy to remove dirt from the sense of human appearance, Means have been adopted.

Polishing treatment of substrate An inorganic substrate mainly composed of a calcium silicate plate or a cement-based plate having a bulk specific gravity of about 1.0 is considerably inferior in surface smoothness as compared with a resin plate, wood or a wood-based plate. . For this reason, when such a material is used as a substrate and a mirror surface is required, the smoothness of the substrate surface must be improved by some method. As a typical example, the surface of these inorganic substrates is polished (abrasive paper count # 120 or more). However, several 10 to 100 such as perlite
When a lightweight aggregate having a particle size of about 0 μm is used in the substrate, the polishing process may cause the aggregate to come off and form a concave portion, or to strengthen the glass fiber or the like. In some cases, through holes such as fibers may be generated, and the polishing may deteriorate the smoothness. For this reason, the polishing treatment may be performed after the inorganic or organic or organic-inorganic composite filling material represented by cement or the like is applied.

Substrate Surface Sealer Treatment Inorganic substrates mainly composed of calcium silicate plates and cement-based plates generally have low surface strength and are brittle. Therefore, a sealant is generally used for the purpose of reinforcing the substrate surface. As these sealants, epoxy-based, urethane-based solvent-based or water-based impregnated types are generally used. In the case of industrial coating, these sealers are usually applied before and after application.
Heat treatment is performed by a dryer such as a jet heater or an infrared dryer to improve the impregnation of the sealer and shorten the curing time.

[0007] Filling treatment and base coat treatment In order to impart a mirror surface to the decorative plate, and only by using the treatment, when an inorganic substrate mainly composed of a calcium silicate plate or a cement-based plate is used, the surface smoothness is still insufficient. It is enough. Therefore, for the purpose of further improving smoothness,
A sealing treatment is performed on the surface after the treatment. Usually, a reactive resin containing a solid content such as calcium carbonate filler or fiber is cured by a method such as heat curing, ultraviolet curing, or electron beam curing, and then the surface is polished with a high count (# 180 or higher). To improve the smoothness of the surface. Further, a base coat layer is formed on this layer for stopping alkali from the substrate, durability, and hiding the undercolor. However, if a substrate with relatively excellent surface smoothness can be used, use the leveling property of the paint itself and apply one or more coatings directly to the sealer-treated surface using a coating machine such as a flow coater. In many cases, many paints are applied, the base coat layer is formed thick, and the filling process is omitted. Generally, a urethane resin is preferably used as the resin for the base coat layer. Like the substrate reinforcement sealer, as industrial coating,
In order to shorten the curing time, the plate may be heated before and after application.

[0008] Decorative layer formation Various methods are known for imparting high decorativeness to decorative boards. In recent years, printing such as transfer printing, screen printing, and direct printing, and sputter coating are often performed directly on the base coat.

Formation of Top Coat Layer For the purpose of further improving the performance and design of the decorative board itself such as surface hardness, durability and washing resistance, a transparent or translucent resin layer is provided on the decorative board surface. Form. As a general forming method, the surface of the decorative plate after the decorative layer is formed is heated in a dryer such as a jet heater or an infrared dryer, and the ultraviolet-curable resin or the electronic resin is coated with a coating machine such as a flow coater. Apply a linear reaction curing resin, then
Utilizing the leveling property of the paint itself by allowing it to stand for several minutes in a dryer adjusted to about 50 ° C, finishing the paint surface smoothly and irradiating it with ultraviolet rays or electron beams,
Cure and finish the resin. Instead of applying an ultraviolet-ray-curable resin or an electron-beam-curable resin coating, instead of applying a film of an ultraviolet-ray-curable resin or an electron-beam-curable resin coating, the resin is transferred by irradiating with ultraviolet light or an electron beam. It may be cured and finished.

[0010] As another conventional technique, for example, a decorative resin layer, a decorative sheet, and decorative paper are adhered to a wooden board via an aluminum foil, and an ultraviolet coating layer is provided on the surface of the decorative sheet. A composite panel comprising a plate (JP-A-2-175240), a resin film-laminated metal panel and an inorganic panel joined together (JP-A-5-175240).
No. 33190), a decorative sheet comprising a composite sheet of a fluororesin film and a non-combustible or flame-retardant sheet substrate such as a metal foil attached to the surface of an inorganic plate (Japanese Patent Laid-Open No. 10-109386). JP-A No. 9-125), a fiber-mixed slag cement plate, a metal plate, and a kitchen panel in which a fluororesin film is further adhered to the surface thereof and a printed pattern is formed on the back surface of the fluororesin film or the surface of the metal plate.
No. 562), in a decorative plate comprising a base plate material, a metal foil, a cosmetic agent and an ultraviolet-curable resin, the coating layer of the ultraviolet-curable resin is 7 to 20 μm, and the urethane having a pencil hardness of 7H or more. A decorative plate (Japanese Unexamined Patent Publication No. 9-216308), which is an acrylate oligomer ultraviolet-curable resin, may be used.

[0011] However, the decorative board obtained by the above-mentioned conventional technique has the following disadvantages. That is, regarding the polishing treatment of the substrate, the inorganic substrate itself has very unevenness and the distribution of the voids is uneven, so that holes having a size of several tens of μm or more cannot be smoothed in polishing, so that there are restrictions on the substrates that can be used. Further, in order to solve such a problem, a filling material is required, which has led to an increase in cost. Regarding the filling treatment and the base coat treatment, a reactive resin containing a solid content such as a filler such as a bulking agent such as a calcium carbonate filler or a reinforcing fiber is cured by a method such as heat curing, ultraviolet curing, or electron beam curing. In any of the curing methods, immediately after curing, the temperature of the resin layer rises, and particularly when a relatively thin substrate having a thickness of about several mm is processed, the substrate is warped. Since the thickness is as thin as several tens to 100 μm, troubles such as unpolishing and overpolishing are likely to occur during the subsequent polishing process. That is, shrinkage due to temperature change of the resin layer on the substrate surface and dimensional change due to the change in moisture content of the substrate are complicatedly related to each other. And many defects such as overpolishing. Furthermore, in order to achieve a high specularity, it is necessary to provide a very smooth finish in this layer, and a very high abrasive paper count. In order to perform high count polishing, it is necessary to perform coarse polishing to fine polishing multiple times in order,
Poor productivity and considerable equipment costs. Furthermore,
When performing fine polishing, abrasive paper for fine polishing is intensely consumed,
Running costs also increase. However, even with such an extremely laborious operation, the final product is never satisfactory in terms of specularity.

The above-mentioned Japanese Patent Application Laid-Open No. 2-17524
0, JP-A-5-33190, JP-A-10-
No. 109386, JP-A-9-125562,
There is still room for improvement in the specularity of the decorative plate disclosed in JP-A-9-216308.

[0013]

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a mirror-finished decorative board which is more excellent in specularity than prior art decorative boards, and is also excellent in fire resistance, non-flammability, workability and the like. And a method for manufacturing the same.

[0014]

Means for Solving the Problems As a result of intensive studies, the present inventors have solved the above-mentioned conventional problems.
That is, the present invention relates to a decorative board in which an adhesive layer, a metal foil layer, a decorative layer, and a transparent or translucent resin layer are laminated in this order on at least one surface of an inorganic substrate. The difference between the center line average roughness when off 2.5 mm and the center line average roughness when cut off 0.8 mm is 0.15 μm or less, and the transparent or translucent resin layer surface has a cut off 2.5 mm The center line average roughness at the time of (1) is not more than 0.15 μm. Further, the present invention provides the above-mentioned specular decorative board, wherein the metal foil layer is an aluminum foil layer or a stainless steel foil layer. Further, the present invention provides the above-mentioned specular decorative board, wherein the transparent or translucent resin layer is an ultraviolet-curable resin or an electron-beam-curable resin. Also, the present invention provides a step of providing an adhesive layer on the surface of the inorganic substrate by a desired method, a step of bonding a metal foil on the adhesive layer to provide a metal foil layer, A printing layer is provided by a method, and a cutoff 2.5
making the difference between the center line average roughness at a height of 0.8 mm and the center line average roughness at a cutoff of 0.8 mm equal to or less than 0.15 μm, and forming a resin for a transparent or translucent resin layer on the print layer. To provide a transparent or translucent resin layer,
2.5 m cut-off of the transparent or translucent resin layer surface
a process of making the center line average roughness when m is 0.15 μm or less. Further, the present invention provides a method for producing the above-mentioned specular decorative board, wherein the metal foil layer is provided on the surface of the inorganic substrate by a steel belt press method or a multi-stage press method.

The specularity means that, for example, when an image of a fluorescent lamp or the like is projected on the surface of a decorative plate or the like, the contrast is not reduced and the image is clearly projected. That is, it can be said that both the smoothness and the gloss are collectively referred to. Morita et al. (Smoothing of the flat surface by painting and appearance / surface technology vol.40, No.1,1989) describe the expression of human appearance and its surface shape (surface roughness) with irregularities (waves) that form the surface shape. When the roughness components are classified according to wavelength, short wavelength components of several tens μm or less mainly provide glossiness, medium wavelength components of several tens μm to several hundreds μm have maggot feeling and muddy feeling, and several hundred μm to several mm. It is assumed that each of them gives the sense of distortion of the image in which the long wavelength component is reflected to the human sense.

Further, the present inventors assume that the wavelength is 2.5 mm.
A center line average roughness (hereinafter referred to as Ra (2.
5)) is closely related to the surface smoothness exhibiting specularity, and the value is 0.15 μm or less, preferably 0.1 μm or less.
It has been found that excellent specularity can be exhibited when the thickness is 10 μm or less, more preferably 0.06 μm or less.

The inventors of the present invention have incombustibility and workability and have a Ra (2.5) of the decorative surface of 0.15 μm.
As a result of intensive research to develop a decorative board having a thickness of preferably 0.10 μm or less, more preferably 0.06 μm or less, the surface of an inorganic substrate mainly comprising a calcium silicate board or a cement-based board is preferably specified. A metal foil layer having a roughness curve is laminated, a printing layer having a specific roughness curve is further formed on the surface of the metal foil layer, and a transparent or translucent resin layer having a specific roughness curve is further formed thereon. The decorative plate formed is excellent in design, washing resistance, workability, and productivity, and has been found to be particularly excellent in specularity, and has accomplished the present invention.

Specifically, the feature of the present invention is to focus on a specific wavelength component on the surface of the printing layer and to limit this component, that is, the cutoff of the layer surface is 2.5 mm and the cutoff is 0.8 mm.
mm difference in center line average roughness (Ra)
(Referred to as “2.5-0.8”) is set to 0.15 μm or less (ΔRa (2.5-0.8) is also taken into consideration for the metal foil layer and the decorative layer provided as needed). Is desirable), Ra on the surface of the transparent or translucent resin layer
(2.5) can be made 0.15 μm or less. According to the present invention, the number 100 μm pointed out by Morita et al.
The length of the long wavelength component from m to several mm, especially the shape of the wavelength of 500 μm to 2000 μm which greatly affects the specularity can be reduced on the substrate surface, and while maintaining the workability and work equivalent to the conventional decorative board, A mirror-finished decorative board can be obtained with high productivity.

[0019]

BEST MODE FOR CARRYING OUT THE INVENTION The center line average roughness (R
The definition of a) and the cutoff value is defined in JISB0601. For example, the cutoff value is described as follows.・ Cutoff value For instruments that directly read the surface roughness parameter electrically,
In order to remove high wavelength components of surface irregularities, consider a wavelength component obtained by Fourier-analyzing a cross-sectional curve without using a reference length and removing a long wavelength component. The limit wavelength at which the long wavelength component is removed is the cutoff value. Note that the reference length means the length of a portion of a cross-sectional curve (a contour that appears at a cut edge when the object to be measured is cut on a plane perpendicular to the surface to be measured).

The roughness component distribution for each wavelength is extremely different from the wavelength of the selected cutoff value, and if the component amount is small at wavelengths near the cutoff value, no matter which cutoff value is selected, There is no difference in Ra. However, if the roughness component distribution for each wavelength is non-uniform in some selected cutoff value wavelength ranges, the surface roughness such as Ra naturally changes depending on the selected cutoff value. For example, like a stainless steel plate,
When the wavelength component of about m dominate, Ra
There is no significant difference between (0.8) and Ra (2.5). vice versa,
In the case where relatively large zinc crystals are precipitated on the surface of the steel sheet, such as hot-dip galvanized steel sheet foil, Ra (0.
8) and Ra (2.5) have a large difference. Table 1 shows Ra for each cut-off of a typical stainless steel foil and a galvanized steel sheet foil.

[0021]

[Table 1]

Ra (0.8) indicates a wavelength component of 0.8 mm or less, and Ra (2.5) indicates a wavelength component of 2.5 mm or less. Therefore, ΔRa (2.5-0.8) defined in the present invention is Ra
It shows the difference between (2.5) and Ra (0.8), and indirectly shows the roughness component around the wavelength of 0.8 mm to around 2.5 μm. That is, conversely, a roughness component with a wavelength of about 0.8 mm or less and a swell component with a wavelength of 2.5 mm or more are not included. That is, ΔRa (2.5-0.8) indicating the difference between Ra (2.5) and Ra (0.8) has a wavelength of 0.8 m
The roughness component around m to 2.5 μm is indirectly shown. Conversely, a roughness component having a wavelength of less than 0.8 mm and a swell component having a wavelength of more than 2.5 mm are hardly contained.

The inorganic substrate used in the present invention is heat-resistant, non-flammable and easily available.
Examples include fiber-reinforced calcium silicate moldings, fiber-reinforced cement moldings, fiber-reinforced ceramic moldings, lightweight cellular concrete (ALC), glass, tile, stone, and composites thereof.

If necessary, a substrate reinforcing resin coating is used for the surface layer of these inorganic substrates. The substrate-reinforcement resin coating is not particularly limited as long as it has good impregnating properties to the substrate, can exhibit sufficient substrate strength, and is not damaged by alkali components of many inorganic substrates. The paint can be solvent-based or water-based, and the resin contained therein is preferably a urethane resin, an epoxy resin, an acrylic resin, or the like. The amount of the substrate reinforcing resin coating applied depends on the substrate to be used, the resin to be used, the viscosity, and the like, and is not particularly limited.
When applying a moisture-curable urethane-based substrate reinforcing resin coating to the front and rear calcium silicate plates, 50 g / m ² to 200 g
A coating amount of about g / m ² is preferred. If it is less than 50 g / m ² , the substrate reinforcement is insufficient, and 200 g / m ²
If more coating is applied, a resin film will be formed on the surface of the calcium silicate plate, and when bonding with a metal foil to be described later, an anchor effect can be expected in which the adhesive partially penetrates the substrate to increase the bonding strength. And the adhesive strength is reduced. A known method can be adopted as a method of applying the substrate reinforcing resin paint. For example, roll coater, flow coater,
A coating machine such as an air spray and an airless spray is used. Further, the surface of the inorganic substrate may be heated in advance in order to increase the impregnation of the inorganic substrate and the productivity. Similarly, after application, heating may be performed for the purpose of shortening the curing time.

As the adhesive used for forming the adhesive layer in the present invention, a conventionally known adhesive can be used. For example, thermosetting resin-based adhesives include urea-based, melamine-based, resorcinol-based, phenol-based, epoxy-based, polyurethane-based, polyaromatic, and polyester-based adhesives, and thermoplastic resin-based adhesives. , Vinyl acetate, polyvinyl alcohol, polyvinyl acetal, acrylic, polyethylene, cellulose and the like. In the estramer system,
Chloroprene rubber, nitrile rubber, SBR, SBS-SIS
System, polysulphate system, butyl rubber system, silicone rubber system and the like. Further, since it is preferable to use an adhesive excellent in heat resistance and flame retardancy as much as possible, it is also preferable to use an inorganic adhesive. As the solidification and curing method, room temperature curing type, thermosetting type, hot melt type, pressure sensitive type, rewetting type and the like can be preferably used. In the form of an adhesive,
An aqueous solution, a solvent, an emulsion, a solid (especially a film), a tape, and the like can be preferably used.

The amount of the adhesive applied is such that the adhesive layer has a thickness of 20 μm or more.
The amount is preferably 200 μm, more preferably 50 μm to 150 μm. When the thickness of the adhesive layer is less than 20 μm, it is difficult to apply the adhesive uniformly, and the unevenness of the inorganic substrate may cause the metal foil to adhere on the metal foil even if the metal foil described below is bonded by a predetermined method. Unevenness is generated on the surface, which is not preferable. If it exceeds 200 μm, it is not economically preferable.

With respect to the method of applying the adhesive, an adhesive, an adhesive applying method and an adhesive method that can reduce the surface roughness curve after bonding the metal foil are used. As the most preferable coating method, a method using a flow coater, a knife coater, a doctor knife coater, or a die coater is preferable since the adhesive can be uniformly applied. Coating using a coating machine such as a roll coater, an air spray, or an airless spray, although it is difficult to finish the coated surface smoothly, can be employed by using the bonding method described later.

The metal foil used in the present invention may be appropriately selected according to the purpose, but is preferably as hard as possible.
For example, an aluminum foil or a stainless steel foil having a thickness of 0.05 mm to 0.5 mm, preferably 0.1 mm to 0.5 mm is preferable. Within this range, irregularities due to the inorganic substrate and the adhesive layer are unlikely to remain, and a good mirror finish can be obtained in the final product. It is also preferable from the viewpoint of economy, durability, workability, and the like. Note that copper foil can also be used. The ΔRa (2.5-0.8) of the metal foil is 0.1.
It is 15 μm or less, preferably 0.10 μm or less, and more preferably 0.06 μm or less. Metal foils satisfying this condition include, for example, surface finishes (finishing symbols, No. 2D, No. 2B, No. 3, No. 4) specified in JIS G4305 “Cold rolled stainless steel sheet and steel strip. , # 24
0, # 320, # 400, BA, HL) after surface treatment. It should be noted that use of a matte finish or a textured pattern exceeding the surface finish may not be preferable. Further, as for galvanized steel sheets, zinc crystals are generated on the surface in a normal solidification process, and those having spangles have a surface shape ΔRa (2.5-0.8) of 0.1. Because it is about 5 μm,
Not preferred for use.

Next, the inorganic substrate and the metal foil are bonded.
The metal foil after bonding also has a Ra (2.5-0.8) of 0.1
The thickness is 5 μm or less, preferably 0.10 μm or less, and more preferably 0.06 μm or less. If it exceeds 0.15 μm, a sufficient smooth surface cannot be obtained in the surface shape of the final product, and as a result, it is difficult to obtain a mirror surface, which is not preferable.

As a method for such adhesion, a steel belt press method or a multi-stage press method in which the pressure applied to the inorganic substrate and the metal foil layer can be applied with a surface pressure is suitably used. FIG. 1 is a diagram for explaining a steel belt press method. The steel belt press 1 mainly has a structure in which a pair of steel belts 11 and 12 are wound by rollers 13 and 14, respectively. The metal foil 21 wound in a roll shape is coated with an adhesive by a coating machine 41 such as a die coater through guide rollers 31 and 32, and is further coated with a steel belt through guide rollers 33, 34, 35 and 36. 1
It is fed between 1 and 12 and is simultaneously bonded to the advanced inorganic substrate 51. The two are adhered while being pressed by pressure rollers 61 and 61 '.
It is not due to 3,14. That is, the rollers 13, 1
The steel belt spacing of the four parts must be larger than the substrate and metal foil. The inorganic substrate 51 and the metal foil 21
The steel belt 11 moves while being pressurized in accordance with the rotation of the steel belt 11, and after the bonding is completed, is cut into a desired size by the cutter 71. In the steel belt press method, the pressurizing time can be adjusted by adjusting the substrate feeding speed or the length of the steel belt, and further, by heating the steel belt, the adhesive It is also possible to accelerate the curing. In order to improve the productivity by the steel belt press method, it is desirable to shorten the pressing time. Therefore, as the adhesive, for example, a two-component curable urethane-based, hot-melt-based, or estramer-based adhesive is used. It is preferable to employ it. When a hot melt adhesive is used, the heating temperature is 100 ° C. to 150 ° C.
C. and pressurization time are preferably about 1 minute to 2 minutes.

FIG. 2 is a diagram for explaining the multi-stage pressing method. As shown in FIG. 2A, the multi-stage press 2 includes press dies 81 and 82 and a plurality of press intermediate plates 83. Between the pressing dies 81 and 82 and the pressing intermediate plate 83 or between the pressing intermediate plates, the inorganic substrate 51 and the metal foil 21 are laminated and installed via an adhesive, and then FIG. The pressure is applied between the pressing dies 81 and 82 as shown in FIG. In addition,
Also in the case of the multi-stage press method, the same adhesive as in the steel belt press method is suitably used. The pressurizing time in the multi-stage press method can be adjusted regardless of the size of the apparatus.
However, since the multi-stage press method is a batch type, the production efficiency is inferior to that of the steel belt press method.

The bonding pressure by the steel belt press method and the multi-stage press method is set to 50 kPa to 1000 k in order to ensure sufficient adhesive strength and smoothness after bonding.
About Pa is preferable. If it is less than 50 kPa, it may not be possible to obtain a sufficient adhesive strength. If it is more than 1000 kPa, ΔRa (2.5-0.8)
Is likely to be larger than 0.15 μm, which is not preferable.

On the other hand, when a roll press method in which the pressure is a linear pressure or a vacuum press method in which air is sucked and bonded between the inorganic substrate and the metal foil is used, the inorganic substrate and the adhesive layer are formed on the surface of the metal foil. Unevenness is likely to occur, and ΔRa (2.5-0.8) tends to be larger than 0.15 μm, which is not preferable.

Next, a decorative layer is formed on the metal foil. The decorative layer is composed of a single layer of a coating layer or a printing layer, or a multilayer of a coating layer and a printing layer, and the coating layer is used for masking the color of the metal foil in connection with printing performed in the next step. It is provided for the purpose of improving the design of a printed pattern, improving the adhesion of a printed layer, and the like.

The surface shape of the coating layer is ΔRa (2.5-
0.8) is 0.15 μm or less, preferably 0.10 μm
Or less, more preferably 0.06 μm or less. Therefore, it is preferable that the coating layer is formed by applying a transparent or pigmented paint by a flow coater. When a spray coater is used, a relatively large shape typified by yuzu skin is likely to be generated, and the final product has poor mirror finish. Also, when a roll coater is used, irregularities such as "rolls" are likely to be formed on the coating film surface, which is similarly unfavorable. When a pigment is used, its particle size is such that its surface roughness ΔRa (2.5-0.8) is 0.15 μm or less, preferably 0.10 μm or less, more preferably 0.06 μm or less. There is no particular limitation as long as the size can satisfy the condition. There is no particular limitation on the resin and curing method that can be used as long as the above conditions are satisfied. The coating layer is not particularly limited as long as it can satisfy the performance required for it. Examples thereof include a polyester resin, an amino resin, an epoxy resin, a polyurethane resin, an acrylic resin, and the like, and those to which a pigment or a dye is added for coloring corresponding to the pattern of the coating layer can be preferably used. As the curing method, methods such as room temperature curing, heat curing, ultraviolet curing, and electron beam curing can be exemplified.In particular, when ultraviolet curing or electron beam curing is used, irregularities hardly occur on the coating layer surface,
Particularly preferred. The thickness of the coating layer is not limited as long as the performance of the coating layer is satisfied. However, if it is substantially thinner than 10 μm, it is difficult to conceal the color of the metal foil, and if it is thicker than 200 μm, it is economically undesirable.

As a method of providing a printing layer on a metal foil or a coating layer, a known method can be used. That is, for example, it is preferable to form a decorative pattern using transfer printing, gravure printing, screen printing, offset printing, or an inkjet printer.

However, the surface of the print layer has a ΔRa (2.5-0.8) of 0.15 μm or less, preferably 0.10 μm or less, more preferably 0.1 μm or less.
It needs to be not more than 06 μm. ΔRa (2.5-0.
If 8) exceeds 0.15 μm, the specularity after forming the transparent or translucent ultraviolet-curable resin layer is significantly reduced.
When printing is performed using a transfer foil, ΔRa (2.5-0.8) on the surface of the ink layer of the transfer foil itself is 0.15 μm or less, preferably 0.10 μm or less, more preferably 0.1 μm or less.
06 μm or less is preferred. Any further ΔRa (2.5-0.
When the transfer foil having the above (8) is printed, the ΔRa (2.5-0.8) of the printed layer naturally becomes larger than 0.15 μm, which is not preferable.

A laminate composed of a metal foil layer and a print layer in advance or a laminate in which a metal foil layer, a coating layer and a print layer are sequentially laminated in advance is prepared by using the steel belt press method described above or the multi-stage method. It may be bonded on an inorganic substrate by a pressing method. Also in this case, the surface shape on the laminate is ΔRa
(2.5-0.8) is 0.15 μm or less, preferably 0.10 μm or less, and more preferably 0.06 μm or less.

The transparent or translucent resin layer used in the present invention can be a conventionally known resin, and the curing method is not particularly limited. However, the lacquer type, such as a nitrocellulose derivative, such that a coating film is formed by physically evaporating the solvent in the paint,
Vinyl chloride resin, acrylic resin, vinyl acetal resin, chlorinated rubber, etc. are all those in which the volatiles in the paint evaporate to form a coating film. However, unevenness may occur on the coating film surface, and care must be taken in its selection and drying conditions.

Therefore, an ultraviolet curable resin or an electron beam curable resin containing no solvent or having an extremely small content is suitable for the present invention. When a transparent or translucent resin is cured by ultraviolet light or electron beam, it receives a large amount of energy when the resin is cured by condensation or addition reaction, and generally has a high crosslink density, thereby increasing the hardness and washing resistance. It has advantages such as excellent productivity and excellent productivity due to a very short curing time, and is preferably used.

The UV-curable paints usable in the present invention are:
A paint obtained by forming a transparent coating film or a translucent coating film having excellent coating film characteristics is preferably used. The ultraviolet-curable paint contains a reactive copolymer, a photopolymerizable compound and a photopolymerizable initiator as essential components, and can be obtained by adding an additive for a colorant paint as necessary. For example, the reactive copolymer mainly includes an alkyd resin, a polyester resin, an acrylic resin, a polyurethane resin, an epoxy resin, and the like. In addition, examples of the photopolymerizable compound (polymerizable monomer) include unsaturated polyester and styrene. As the photopolymerizable initiator, a carbonyl compound, an organic peroxide, an azo compound, a halide, a sulfur compound, and the like can be mainly used.

The transparent coating or semi-transparent coating formed of the electron beam-curable resin is made of a resin which can be crosslinked and polymerized by irradiation with an electron beam. The resin cured by this method has an advantage that unlike an ultraviolet curable resin, there is little discoloration and deterioration due to ultraviolet rays, and it can be used outdoors. The resin is
Acrylic resin, polyester resin, epoxy resin, amino resin (melamine resin, etc.), polyamide resin, urethane resin, etc., a functional group-containing substrate having a saturated bond as a skeleton, a vinyl-based substrate having a group capable of being added or polymerized with the functional group And a reactive diluent or a crosslinkable oligomer can be added if necessary. Examples of the vinyl monomer include acrylic acid, methacrylic acid, allyl alcohol, maleic anhydride, methylol acrylamide, methacrylamide, hydroxylethyl acrylate, hydroxylethyl methacrylate, glycidyl acrylate, aminoalkyl, aminoalkyl methacrylate and the like. There is.
As the reactive diluent, acrylic esters,
Examples include methacrylic acid esters, acrylonitrile, methacrylonitrile, styrene, α-methylstyrene, and the like.
Examples of the crosslinkable oligomer include compounds having a molecular weight of 1,000 or less and having 2 to 4 polymerizable vinyl groups, and include diallyl phthalate, ethylene glycol methacrylate, tetraethylene glycol di (meth) acrylate, and bis- (ethylene glycol). (Phthalate) di (meth) acrylate, bis- (diethylene glycol phthalate) di (meth) acrylate, polyethylene glycol di (meth) acrylate, polypropylene glycol di (meth) methacrylate, and the like.

Ra (2.
5) is 0.15 μm or less, preferably 0.10 μm
μm or less, more preferably 0.06 μm or less.
If it is larger than 0.15 μm, the specularity is deteriorated due to a decrease in gloss, sharpness and the like. As a method for forming such a surface shape, a flow coater is suitably used. When a spray coater is used, relatively large shapes such as citron skin are easily generated, and the specular direction of light incident on the coating surface changes, resulting in a decrease in specularity. Resulting in. Also, when a roll coater is used, irregularities such as "rolls" are likely to be formed on the coating film surface, which is similarly unfavorable. Furthermore, in recent years, there is a method in which a UV transparent or translucent film is adhered by a roll press and then cured by UV irradiation. However, this method is also not preferable because irregularities easily occur on the coating film surface similarly to the roll coater.

[0044] The amount of coating, the thickness of the transparent or semi-transparent resin layer may have a coating weight such that the larger 200μm or less than 20 [mu] m, for example 20g / m ² ~250g / m ² is preferably about. In order to obtain a smooth surface by using leveling after application of the paint, the larger the amount of application, the better. Therefore, it is desired that the thickness of the coating film is larger than 20 μm.
However, the curing method using such ultraviolet rays is
The thickness of the coating must be such that the ultraviolet rays enter, and therefore the thickness of the coating is preferably 200 μm or less. In the present invention, “transparent or translucent” means that the total light transmittance is 70%.
Means ~ 100%.

[0045]

The present invention will be described below with reference to examples and comparative examples, but the present invention is not limited by the following examples. The surface roughness (Ra) of each layer is JIS B06
Measured according to Appendix 01. In addition, the metal foil layer, the coating layer, and the printing layer were measured during preparation. Table 2 shows the measurement conditions.

[0046]

[Table 2] Ra cut-off (mm) Evaluation length (mm) Ra (0.8) 0.8 8 Ra (2.5) 2.5 8

Example 1 First, a calcium silicate plate (manufactured by Ask Co., Ltd., trade name: Cellstone, thickness: 6 mm) polished in advance with a polishing paper count 120
100g of a moisture-curable urethane sealer (trade name TOA AS sealer, manufactured by Tope Co., Ltd.) using a roll coater
/ M ² and left in the room for 24 hours, stacking, 2
It was left to cure further indoors for another week. Next, a hot-melt adhesive was applied to the back of a 0.1 mm thick stainless steel foil (SUS304 BA finish, manufactured by Kawasaki Steel Corporation) using a die coater.
0 g / m ² (manufactured by Takeda Pharmaceutical Co., Ltd.)
After leaving it for 0 seconds, it was bonded to a calcium silicate plate by a steel belt press method at a press pressure of 300 kPa.
The substrate having the metal foil layer is allowed to stand in a dryer controlled at 100 ° C. for 5 minutes to set the surface of the metal foil to about 50 ° C., and then coated with a flow coater (Nippon Paint Co., Ltd.).
Co., Ltd., trade name: Rurile 310 / solvent urethane system) and baked in a dryer adjusted to 100 ° C. for 5 minutes to form a 30 μm thick coating layer. Next, the transfer foil (Dai Nippon Printing Co., Ltd. natural stone pattern) was subjected to hot roll transfer under the conditions of a rubber hardness of 70, a roll temperature of 200 ° C., and a feed speed of 3 m / min to form a print layer. Next, using a flow coater on the printing layer, an ultraviolet-curable paint (Nippon Paint Co., Ltd.)
Co., Ltd., trade name AF1 clear) 80 g / m ² was applied. After leaving it to stand in a room for 2 minutes, it was irradiated with ultraviolet rays and cured to form a top coat layer (transparent or translucent resin layer).

Example 2 In the same manner as in Example 1, a sealer was applied to a calcium silicate plate and cured. Next, a synthetic rubber-based adhesive (Konishi Co., Ltd.) was applied to the back of the 0.1 mm thick stainless steel foil (SUS304 No.4 finish, manufactured by Kawasaki Steel Corp.) and the surface of the calcium silicate plate.
(Trade name: Bond G series) was applied by air spray at a rate of 100 g / m ² each. After leaving for 1 minute after application, the stainless steel foil and calcium silicate plate were stuck together and pressed lightly with a hand roll.
a, A multi-stage press was performed under the conditions of a pressurization time of 60 minutes to bond the stainless steel foil and the calcium silicate plate. Next, a decorative layer, a printing layer, and a top coat layer were formed in the same manner as in Example 1.

Example 3 In the same manner as in Example 1, a sealer was applied to a calcium silicate plate, cured, and a metal foil and a calcium silicate plate were bonded.
No coating layer was formed. Next, transfer foil (topographic printing
Rubber stone hardness 70, roll temperature 200
Heat roll transfer under the condition of ° C and feed rate 3m / min,
A printing layer was formed. Next, the top coat layer was formed in Example 1.
It was formed in the same manner as described above.

Example 4 In the same manner as in Example 2, a sealer was applied to a calcium silicate plate, cured, and a metal foil and a calcium silicate plate were bonded.
The metal foil used was an aluminum foil having a thickness of 0.1 mm (manufactured by Tokai Aluminum Foil Co., Ltd.). About a coating film layer, a printing layer, and a top coat layer, it carried out similarly to Example 1.

Comparative Example 1 In the same manner as in Example 1, a sealer was applied to a calcium silicate plate and cured. Next, 80 g / m ² of an acrylic urethane emulsion adhesive (manufactured by Konishi Co., Ltd., trade name: CVC series) was applied to the same aluminum foil back surface as in Example 4 using a roll coater. Furthermore, press pressure 300kP
a, The aluminum foil and the calcium silicate plate were bonded by a vacuum press method under the conditions of a temperature of 110 ° C. and a pressing time of 3 minutes.
For the coating layer, printing layer, and topcoat layer, see Example 1.
The same was done.

Comparative Example 2 The procedure up to the formation of the coating layer was carried out in the same manner as in Example 1. Next, transfer foil (marble pattern manufactured by Wasin Chemical Industry Co., Ltd.) by roll transfer
With a rubber hardness of 70, a roll temperature of 200 ° C., and a material feeding speed of 3.
The transfer pattern was printed under the condition of m / min to form a print layer.
Next, the same top coat layer as in Example 1 was formed.

Comparative Example 3 The procedure up to the formation of the print layer was performed in the same manner as in Example 1. Then UV
A transparent or translucent film (manufactured by Nippon Paint Co., Ltd.) has a rubber hardness of 70, a roll temperature of 200 ° C., and a material feeding speed of 3 m /
After bonding by a roll press under the conditions of minutes, the composition was cured by UV irradiation to form a top coat layer.

Comparative Example 4 In the same manner as in Example 2, a sealer was applied to a calcium silicate plate, cured, and a metal foil was bonded to the calcium silicate plate.
Note that a hot-dip galvanized steel sheet (Regular spangle, manufactured by Kawasaki Steel Co., Ltd.) having a thickness of 0.1 mm was used as the metal foil. About a coating film layer, a printing layer, and a top coat layer, it carried out similarly to Example 1.

Comparative Example 5 A calcium silicate plate (manufactured by Ask Co., Ltd., trade name: Cellston 6 mm) polished in advance with a polishing paper count 120 was used. The substrate was left in an atmosphere of 100 ° C. for about 5 minutes, and then a moisture-curable urethane sealer (trade name: U-60, manufactured by Nippon Paint Co., Ltd.) of 60 g / roll coater was used.
and m ² is applied. Thereafter, 60 g / m ² of an ultraviolet-curable paint (trade name: Ubicoat 60 Sanding Sealer, manufactured by Nippon Paint Co., Ltd.) is applied by a roll coater and a natural reverse coater, and then irradiated with ultraviolet rays.
Cured. Immediately thereafter, polishing was performed with a polishing paper count 180. Next, 110 g / m ² of a baking type urethane paint (manufactured by Nippon Paint Co., Ltd., trade name: Rurile 310) was applied by a flow coater, and baked in a 100 ° C. atmosphere for 5 minutes. The processing after the roll transfer was performed in the same manner as in Example 1.

With respect to the test pieces prepared in the examples and comparative examples, Ra (2.5), Ra (0.8) and Δ
Table 3 shows Ra (2.5-0.8). From Table 3, it can be seen that the decorative plate of the example has a surface shape Ra under the top coat layer of ΔRa.
(2.5-0.8) is smaller than that of the comparative example, and Ra (2.5) on the top coat layer is also smaller. As a result, it is understood that the mirror surface is excellent.

[0057]

[Table 3]

[0058]

According to the present invention, it is possible to provide a decorative board which has both nonflammability, heat resistance and washing resistance, and furthermore has excellent design properties, especially excellent mirror finish. The production method of the present invention can provide such a decorative board with high productivity. INDUSTRIAL APPLICABILITY The decorative panel of the present invention can be suitably used particularly for a kitchen panel arranged around a gas stove in a kitchen.

[Brief description of the drawings]

FIG. 1 is a view for explaining a steel belt press method.

FIG. 2 is a diagram for explaining a multi-stage pressing method.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Steel belt press machine 11, 12 Steel belt 13, 14 Roller 21 Metal foil 31, 32, 33, 34, 35, 36 Guide roller 51 Inorganic substrate 61, 61 'Pressure roller 71 Cutter 81, 82 Pressing die 83 Intermediate plate for press

Continuing from the front page (72) Inventor Kokuni Nakamura 6-1, Kashiwara, Ishioka City, Ibaraki Prefecture Inside the Building Materials Techno Lab. 72) Inventor Hideki Honma 3-8-1, Nishikanda, Chiyoda-ku, Tokyo F-term in the Building Materials Techno-Research Laboratory (reference) 2E110 AA02 AA57 AB43 BA04 BA12 BB02 BB04 EA09 GA05W GA07W GA23X GA24X GA32Z GA33X GA42X GB03Z GB06Z GB07 GB17 GB23X GB26X GB28X GB32X GB44W GB46W

Claims (5)

[Claims] 1. A decorative plate comprising an inorganic substrate, an adhesive layer, a metal foil layer, a decorative layer, and a transparent or translucent resin layer laminated in this order on at least one surface of the inorganic substrate. The difference between the center line average roughness when off 2.5 mm and the center line average roughness when cut off 0.8 mm is 0.15 μm or less, and the transparent or translucent resin layer surface has a cut off 2.5 mm The mirror-finished decorative board, wherein the center line average roughness at the time of (1) is 0.15 μm or less. 2. The mirror-finished decorative board according to claim 1, wherein the metal foil layer is an aluminum foil layer or a stainless steel foil layer. 3. The mirror-finished decorative board according to claim 1, wherein the transparent or translucent resin layer is an ultraviolet curable resin or an electron beam curable resin. 4. A step of providing an adhesive layer on a surface of the inorganic substrate by a desired method, a step of bonding a metal foil on the adhesive layer to provide a metal foil layer, and a step of providing a desired metal layer on the metal foil layer. A printing layer was provided by a method, and the center line average roughness and the cutoff of 0.8 mm when the cutoff of the surface of the printing layer was 2.5 mm.
a step of making the difference from the center line average roughness at the time of 0.1 mm or less, and providing a transparent or translucent resin layer by laminating a transparent or translucent resin layer resin on the print layer, Making the center line average roughness of the transparent or translucent resin layer surface at a cutoff of 2.5 mm equal to or less than 0.15 μm. 5. The method for producing a specular decorative board according to claim 4, wherein the metal foil layer is provided on the surface of the inorganic substrate by a steel belt press method or a multi-stage press method.