JP2006341416A - Method for manufacturing decorative laminate and adhesive layer transfer sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a decorative laminate with excellent designability, water resistance and durability, using a printable image receiving layer transfer sheet and an adhesive layer transfer sheet by an oily pigment-series inkjet process, and an adhesive layer transfer sheet used for this method. <P>SOLUTION: This method comprises the following processes: a process to superpose the adhesive layer transfer sheet with at least an adhesive layer formed releasably on a base material sheet A, over a decorative substrate, and heat-transfer the adhesive layer to the decorative substrate by heat-pressurizing; a process to form an image on the surface of an image receiving layer transfer sheet with at least an image receiving layer formed releasably on a base material sheet B by discharging the oily pigment-series ink with the help of an inkjet printer according to image information; and a process to superpose the decorative substrate with the transferred adhesive layer over the image receiving layer transfer sheet with the formed image, and transfer the image receiving layer to the adhesive layer by heat-pressurizing. The adhesive layer of the adhesive layer transfer sheet contains at least a urethane resin. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

The present invention relates to a method for producing a decorative board using a transfer sheet that can be recorded by an oil-based pigment-based ink jet system, and an adhesive layer transfer sheet used therefor.

As a method for producing a decorative board having excellent design properties, a method for printing directly on a decorative substrate has been conventionally known. As these printing methods, known printing techniques such as normal gravure printing, offset printing, silk screen printing, and ink jet printing can be used. In particular, ink jet printing is simple in output method, print quality, and printing in small lots. Is characterized by low cost.
However, when printing directly on a decorative substrate with an ink jet or when a decorative sheet is produced by providing an adhesive layer on the back of a decorative sheet printed with an ink jet and pasting the decorative substrate, the final product surface is the printed surface. Therefore, the durability of the surface is inferior, and the water resistance of the product obtained is inferior when the printing method is an ink jet method using a water-based ink.

  On the other hand, in the case of a method in which a pressure-sensitive adhesive layer is provided on the back of a decorative sheet printed with an oil-based pigment-based ink jet and bonded to a resin plate, a product superior in water resistance can be obtained as compared with a water-based ink jet method. Also, the printed surface was exposed to the pigment, and the durability was not sufficient. It has also been proposed to use a protective film or the like laminated on the print surface, but in the printed portion, the pigment ink and the decorative substrate are difficult to adhere and cannot be said to have sufficient quality.

  In Patent Document 1, a transfer medium in which an image forming layer is provided on a base material and an adhesive layer transfer sheet are prepared, and an image is formed on the image forming layer by inkjet. On the other hand, the adhesive layer transfer sheet is heated and pressed in accordance with the transfer object to transfer the adhesive layer. There is provided an image forming method in which an image forming layer having an image formed on an adhesive layer surface is transferred by heating and pressing. However, nothing is provided about a method for producing a decorative board having excellent design properties, water resistance, and durability by image formation by an oil-based pigment-based ink jet, and a specific configuration of an adhesive layer transfer sheet for use therein. There wasn't.

Japanese Patent Laid-Open No. 2001-310597

Accordingly, an object of the present invention is to provide a method for producing a decorative board excellent in design, water resistance, and durability using an image-receiving layer transfer sheet and an adhesive layer transfer sheet that can be printed by an oil-based pigment-based inkjet method, and to be used for the method. An adhesive layer transfer sheet is provided.

In order to solve the above-mentioned problems, the present invention is such that at least an adhesive layer transfer sheet provided with a peelable adhesive layer and a decorative substrate are superposed on a base sheet A, and heated and pressed to apply the adhesive layer to the decorative substrate. And a step of forming an image by ejecting oil-based pigment-based ink according to image information with an ink jet printer onto the surface of the image-receiving layer transfer sheet on which at least the image-receiving layer is detachably provided on the base material sheet B And a step of transferring the image receiving layer onto the adhesive layer by superimposing and heating the decorative substrate onto which the adhesive layer has been transferred and the image-formed image receiving layer transfer sheet. It was set as the manufacturing method.
Furthermore, the present invention provides a method for manufacturing a decorative board, wherein the decorative substrate is a plastic substrate.

  In the present invention, the adhesive layer of the adhesive layer transfer sheet can be thermally transferred to a decorative substrate by heating and pressurization, and the image receiving layer is formed with an oil-based pigment-based inkjet ink on the image receiving layer transfer sheet. The adhesive layer transfer sheet can be bonded by heating and pressing.

Furthermore, the adhesive layer transfer sheet is characterized in that the adhesive layer contains a material having a softening point lower than the softening point of the decorative substrate.
Furthermore, the adhesive layer transfer sheet is characterized in that the adhesive layer contains at least a urethane resin.

If the production method and adhesive layer transfer sheet of the present invention are used, a decorative board excellent in design, water resistance and durability can be obtained.

Embodiments of the present invention will be described below.
The decorative substrate used in the present invention can be a plastic substrate, a metal substrate, a glass substrate or the like that is usually used, and the thickness of the plate can be about 1 mm to 50 mm, but is not particularly limited. .

FIG. 2 is a cross-sectional view showing the form of the image-receiving layer transfer sheet used in the present invention, and a peelable image-receiving layer is provided on one surface of the substrate sheet B.
Various resin sheets can be used for the base sheet B, and polyethylene, polypropylene, polybutene, ethylene propylene copolymer, ethylene-vinyl acetate copolymer, polyethylene terephthalate, acrylic, vinyl chloride, polycarbonate, polyamide, etc. are used. Is possible. Particularly preferably, it is a base sheet mainly composed of polyethylene terephthalate, and may contain an additive for the purpose of improving sheet physical properties. Further, the thickness of the substrate sheet is preferably 20 μm to 200 μm from the viewpoint of workability, but is not limited thereto. The base sheet may be appropriately subjected to known easy adhesion treatment or antistatic treatment as necessary.

  As a component of the image receiving layer, known materials can be used, such as vinyl chloride resin, vinyl chloride-vinyl acetate copolymer resin, chlorinated polyolefin, urethane resin, polyester resin, ethylene-vinyl acetate copolymer resin, acetic acid. Vinyl resin, acrylic resin, etc. can be used. Among these, it is preferable to contain a vinyl chloride resin, a vinyl chloride vinyl acetate copolymer resin, and a chlorinated polyolefin. If the image receiving layer contains a vinyl chloride resin, a vinyl chloride vinyl acetate copolymer resin, or a chlorinated polyolefin, a high-definition image can be formed with an oil-based pigment inkjet ink. In particular, when the content of the resin such as vinyl chloride resin, vinyl chloride vinyl acetate copolymer resin, chlorinated polyolefin or the like in the image receiving layer is 50% by weight or more, the above effect can be sufficiently obtained.

  In addition to the above components, it is possible to add fine particles, an ultraviolet ray inhibitor, an antistatic agent, a lubricant and the like to the image receiving layer. Examples of additives that can be added include silica, alumina, calcium carbonate, magnesium carbonate, aluminum hydroxide, magnesium hydroxide, zinc oxide, magnesium oxide, aluminum silicate, calcium silicate, zeolite, mica, carbon black, titanium white, and zinc white. , Petal, bitumen, cadmium red, azo pigment, lake pigment, anthraquinone pigment, phthalocyanine pigment, quinacridone pigment, isoindolinone pigment, imidazolone pigment, dioxazine pigment, gold powder, silver powder, copper powder, aluminum powder, fish scale powder, pearl pigment , Fluorescent pigments, luminescent pigments, or a mixture of two or more selected from these pigments can be used.

  The thickness of the image receiving layer is not particularly limited, but is preferably 2 μm or more from the appropriate recording property of the oil-based pigment inkjet ink.

  FIG. 1 is a cross-sectional view showing a form of an adhesive layer transfer sheet of the present invention, and a peelable adhesive layer is provided on one surface of a base sheet A. FIG. Various resin sheets can be used for the base sheet A, and polyethylene, polypropylene, polybutene, ethylene propylene copolymer, ethylene-vinyl acetate copolymer, polyethylene terephthalate, acrylic, vinyl chloride, polycarbonate, polyamide, etc. are used. Is possible. Particularly preferably, it is a base sheet mainly composed of polyethylene terephthalate, and may contain an additive for the purpose of improving sheet physical properties. Further, the thickness of the substrate sheet is preferably 20 μm to 200 μm from the viewpoint of workability, but is not limited thereto. The base sheet may be appropriately subjected to known easy adhesion treatment or antistatic treatment as necessary.

  Adhesive layer has adhesiveness to decorative substrate and image-receiving layer transfer sheet by heating and pressing, and is characterized by acrylic resin, vinyl chloride resin, vinyl acetate resin, vinyl chloride-vinyl acetate copolymer resin, urethane resin, polyester Contains resin, epoxy resin, ethylene-vinyl acetate copolymer resin, polyamide resin, chlorinated polyolefin, and the like.

In particular, it is preferable to contain a urethane resin from the viewpoint of adhesiveness with the image receiving layer transfer sheet.
In addition to the above-mentioned components, fine particles, ultraviolet light inhibitors, antistatic agents, lubricants and the like can be added to the adhesive layer. Examples of additives that can be added include silica, alumina, calcium carbonate, magnesium carbonate, aluminum hydroxide, magnesium hydroxide, zinc oxide, magnesium oxide, aluminum silicate, calcium silicate, zeolite, mica, carbon black, titanium white, and zinc white. , Petal, bitumen, cadmium red, azo pigment, lake pigment, anthraquinone pigment, phthalocyanine pigment, quinacridone pigment, isoindolinone pigment, imidazolone pigment, dioxazine pigment, gold powder, silver powder, copper powder, aluminum powder, fish scale powder, pearl pigment , Fluorescent pigments, luminescent pigments, or a mixture of two or more selected from these pigments can be used.

  The adhesive layer may contain a material having a softening point lower than that of the decorative substrate. In particular, when a plastic substrate is used as the decorative substrate, the adhesive layer preferably contains a material lower than the softening point of the plastic substrate. By containing a material lower than the softening point of the decorative substrate, the heating temperature does not need to be excessively higher than the softening point of the plastic substrate in the step of heating and pressing to thermally transfer the adhesive layer to the decorative substrate. As a result, it is possible to prevent the decorative board from warping (and the like in the process of transferring the image receiving layer by heating and pressing).

  Examples of the plastic substrate material include acrylic resin, polycarbonate resin, ABS resin, polyester resin, polypropylene resin, and vinyl chloride resin.

  Materials that are lower than the softening point of the decorative substrate include urethane resin, acrylic resin, epoxy resin, polyamide resin, polyester resin, ketone resin, chlorinated polyolefin resin, maleic acid-modified olefin resin, ethylene-vinyl acetate copolymer resin, etc. Is possible.

  The thickness of the adhesive layer is not particularly limited, but is preferably 1 μm and more preferably 3 μm or more in order to ensure adhesion between the decorative substrate and the oil-based pigment inkjet ink. In consideration of productivity, the thickness is preferably 100 μm or less.

Next, the manufacturing method of the decorative board of this invention is demonstrated. On the base material sheet A, the adhesive layer transfer sheet on which at least the adhesive layer is detachable and the decorative substrate are superimposed, and heated and pressed. Although heating temperature is not specifically limited, 60 degreeC or more is preferable. In the case of 60 ° C. or lower, the adhesive layer transfer sheet and the decorative substrate may not be sufficiently bonded. Moreover, it is preferable to set it as 180 degrees C or less. In the case of 180 degreeC or more, the base material sheet A may receive damage, such as shrinkage | contraction by a heat | fever. Moreover, when a plastic substrate is used for the decorative substrate, the plastic substrate may be deformed, which is not preferable. Next, the base material sheet A is peeled off, and the adhesive layer is transferred onto the decorative substrate. On the other hand, an oil-based pigment-based ink is ejected on the surface of the base sheet B according to image information by an ink jet printer on the surface of the image receiving layer transfer sheet provided with at least the image receiving layer so as to be peeled off, thereby forming an image. Next, the decorative substrate having the adhesive layer transferred thereon and the image-formed image-receiving layer transfer sheet are superposed and heated and pressed. Although heating temperature is not specifically limited, It is preferable to set it as the same range of 60-180 degreeC as the temperature which piles up and heats an adhesive layer transfer sheet and a decorative substrate. Next, the base sheet B is peeled off, and the image receiving layer is transferred to the decorative substrate on which the adhesive layer is transferred to produce a decorative board. As a method for heating and pressurizing, a method using a hot laminator, a hot plate, a hot stamper, a line heater, an iron or the like is suitable, but is not limited thereto.

Example 1
The adhesive layer coating solution 1 is applied to a substrate sheet made of polyethylene terephthalate having a thickness of 25 μm (trade name; Lumirror S10, manufactured by Toray Industries, Inc.) with a Meyer bar coater so as to be 4 μm at the time of drying. A layer transfer sheet 1 was produced. Next, the surface of the adhesive layer of the obtained adhesive layer transfer sheet 1 is opposed to the surface of a plastic substrate made of polymethyl methacrylate having a thickness of 4 mm and a softening point of 120 ° C., and heated using two rubber rolls heated to 130 ° C. The adhesive layer was thermally transferred onto the plastic substrate by pressing.
On the other hand, the image-receiving layer coating solution 1 is applied to a substrate sheet made of polyethylene terephthalate having a thickness of 38 μm (trade name; Lumirror S10, manufactured by Toray Industries, Inc.) with a Mayer bar coater so as to be 10 μm when dried. Thus, an image receiving layer transfer sheet 1 was prepared. Next, an image was printed on the surface of the image-receiving layer of the obtained image-receiving layer transfer sheet with an oil-based pigment-based ink jet printer (trade name; JV-3, manufactured by Mimaki Engineering Co., Ltd.) to produce an image-receiving layer transfer sheet 1 on which the image was formed. Furthermore, the image receiving layer surface of the image receiving layer transfer sheet 1 on which the image is formed is opposed to the surface of the plastic substrate on which the adhesive layer is transferred, and the image receiving layer is heated and pressed by using two rubber rolls heated to 130 ° C. A decorative board was produced by thermally transferring the film onto a plastic substrate.

Adhesive layer coating solution 1
Urethane resin (trade name: Samprene IB-104, solid content 30%, softening point 110 ° C., manufactured by Sanyo Chemical Co., Ltd.) 40 parts by weight methyl ethyl ketone 60 parts by weight Image-receiving layer coating solution 1
Vinyl chloride-vinyl acetate copolymer (trade name: VAGH, manufactured by Union Carbide) 20 parts by weight Methyl ethyl ketone 80 parts by weight

(Example 2)
A decorative board was produced in the same manner as in Example 1 except that the adhesive layer coating solution 2 was used as the adhesive layer coating solution.
Adhesive layer coating solution 2
Urethane resin (trade name: Samprene IB-582, solid content 42%, softening point 120 ° C., Sanyo Chemical Co., Ltd.) 20 parts by weight chlorinated polypropylene resin (trade name; Supercron C, solid content 55%, softening point 70 ° C., Nippon Paper Chemicals) 20 parts by weight Toluene 60 parts by weight

(Example 3)
A decorative board was produced in the same manner as in Example 1 except that the adhesive layer coating solution 3 was used as the adhesive layer coating solution.
Adhesive layer coating solution 3
Urethane resin (trade name: Samprene IB-582, solid content 42%, softening point 120 ° C., Sanyo Kasei) 20 parts by weight ketone resin (trade name: Synthetic Resin AP, solid content 100%, softening point 80 ° C., Union Carbide 20 parts by weight toluene 60 parts by weight

Example 4
A decorative board was produced in the same manner as in Example 1 except that the adhesive layer coating solution 4 was used as the adhesive layer coating solution.
Adhesive layer coating solution 4
20 parts by weight of urethane resin (trade name: Samprene IB-582, solid content 42%, softening point 120 ° C, manufactured by Sanyo Chemical Co., Ltd.) (trade name; Aurolen 200S, solid content 100%, softening point 70 ° C) (Made by Nippon Paper Chemicals) 5 parts by weight Toluene 75 parts by weight

(Example 5)
A decorative board was produced in the same manner as in Example 1 except that the adhesive layer coating solution 5 was used as the adhesive layer coating solution.
Adhesive layer coating solution 5
Urethane resin (trade name: Samprene IB-582, solid content 42%, softening point 120 ° C., manufactured by Sanyo Chemical) 25 parts by weight Toluene 75 parts by weight

(Example 6)
A decorative board was prepared in the same manner as in Example 1 except that the adhesive layer coating solution 6 was used as the adhesive layer coating solution, and two rolls were heated to 150 ° C. when the image receiving layer was thermally transferred to the surface of the plastic substrate. .
Adhesive layer coating solution 6
Urethane resin (trade name: Samprene IB-582, solid content 42%, softening point 120 ° C., Sanyo Kasei) 15 parts by weight polyester resin (trade name: Elitel UE3200, solid content 100%, softening point 165 ° C., manufactured by Unitika) 5 parts by weight Toluene 40 parts by weight Methyl ethyl ketone 40 parts by weight

(Comparative Example 1)
The image-receiving layer coating solution 7 is applied to the surface of a substrate sheet (trade name; Lumirror S10, manufactured by Toray) made of polyethylene terephthalate having a thickness of 100 μm by a Meyer bar coater so as to be 10 μm when dried, and the image-receiving sheet is dried. 7 was produced. Next, an image was printed on the surface of the image-receiving layer of the obtained image-receiving sheet 7 with an aqueous pigment-based inkjet printer (trade name; JV-4, manufactured by Mimaki Engineering Co., Ltd.) to produce an image-receiving sheet 7 on which an image was formed. Further, after an acrylic pressure-sensitive adhesive layer is applied to the back surface of the image-receiving sheet 7 on which an image has been formed, the pressure-sensitive adhesive layer surface of the image-receiving sheet is opposed to the plastic substrate surface, and pressure is applied using two rubber rolls at 25 ° C. The image receiving sheet was laminated on a plastic substrate to produce a decorative board.
Image-receiving layer coating solution 7
Polyvinyl alcohol resin (trade name; Poval 205, solid content 100%, manufactured by Kuraray) 5 parts by weight Silica (trade name; Aerosil # 200, manufactured by Degussa) 15 parts by weight Water 40 parts by weight Methanol 40 parts by weight

(Evaluation)
Observe the image quality of the decorative panel.
○: Excellent dot reproducibility and particularly high image quality. X: The dot reproducibility is poor and the image quality is inferior.

Water resistance After the obtained decorative board is immersed in water at 25 ° C. for 24 hours, the state of the image receiving layer is observed.
: No change. X: The image receiving layer peels off.

Non-image area durability The adhesion of the surface of the decorative board where the ink-jet ink was not printed was measured by a cross-cut tape peeling method of the JIS K 5600 coating film general test method.
○: No peeling of the image receiving layer. Δ: Part of the image-receiving layer is peeled off. X: There is peeling of the entire image receiving layer.

Image line endurance The adhesion strength of the surface of the decorative board where the ink-jet ink was printed was measured by a cross-cut tape peeling method of JIS K 5600 coating film general test method.
○: No peeling of the image receiving layer. Δ: Part of the image-receiving layer is peeled off. X: There is peeling of the entire image receiving layer.

Observe the warpage of the decorative board.
: There is no warping on the decorative board. X: Warp has occurred in the decorative board.
The above evaluation results are shown in Table 1.

It is a schematic cross section which shows the form of the contact bonding layer transfer sheet of this invention. FIG. 2 is a schematic cross-sectional view showing the form of an image receiving layer transfer sheet used in the present invention. It is a schematic cross section which shows the form printed by the oil-based inkjet system on the image receiving layer transfer sheet used for this invention. It is a schematic cross section which shows the form of the decorative board | substrate with which the contact bonding layer produced by the method of this invention was transcribe | transferred. It is a schematic cross section which shows the form of the decorative board produced by the method of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Adhesion layer transfer sheet 2 ... Base material sheet A
3 ... Adhesive layer 4 ... Image-receiving layer transfer sheet 5 ... Base material sheet B
6 ... Image-receiving layer 7 ... Decorative substrate 8 ... Decorative plate 9 ... Oil-based pigment-based inkjet ink

Claims (5)

A step of superimposing an adhesive layer transfer sheet provided with at least an adhesive layer on the base material sheet A so as to be peelable and a decorative substrate, and applying heat and pressure to thermally transfer the adhesive layer to the decorative substrate; and base material sheet B A step of forming an image by ejecting oil-based pigment-based ink according to image information with an ink jet printer on the surface of the image-receiving layer transfer sheet provided with at least the image-receiving layer so as to be peelable; and a makeup on which the adhesive layer is transferred A process for producing a decorative board comprising the steps of: superimposing a substrate and the image-receiving layer transfer sheet on which the image has been formed, heating and pressing to transfer the image-receiving layer to an adhesive layer. 2. The method of manufacturing a decorative board according to claim 1, wherein the decorative substrate is a plastic substrate. The adhesive layer of the adhesive layer transfer sheet can be thermally transferred to a decorative substrate by heating and pressing, and the image receiving layer on which the image is formed with an oil-based pigment-based inkjet ink is heated and pressed. The adhesive layer transfer sheet according to claim 1, wherein the adhesive layer transfer sheet is capable of adhering. The adhesive layer transfer sheet according to claim 3, wherein the adhesive layer contains a material having a softening point lower than the softening point of the decorative substrate. The adhesive layer transfer sheet according to claim 3, wherein the adhesive layer contains at least a urethane resin.

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