JP2020093527A - Woody decorative plate, method for manufacturing the same, and molded article with woody decorative plate - Google Patents

Abstract

To provide a woody decorative plate applicable to an industrial product and having reliability while maintaining lusterless feeling and touch feeling of a surface of a veneer plate: to provide a method for manufacturing the woody decorative plate: and to provide a molded article using the plate.SOLUTION: A woody decorative plate includes a sliced veneer made of natural wood on the surface of which a plurality of irregularities caused by vessels of the wood are formed; and a hard coat layer 104 or a protection layer where the irregularities different in size from each other are formed on the surface of the sliced veneer. The surface of the hard coat layer or the protection layer is provided with recessed parts formed on the hard coat layer or the protection layer, and a plurality of recessed parts smaller than the recessed parts formed on the surface of the hard coat layer or the protection layer.SELECTED DRAWING: Figure 1A

Description

The present invention relates to a wooden decorative board, a method for manufacturing the same, and a molded article using the same. In particular, the present invention relates to a wooden decorative board having an appearance of a sliced veneer thinly sliced from natural wood and an uneven structure on the surface of the hard coat layer or the protective layer formed on the surface of the sliced veneer. TECHNICAL FIELD The present invention relates to a wooden decorative board for a decorative part that maintains the matte surface and the texture due to unevenness unique to real wood, while satisfying the durability required for industrial products, a method for producing the same, and a molded article using the same.

In recent years, as decoration needs in the exterior and in-vehicle interior fields of home appliances, a wide range of design expressions has been required due to the diversification of customer tastes, and high designability is centered on high-grade products using natural wood veneer. Sometimes design is required.

In addition to the method of sticking the veneer itself to the surface of the case such as molded parts and expressing the appearance with a wooden decorative board, the decoration method using the veneer also has an adhesive layer that adheres to the injection molding resin on the back side of the veneer in advance. There is a method of arranging a functional layer having the same function and integrating the wood decorative board and the molding resin by injection molding or vacuum molding.

The layer structure of a molded product using a conventional wooden decorative board will be described with reference to FIG. FIG. 5 is a cross-sectional view showing the layer structure of an insert-molded product 9 using a conventional wooden decorative board 8. The conventional wooden decorative board 8 has a multilayer structure. First, there is a first adhesive layer 2 for adhering to an injection-molded resin, and there are a veneer 4 manufactured by slicing natural wood and a support 3 for laminating the veneer 4 into a sheet. .. Further, on the surface of the projecting plate 4 opposite to the support body 3, there is a transparent film 6 for protecting the surface of the projecting plate 4 and a second adhesive layer 5 for bonding the transparent film 6 and the projecting plate 4 together. A hard coat layer 7 for increasing the hardness of the surface of the transparent film 6 is formed. This wooden decorative board 8 is arranged by a general insert molding method with the first adhesive layer 2 of the wooden decorative board 8 facing the injection molding resin side, and the injection molding resin layer 1 integrated by insert molding is formed. There is a decorative construction method using such a wooden decorative board (for example, refer to Patent Document 1).

Further, FIG. 6 illustrates a layer structure of a molded product of a conventional open-pore type wooden decorative board. Here, the open pores refer to a wooden decorative board having a design surface in which a conduit on the surface of the veneer is opened. The same components used in FIG. 5 will be described using the same reference numerals. FIG. 6 is a cross-sectional view of a layer structure of a molded product of an open-pore type wooden decorative board. Reference numeral 11 in FIG. 6 is a wooden decorative board having a veneer 4 without a protective layer on the surface, and the wooden decorative board 11 is integrated with the injection-molded resin layer 1 by insert molding to form a molded product. .. After that, in order to leave the unevenness due to the conduit on the surface of the projecting plate 4 by painting, a decoration method for obtaining a molded part 12 in which the protective layer 10 with the unevenness due to the conduit on the surface of the projecting plate 4 is formed by applying a thin film thickness is used. is there.

JP, 11-983, A

However, the molded product using the conventional wooden decorative board described in FIGS. 5 and 6 has the following problems. In the method of decorating the molded product 9 using the conventional wooden decorative board of FIG. 5, a transparent film having a thick film of, for example, 100 μm or more is arranged on the surface of the projecting plate 4. As a result, it is possible to decorate the surface of the veneer 4 with a glossy feeling and a sense of depth due to the thickness of the transparent film surface to give a high-class feeling. Is covered with a transparent film. Therefore, it is difficult to secure the reliability as an industrial product while maintaining the original texture of wood because it does not easily appear on the surface. In addition, when the transparent film is arranged on the surface of the projecting plate 4, when the projecting plate 4 is deformed by molding for the purpose of using it in an industrial product, the shape may be deformed. Further, there is a problem that breakage or delamination may occur between the transparent film and the projecting plate 4 which are more easily stretched than the projecting plate 4 due to the difference in mechanical properties of expansion and contraction between the projecting plate 4 and the transparent film as the drawing amount increases.

Further, in the case of the molded product of the conventional open-pore wood decorative board shown in FIG. 6, the protective layer 10 having the unevenness is left unpainted by the conduit on the surface of the veneer 4 due to the coating that leaves the wooden conduit on the surface of the veneer 4. However, it is difficult to apply uniform coating on the surface of the veneer 4 so that the protective layer 10 formed by coating becomes an uneven uneven film, which does not lead to defective skin. Was difficult to keep. In addition, the coated surface may be polished in a later step as necessary to eliminate the orange peel, which causes a problem of increasing the number of steps.

In addition to the above, as a fundamental problem of coating, a post-process after molding is indispensable, and there is a problem that the number of processes is increased and the coating efficiency of the coating during coating is poor and material loss is large. Moreover, quality control for leaving the conduit on the surface of the projecting plate 4 neat is difficult, and the manufacturing cost tends to increase. Also, since the surface of the veneer plate 4 is uneven due to the coating in a later process, a smooth portion remains on the coated surface, and it is difficult to maintain the matte feeling of the original surface of the veneer plate 4, and thus a glossy feeling appears. It will be a molded product made of wood veneer that looks different from the original texture of natural wood.

Therefore, it has been difficult to make a wooden decorative plate that is durable and can be used for industrial products and can be manufactured with less loss while maintaining the original matte feel and touch of sliced natural wood.

The present invention is to solve the above-mentioned conventional problems, and a wooden decorative board having reliability that can be applied to industrial products while maintaining the matte feeling and tactile feel of the veneer surface, a method for producing the same, and a molded product using the same. The purpose is to provide.

In order to achieve the above object, the wood decorative board according to the present invention is a veneer made of natural wood having a plurality of unevenness formed by wood conduits on its surface,
A hard coat layer or a protective layer in which irregularities having different sizes are formed on the surface of the veneer;
Equipped with
On the surface of the hard coat layer or the protective layer, a plurality of recesses formed on the surface of the hard coat layer or the protective layer, and a plurality of smaller than the recesses formed on the surface of the hard coat layer or the protective layer. And a recess.

The method for manufacturing a wooden decorative board according to the present invention comprises a step of preparing a veneer made of natural wood having a plurality of irregularities formed by wooden conduits on its surface,
A transfer film having at least a base film, a peeling layer, a hard coat layer or a protective layer, wherein two or more kinds of fillers having different sizes are added to the peeling layer, and the surface of the peeling layer has the above-mentioned size. A plurality of convex shapes of different sizes formed by different fillers are formed, and further formed on the release layer on the surface of the hard coat layer or the protective layer formed on the release layer thereon. There are a plurality of concave shapes of different sizes, the surface of the release layer and the unevenness are formed in a reversed state, the step of preparing a transfer film,
Using the transfer film, a step of transferring the hard coat layer or the protective layer of the transfer film to the surface of the veneer,
including.

As described above, according to the wooden decorative board and the method for manufacturing the same according to the present invention, it is difficult to realize the conventional wooden decorative board and the molded parts decorated with them. Molded products can be made that maintain the texture and texture of the product. As a result, both the original appearance quality of the veneer and the durability usable for industrial products can be achieved. Further, by using the present invention, it is possible to provide a wooden decorative board which is highly reliable and has the original appearance quality of the veneer at low cost and stable manufacturing.

3 is a cross-sectional view showing the layer structure of the transfer film according to Embodiment 1. FIG. It is a SEM image which shows the state which expanded the surface of the mat peeling layer of FIG. 1A 200 times (partial enlarged view 1-1). 1B is a SEM image obtained by further enlarging FIG. 1B and observing at 5000 times (partially enlarged view 1-2). It is a SEM image which shows the state which expanded the surface of the hard-coat layer peeled from the mat peeling layer 200 times with SEM (partially enlarged view 1-3). It is a SEM image which shows the state which expanded the hard-coat layer surface 1000 times (partially enlarged view 1-4). FIG. 5 is a schematic cross-sectional view illustrating step 1 of the method for manufacturing a wooden decorative board according to the first embodiment. FIG. 5 is a schematic cross-sectional view illustrating step 2 of the method for manufacturing a wooden decorative board according to the first embodiment. FIG. 6 is a schematic cross-sectional view illustrating step 3 of the method for manufacturing a wooden decorative board according to the first embodiment. FIG. 3 is a cross-sectional view (a) showing the layer structure of the wooden decorative board according to Embodiment 1 and an SEM image (b) in which the surface of the hard coat layer which is the outermost surface of the transfer layer is magnified 200 times (partially enlarged view 3). -1). FIG. 5 is an explanatory diagram of a method for manufacturing an insert-molded product using the wooden decorative board according to the first embodiment. FIG. 5 is an explanatory diagram of a method for manufacturing an insert-molded product using the wooden decorative board according to the first embodiment. FIG. 5 is an explanatory diagram of a method for manufacturing an insert-molded product using the wooden decorative board according to the first embodiment. FIG. 5 is an explanatory diagram of a method for manufacturing an insert-molded product using the wooden decorative board according to the first embodiment. FIG. 5 is an explanatory diagram of a method for manufacturing an insert-molded product using the wooden decorative board according to the first embodiment. FIG. 5 is an explanatory diagram of a method for manufacturing an insert-molded product using the wooden decorative board according to the first embodiment. FIG. 5 is an explanatory diagram of a method for manufacturing an insert-molded product using the wooden decorative board according to the first embodiment. FIG. 5 is an explanatory diagram of a method for manufacturing an insert-molded product using the wooden decorative board according to the first embodiment. FIG. 5 is an explanatory diagram of a method for manufacturing an insert-molded product using the wooden decorative board according to the first embodiment. It is a SEM image showing the state where the hard coat layer on the surface of the insert-molded product was magnified 200 times (partially enlarged view 4-1). It is sectional drawing which shows the laminated constitution of the molded product of the conventional wooden decorative board. FIG. 6 is a cross-sectional view showing a layer structure of a molded product of a conventional open-pore type wooden decorative board.

The wooden decorative board according to the first aspect is a veneer made of natural wood having a plurality of irregularities formed by wooden conduits on its surface,
A hard coat layer or a protective layer having irregularities of different sizes formed on the surface of the veneer;
Equipped with
On the surface of the hard coat layer or the protective layer, a concave portion formed on the surface of the hard coat layer or the protective layer, and a plurality of smaller than the concave portion formed on the surface of the hard coat layer or the protective layer. And a recess.

According to the above structure, the transfer film can be used to give the veneer surface a textured or matte feel. Also, on the base film used for the transfer film, a mat peeling layer having different small and large complex irregularities smaller than the size of the conduit of the veneer is formed, and a transfer layer for transferring to the veneer surface is formed on the mat peeling layer. It is formed as a transfer layer that is a thin film and has multiple functions. The transfer layer is composed of a plurality of layers, a hard coat layer or a protective layer is formed on the peeling layer, and a UV blocking layer (hereinafter, UV blocking layer), an anchor layer, and a veneer for bonding with a veneer. This is a structure in which an adhesive layer or the like for use is formed.

Further, by using the above-mentioned transfer film, a hard coat layer or a protective layer can be formed on the surface of the veneer plate along the unevenness of the conduit on the surface of the veneer plate.

Further, in the above structure, when the transfer film is peeled off, the matte peeling layer on the base film is peeled off from the hard coat layer or the protective layer. As a result, the original texture of the veneer and the complex recesses of different sizes formed on the surface of the hard coat layer or the protective layer are maintained, and it is used for industrial products while maintaining the original matte texture. A wooden veneer with durability can be created.

In the wood decorative board according to a second aspect, in the first aspect, the height difference of the uneven shape of the surface of the hard coat layer or the protective layer or the depth relationship is similar to the shape of the conduit of the veneer. H1 is the height or depth of the uneven portion, H2 is the height or depth of the concave portion formed on the surface of the hard coat layer or the protective layer, and the height or depth of the concave portion is formed on the surface of the hard coat layer or the protective layer. The height or depth of the plurality of recesses smaller than the recesses may be set to H3, and the respective magnitude relationships may satisfy the relational expression of H1>H2>H3.

The wood decorative board according to a third aspect is the same as the second embodiment, wherein the plurality of concave portions formed on the surface of the hard coat layer or the protective layer on the surface of the wood decorative board have fillers of different sizes. It may be transferred via.

The wooden decorative board according to a fourth aspect is the same as the third aspect, wherein the height or depth H2 of the concave portion formed on the surface of the hard coat layer or the protective layer is 15 μm or more and 30 μm or less. Good.

The recess having the height or the depth H2 is formed of a filler having an average particle diameter of 15 μm or more and 30 μm or less. As a result, the surface of the hard coat layer 104 can be made to feel uneven.

A wood decorative board according to a fifth aspect is the third or fourth aspect, wherein the height or depth H3 of the recesses smaller than the recesses formed on the surface of the hard coat layer or the protective layer is 0. It may be 0.5 μm or more and 8 μm or less.

The recess having the height or the depth H3 is formed of a filler having an average particle diameter of 4 μm or more and 8 μm or less and an average particle diameter of 0.5 μm or more and 2 μm or less. This makes it possible to configure a light scattering recess.

A wood decorative board according to a sixth aspect is the wood decorative board according to any one of the first to fifth aspects, wherein the hard coat layer or the protective layer on the surface of the wooden decorative board has a glossiness of 20°, 60°, Both may be 10% or less at an angle of 85°.

The wood decorative board according to a seventh aspect is the wood decorative board according to any one of the first to sixth aspects, wherein the hard coat layer or the protective layer formed on the surface of the wood decorative board is an after-cure type ultraviolet ray. It may be made of a curable resin or an electron beam curable resin.

The wood decorative board according to an eighth aspect is the wood decorative board according to any one of the first to seventh aspects, wherein the layer structure of the film formed on the surface of the wood decorative board is ultraviolet light other than the hard coat layer or the protective layer. It may be composed of a plurality of layers including at least one layer of a cut layer, an anchor layer, and an adhesive layer.

In the wooden decorative board according to a ninth aspect, in any one of the first to eighth aspects, the total thickness of the film formed on the surface of the wooden decorative board may be 4 μm or more and 80 μm or less.

In the wood decorative board according to the tenth aspect, in any one of the first to ninth embodiments, the veneer used in the wood decorative board may have a resin impregnated inside the veneer.

A method for manufacturing a wooden decorative board according to an eleventh aspect includes a step of preparing a veneer made of natural wood having a plurality of irregularities formed by wooden conduits on its surface,
A transfer film having at least a base film, a peeling layer, a hard coat layer or a protective layer, wherein two or more kinds of fillers having different sizes are added to the peeling layer, and the surface of the peeling layer has the above-mentioned size. A plurality of convex shapes of different sizes formed by different fillers are formed, and further formed on the release layer on the surface of the hard coat layer or the protective layer formed on the release layer thereon. There are a plurality of concave shapes of different sizes, the surface of the release layer and the unevenness are formed in a reversed state, the step of preparing a transfer film,
Using the transfer film, a step of transferring the hard coat layer or the protective layer of the transfer film to the surface of the veneer,
including.

A method for manufacturing a wooden decorative board according to a twelfth aspect is the same as the eleventh aspect, wherein the transfer layer side of the transfer film and the projecting plate are overlapped with each other, and hot pressing, vacuum heat laminating, vacuum forming, pressure forming, A transfer layer including the hard coat layer or the protective layer of the transfer film is adhered to the surface of the veneer by a method selected from the group of vacuum pressure forming, and the hard coat layer or the protective layer is included on the surface of the veneer. The transfer layer may be formed.

With the above structure, random (irregular) complex concaves having different sizes are formed on the surface of the hard coat layer or the protective layer through the matte release layer. As a result, the small recesses among these recesses finely scatter the external light falling on the surface of the hard coat layer or the protective layer to generate scattered light, so that the original matte feeling of the veneer surface is maintained.
Further, according to the above configuration, the plate for hot pressing does not directly touch the hard coat layer or the protective layer formed on the surface of the veneer during hot pressing, and is pressed through the base film of the transfer film, The hard coat layer or the protective layer formed via the matte release layer has a complicated concave portion having different heights or different depths on the surface, or the original texture of the surface of the veneer surface caused by unevenness is not easily destroyed.

The method for manufacturing a wooden decorative board according to a thirteenth aspect is the method for producing a wooden decorative board according to the eleventh or twelfth aspect, wherein the hardcoat layer or the protective layer on the transfer film is formed on the side where the transfer layer is formed. By changing the surface roughness and matte feeling of the release layer, it is possible to adjust the surface roughness and matte feeling of the surface of the hard coat layer or the protective layer transferred to the surface of the veneer, and,
The method for changing the surface roughness and matte feeling of the release layer is to add a plurality of fillers of different sizes to the release layer, and to adjust the size of the filler and the amount of each filler added. Good.

Further, according to the above configuration, the matte feeling and the concave portion of the hard coat layer or the protective layer surface transferred to the surface of the veneer, the size of the plurality of kinds of fillers added to the matte release layer on the transfer film, and the addition amount It is possible to make fine adjustments by changing the combination. As a result, it is possible to finely adjust the matte feeling of the surface of the hard coat layer or the protective layer and the size of the concave portion while maintaining the original matte feeling of the veneer surface and the touch feeling due to the unevenness, according to customer needs. As a result, it is possible to provide a wooden decorative board that can be finely customized and a molded part using the same in accordance with customer needs that were difficult with the conventional method.

A method for manufacturing a wooden decorative board according to a fourteenth aspect is the method according to any one of the eleventh to thirteenth aspects, wherein the depth of the convex portion on the surface of the release layer formed on the transfer film is It may be smaller than the height difference or depth of the unevenness due to the conduit on the surface of the veneer.

A method for manufacturing a molded article according to a fifteenth aspect uses a wood decorative board produced by the production method according to any one of the eleventh to fourteenth aspects to hot press the veneer into a shape close to a final product. Preform process to preform by
The hard coat layer or the transfer layer including the protective layer is injection-molded on the adhesive layer or the adhesive functional surface formed on the surface of the veneer on the side where the transfer is not performed to form a molding resin layer, and the transfer layer is An insert molding step of manufacturing a resin part in which the applied veneer is formed on the surface,
including.

A method for producing a molded article according to a sixteenth aspect is the method for producing a molded article according to the fifteenth aspect, wherein the preform step or the insert molding step, or both, are made in contact with the protrusion plate side on which the transfer layer is formed. A wrinkle is formed on the mold surface, and the surface of the mold coat is formed on the surface of the hard coat layer or the protective layer formed on the surface of the veneer in either or both of the preforming step and the insert molding. Part or all may be transcribed.

The method for producing a molded article according to a seventeenth aspect is the method according to the fifteenth or sixteenth aspect, wherein the base film of the transfer film is the surface of the wooden decorative board in the final step of completing the molded article in the insert molding step. You can peel it off.

A molded article according to an eighteenth aspect is a molded article using the wood decorative board according to any one of the first to tenth aspects, and has different sizes on the surface of the hard coat layer or the protective layer. A plurality of uneven shapes are formed, and there is an uneven shape transferred other than the unevenness due to the conduit of the projecting plate, and the largest unevenness among the transferred uneven shapes is the concave shape.

Hereinafter, a transfer film, a wooden decorative board and a method for manufacturing the same, a molded article using the wooden decorative board, and a method for manufacturing the same according to the embodiments will be described with reference to the drawings. In the drawings, substantially the same members are designated by the same reference numerals.

(Embodiment 1)
<Transfer film>
FIG. 1A is a cross-sectional view of the layer structure of the transfer film according to the first embodiment. In FIG. 1, the same components as those in FIGS. 5 and 6 are designated by the same reference numerals and the description thereof will be omitted. The transfer film 100 shown in FIG. 1A is used for a wooden decorative board. In this transfer film 100, a mat release layer 103 having a plurality of convex portions formed on the surface is formed on a base film 102. Further, a hard coat layer 104 is formed on the mat release layer 103, and an anchor layer 105, a UV cut layer 106, and a veneer adhesive layer 107 are formed on the hard coat layer 104. The transfer film 100 is composed of a hard coat layer 104, an anchor layer 105, a UV cut layer 106, and a veneer adhesive layer 107. Of these, the hard coat layer 104, the anchor layer 105, the UV cut layer 106, and the adhesive layer 107 for a veneer are transferred to the surface of the veneer to form the transfer layer 101. The transfer film 100 may be manufactured by a continuous roll film or a sheet film, but it is generally manufactured by a roll film having high productivity.

The constituent elements of the transfer film 100 will be described below.

<Base film>
The average thickness of the base film 102 is preferably 20 μm or more and 50 μm or less. Further, in order to further improve the followability of the transfer film 100 when transferring onto the surface of the veneer, the average thickness is preferably 30 μm or more and 50 μm or less. When the transfer film 100 is manufactured, the mat release layer 103, the hard coat layer 104, the anchor layer 105, the UV cut layer 106, and the adhesive layer 107 for the veneer board are formed on the base film 102. When heat-drying or UV-curing is performed in the process of forming each layer, if the base film 102 is thinner than 20 μm, wrinkles, tears, and warps are likely to occur, resulting in poor handling. Further, when the thickness of the base film 102 is thicker than 50 μm, the followability of the transfer film to the transferred object is likely to be deteriorated. Further, when it is desired to hold the base film 102 immediately after transfer of the transfer film 100 without being peeled off from the transferred body, when the contraction amounts of the projecting plate 4 and the base film 102 are compared, the contraction amount of the base film 102 shows that the projecting plate 4 is contracted. Greater than. Therefore, the projecting plate 4 is pulled by the contraction of the base film 102 and the warp increases, which makes it difficult to handle as a wooden decorative plate. Further, when the thickness is thicker than 50 μm, the roll film having the same number of turns as the transfer film 100 becomes thicker and heavier than when a thin film is used as the base film 102. For this reason, the handling property becomes poor when the film is carried, and the cost of the base film becomes high. The thickness of the base film may be appropriately selected within the above range depending on the purpose, but there is no problem even if the thickness exceeds the above range as long as the same effect can be obtained. Generally, PET or acrylic film is used for the base film, but other materials are not limited as long as the same effect can be obtained.

<Mat release layer>
The matte release layer 103 plays a role of releasing the hard coat layer 104, the anchor layer 105, the UV cut layer 106, and the adhesive layer 107 for the veneer from the transfer film 100, and transferring the peeled layer to the veneer. For the mat release layer 103, a thermosetting melamine resin, a two-component curing type urethane resin, a thermosetting silicone resin, or the like is generally used. However, the material is not particularly limited as long as the same peeling effect is obtained. Further, in order to make the surface of the matte release layer 103 matte and to make it easier to feel the touch when touched with a hand, a plurality of types of fillers of different sizes are added together with the resin to form the matte release layer 103. You may.

<Filler>
As the filler, it is common to use general cross-linked acrylic beads or silica particles of an inorganic material, which have high merit in terms of availability and cost. However, other materials may be used as long as the same effect can be obtained. Regarding the shape of the filler, spherical shape is easy to obtain, and it is easy to form a convex shape, but other shapes such as scale shape, hemispherical shape, and irregular shape other than spherical shape are not particularly limited as long as the same effect can be obtained. In addition, the properties of the filler such as solid, porous and hollow fillers are not particularly limited as long as the intended effect can be obtained.
The filler added to the mat release layer 103 this time is, for example, spherical cross-linked acrylic beads having an average particle diameter of 20 μm, silica particles having an average particle diameter of 4.5 μm, and spherical particles having an average particle diameter of 1.5 μm. There are three types of silica particles. These three types of fillers were added to form a plurality of random convex portions on the surface of the matte release layer 103.
FIG. 1B is an SEM image showing a state in which the surface of the matte release layer 103 is magnified 200 times (partially enlarged view 1-1). As shown in FIG. 1B, it can be seen that the surface of the matte release layer 103 is formed with a 20 μm-sized acrylic bead-shaped convex shape having a large particle size. In addition, a surface state is formed in which minute convex portions made of filler having an average particle size of 4.5 μm and an average particle size of 1.5 μm are randomly formed between acrylic beads having an average particle size of 20 μm.

Next, FIG. 1C is an SEM image obtained by further enlarging FIG. 1B and observing at 5000 times (partially enlarged view 1-2). This will be described with reference to the partially enlarged view 1-2 of FIG. 1C. As can be seen from the partially enlarged view 1-2, around the acrylic filler having an average particle diameter of 20 μm, silica particles having an average particle diameter of 4.5 μm and silica particles having an average particle diameter of 1.5 μm are randomly covered. As a result, the surface of the matte release layer 103 does not have a smooth surface between the convex portions of the acrylic filler and can be filled with fine convex portions. As a result, it becomes possible to eliminate the smooth surface on the surface of the matte release layer 103, finely disperse the reflected light when external light strikes the surface of the matte release layer 103, create a scattering state, and create a matte surface. .. Further, the surface of these different size fillers contained in the matte release layer 103 is coated with a release resin used for the matte release layer 103, that is, a melamine resin. That is, the filler itself is not exposed from the melamine resin. As a result, the mat peeling layer 103 can maintain the originally required peeling function even when the convex portions having different complicated sizes are formed on the surface.

As the filler added to the matte release layer 103, it is preferable to use particles having an average particle diameter of 0.5 μm or more and 30 μm or less. Further, by selecting one or more kinds of two or more kinds having an average particle diameter of 0.5 μm or more and 2 μm or less and one or more kinds of particles having an average particle diameter of 4 μm or more and 8 μm or less, the matte surface of the original wood is matted. It is possible to obtain a matte surface having a glossiness of 85%, which is the same as the feeling, and a glossiness of 10% or less. By using a filler having an average particle diameter of 0.5 μm or more and 2 μm or less and a filler having an average particle diameter of 4 μm or more and 8 μm or less, large and small convex portions are randomly formed on the surface of the mat release layer 103 without gaps. it can. Therefore, it is possible to eliminate a smooth surface from the surface of the matte release layer 103, and to create a surface with a small angle of specular reflection at a wide viewing angle when external light hits the surface, which can be evaluated by a gloss meter at 20° and 60°. The glossiness can be reduced to 10% or less at all of the angles of 85° and 85°. Further, in order to give an uneven tactile sensation when touched by hand, since the average value of the surface roughness Rz of the projecting plate 4 is 15 μm or more, one or more fillers having an average particle diameter of 15 μm to 30 μm are selected and added. It is desirable to do. Regarding the size range of the filler described above, if the average particle size of the filler is smaller than 0.5 μm, the size for forming fine protrusions for scattering external light even if the filler is added Is insufficient, and smooth parts are easily formed. When the average particle diameter of the filler is larger than 30 μm, the filler is too large on the surface of the matte release layer 103, and it is difficult to cover the filler forming the release layer with the resin larger than 30 μm. Then, the filler larger than 30 μm is easily exposed from the resin of the matte release layer 103, which causes the filler larger than 30 μm to fall off from the matte release layer 103. When the filler larger than 30 μm falls off from the mat release layer 103, it scatters to other places and becomes a cause of defective foreign matter in a post process. However, the size of the filler to be added, the type of the filler to be added, and the amount of the filler to be added may be outside the above range depending on the purpose as long as the same effect can be obtained outside the above range, and there is no particular limitation.

Further, it is preferable that the total amount of the fillers having different sizes in the mat release layer 103 to be added is mixed with the resin forming the release layer in the range of 3 wt% or more and 45 wt% or less. If it is less than 3 wt %, a sufficient effect cannot be obtained for forming the tactile projections and the light scattering projections on the mat release layer 103. Further, when it is more than 45 wt %, when the paint for applying the matte release layer 103 to the base film 102 is manufactured, the viscosity becomes high and the dispersibility of the filler and the resin becomes poor, so that the base film 102 is uniformly wet. It becomes difficult to apply. The total addition amount of the filler is in the above range, and the addition ratio of the fillers having different sizes is such that, by weight ratio, the weight of the filler having an average particle diameter of 15 μm or more and 30 μm or less≧the average particle diameter of 4 μm or more and 8 μm or less Weight of filler> Addition in a weight ratio that maintains the relational expression of the weight of the filler having an average particle diameter of 0.5 μm or more and 2 μm or less.

In the first embodiment, the filler having an average particle diameter of 15 μm to 30 μm is 6 wt%, the filler having an average particle diameter of 4 μm to 8 μm is 5 wt%, and the average particle diameter is 2 μm to 2 μm. A total of 13 wt% was added. When more filler having an average particle size of 4 μm to 8 μm is added than filler having an average particle size of 15 μm to 30 μm, a convex shape for providing a tactile sensation is not sufficiently formed, and a filler having an average particle size of 4 μm to 8 μm is used. Thus, the convex shape formed by the filler having an average particle diameter of 15 μm or more and 30 μm or less is covered, and it is difficult to form a sufficient convex shape for providing a tactile sensation. Further, even if a larger amount of filler having an average particle size of 0.5 μm to 2 μm is contained than filler having an average particle size of 4 μm to 8 μm, it is formed between convex shapes having an average particle size of 15 μm to 30 μm. The smaller convex shape for light scattering is not sufficiently formed. The addition ratio of the filler having an average particle diameter of 4 μm to 8 μm and the filler having an average particle diameter of 0.5 μm to 2 μm is preferably 100 wt% of the filler having an average particle diameter of 4 μm to 8 μm. In this case, it is desirable that the addition ratio of the average particle diameter of 0.5 μm to 2 μm is 20 wt% to 60 wt %.

However, there is no need to be particularly limited to the above range as long as a concave portion having the same effect outside the above range can be formed on the surface of the hard coat layer or the protective layer 104.

<Hard coat layer>
Next, the hard coat layer 104 formed on the mat release layer 103 will be described. A protective layer may be formed instead of the hard coat layer 104. The hard coat layer 104 has a role of protecting the surface of the veneer when it is transferred to the surface of the veneer. It is common to use an ultraviolet curing type after-cure type acrylic resin for the hard coat layer 104, but the hard coat layer 104 is not limited to this. For example, pre-cure type UV-curable acrylic resin, heat-drying type one-pack type acrylic resin, heat-drying type two-pack type urethane acrylic resin, electron beam (EB) curing type The acrylic resin may be used and may be appropriately selected depending on the application. As long as the desired effect is obtained, materials other than the above may be used without problems. When an after-cure type material is used, it is generally desirable to form a wood decorative board and peel off the base film 102 and the matte release layer 103, and then irradiate with ultraviolet rays and EB. The reason is that if the hard coat layer 104 is not completely hardened when the wooden decorative board is molded, the hard coat layer 104 has better followability during molding and is less likely to crack. However, it is not particularly limited to the final step, and if it is better to first irradiate with ultraviolet rays or EB depending on the application, it may be cured at an appropriate timing even before molding.

The average thickness of the hard coat layer 104 is preferably 2 μm or more and 15 μm or less. It is more preferably 5 μm or more and 10 μm or less. When the average thickness of the hard coat layer 104 is less than 2 μm, the function of protecting the veneer surface is weakened. Further, if the average thickness exceeds 15 μm, the followability at the time of molding into a curved shape or the like tends to deteriorate. Further, it is difficult to sufficiently form a large convex portion on the surface of the hard coat layer 104 for giving a feel on the mat release layer 103. However, if the desired effect is obtained, there is no problem even if the film thickness is out of the above range, and it is not particularly limited.

Further, functional fine particles may be added to the hard coat layer 104 as needed. For example, the surface hardness and chemical resistance of the hard coat layer 104 can be increased by simultaneously adding zirconia particles of acrylic crosslink type having an average particle diameter of 50 nanometers (nm).

Hard coat layer 104 of the first embodiment was formed to have an average thickness of 5 μm. The hard coat layer 104 is formed on the mat peeling layer 103 in which a plurality of fillers are added and a plurality of irregularities having different sizes are randomly formed on the surface. Therefore, on the surface of the hard coat layer 104, a concave portion that is the reverse of the convex portion formed on the matte release layer 103 is formed on the surface of the hard coat layer 104.
FIG. 1D is a SEM image showing a state in which the surface of the hard coat layer 104 separated from the matte release layer 103 is magnified 200 times by SEM (partially enlarged view 1-3). FIG. 1E is an SEM image showing a state in which the surface of the hard coat layer 104 is magnified 1000 times (partially enlarged view 1-4). In the first embodiment, a protrusion is formed on the mat peeling layer 103 by the filler having an average particle diameter of 20 μm added to the mat peeling layer 103 in order to improve the feeling of touch, but as shown in a partially enlarged view 1-4, a hard coat On the surface of the layer 104, recesses having a reverse pattern are formed. Further, other fillers having an average particle diameter of 4.5 μm added to the matte release layer 103 from the partially enlarged views 1-4 and convex portions formed by the filler of 1.5 μm are also formed on the surface of the hard coat layer 104. It can be seen that fine recesses are randomly (irregularly) formed so as to fill the spaces between the recesses formed by the filler having the average particle diameter of 20 μm.

As a result, the same effect as that of the matte release layer 103 can be obtained with respect to the matte feeling of the surface of the hard coat layer 104.

The relationship between the height difference or the depth of the uneven shape formed on the surface of the hard coat layer 104 is that the size of the unevenness formed by the conduit on the original surface of the veneer 4 is H1, and the surface of the hard coat layer 104 has a feeling of unevenness. The size of the recesses formed by the filler having an average particle size of 15 μm or more and 30 μm or less formed for discharging is H2, and the average particle size of 4 μm or more, 8 μm or less and the average particle size of 0.5 μm or more and 2 μm or less. When the size of the light scattering recesses formed by the fillers is H3, the magnitude relationship of H1>H2>H3 is established.
Further, the size of the conduit on the original surface of the veneer 4 varies depending on the type of wood, and there is a large hole for the conduit and a small hole for the conduit smaller than the annular hole, and the average diameter of the conduit is in the range of 20 μm to 400 μm. to go into. As a result of verifying the range of the size H1 of the unevenness that makes it easy for a person to feel the surface roughness of the veneer 4, the range was 70 μm or more and 400 μm or less.

<Anchor layer>
In addition, the anchor layer 105 is a layer that plays a role of improving the adhesion between the hard coat layer 104 and another functional layer. As the material of the anchor layer 105, a two-component curing type urethane acrylic resin or the like is generally used from the viewpoint of weather resistance, adhesion, heat resistance, etc., but a two-component type having a urethane bond is used depending on the application. A vinyl chloride vinyl acetate copolymer, an acrylic resin, or a composite resin material obtained by mixing them may be used. It is desirable that the average thickness is formed between 2 μm and 5 μm. If the average thickness is less than 2 μm, it is difficult to obtain sufficient adhesion between layers, and if the thickness is more than 5 μm, the adhesion does not change particularly. In addition, it is not appropriate because the dry film thickness that can be coated neatly with a gravure coater or the like is exceeded, and the drying time of the coating agent becomes long, resulting in high material costs and processing costs. However, it is not necessary to be limited to the above range as long as the desired effect can be obtained depending on the application even outside the above range. In Embodiment 1, it is formed to have an average thickness of 3 μm. However, there is no need to be limited to the above range as long as the desired effect can be obtained outside the above range depending on the application.

<UV cut layer>
Next, the UV cut layer 106 has a role of preventing discoloration of the projecting plate 4 under the influence of ultraviolet rays. For the UV cut layer 106, a material in which a UV absorber or an antioxidant is incorporated in the molecular chain as a functional group, or a material in which a UV absorber or an antioxidant is separately added to a resin having high weather resistance may be used. ..

The UV cut layer 106 is preferably formed with an average thickness of 2 μm or more and 10 μm or less.

If the average thickness of the UV cut layer 106 is less than 2 μm, the UV cut function is not sufficiently exhibited, and if it is thicker than 10 μm, the yellow color peculiar to the UV cut layer becomes strong and the appearance of the appearance is affected. It is desirable to form the inside. However, if the same effect is obtained outside the above range depending on the purpose, it is not particularly limited to the above range. In the first embodiment, a material in which a UV absorber or an antioxidant is incorporated into a molecular chain as a functional group is used, and the UV cut layer 106 is formed to have an average thickness of 4 μm.

<Adhesive layer for veneer>
Next, the veneer adhesive layer 107 has a role of bonding the UV cut layer 106 and the veneer 4 together. The veneer adhesive layer 107 can be made of vinyl chloride vinyl acetate copolymer resin, acrylic resin, urethane acrylic resin, polyolefin resin, or the like, and is also a thermoplastic resin, a two-component curable resin, an ultraviolet curable resin, a thermosetting resin. There are types such as mold resin and EB curing resin. However, if the transfer layer 101 and the projecting plate 4 can be adhered to each other, there is no particular limitation on the material, and a material other than those described above will not cause any problem. For example, as the adhesive layer 107 for the veneer plate, just before the veneer plate 4 is formed into a sheet without being applied to the transfer film 100 in advance, a hot resin such as thermoplastic or thermosetting is provided between the veneer plate 4 and the transfer layer 101 side of the transfer film 100. A transfer sheet 101 of the transfer film 100 and the projecting plate 4 may be adhered by inserting a melt sheet.

Other than the hot melt sheet, for example, a pressure sensitive adhesive having a separator may be used instead of the adhesive layer 107 for the veneer board. Further, a plurality of these adhesive materials may be used in combination to improve the adhesiveness. The average thickness of the adhesive layer 107 for veneer is preferably 3 μm or more and 50 μm or less. If the thickness of the adhesive layer 107 for the veneer plate is less than 3 μm, the function of adhering the UV cut layer 106 and the veneer plate 4 becomes weak, and sufficient adhesiveness cannot be obtained. The reason is that the veneer plate 4 has a porous structure at the time of bonding, so that a part of the veneer plate adhesive layer 107 easily enters the inside of the veneer plate 4 and a sufficient amount of the veneer plate adhesive layer 107 is provided between the transfer layer 101 and the veneer plate 4. Is less likely to remain, and it becomes difficult to secure the film thickness necessary to secure the strength of the adhesive layer 107 for the veneer plate. Further, when a hot melt sheet is used as the adhesive layer 107 for the veneer plate, a thickness of 35 μm or more is the mainstream, but even if a thickness of more than 50 μm is used, there is no significant change in the adhesive function and only the manufacturing cost is high, which is meaningless. .. However, there is no need to specifically limit to the above range when the desired effect is obtained even if it is out of the above range, or when it is advantageous to further increase the thickness of the veneer adhesive layer 107 for other purposes.

Further, the transfer film 100 may be formed by adding or deleting other functional layers or changing the layer structure as necessary. For example, the transfer film 100 may be formed by adding a hydrophilic layer that imparts an antifouling function to the surface of the hard coat layer. On the contrary, when it is easy to secure the weather resistance and the adhesiveness, the anchor layer 105 and the UV cut layer 106 may be eliminated to reduce the number of layers of the transfer film 100 to reduce the cost, and the purpose, The required functional layer can be appropriately selected according to the application. The minimum required functional layers of the transfer film are the base film 102, the matte release layer 103, the hard coat layer or the protective layer 104, and the adhesive layer 107 for the veneer for adhering to the veneer.
The average thickness of the transfer layer 101 is preferably formed in the range of 5 μm or more and 80 μm or less, more preferably 10 μm or more and 50 μm or less. If the average thickness of the transfer layer 101 is less than 5 μm, the minimum required function cannot be sufficiently exhibited in each layer. On the other hand, when the thickness is more than 80 μm, when the transfer film 100 is transferred onto the projecting plate 4, the conformability to the uneven shape on the surface of the projecting plate 4 deteriorates. For this reason, it becomes difficult for irregularities due to the conduit on the surface of the veneer to be reflected on the surface of the hard coat layer 104 as a similar shape, and the thickness of the transfer layer 101 becomes thick to easily give a sense of depth visually, and the original texture of the veneer is maintained. It will be difficult.

<Wood veneer manufacturing process>
FIG. 2A(a) is a schematic cross-sectional view illustrating step 1 of the method for manufacturing a wooden decorative board according to the first embodiment. FIG. 2A(b) is an enlarged cross-sectional view of the transfer film 100 and the projecting plate 4 (partial enlarged view 2-1). FIG. 2B(a) is a schematic cross-sectional view illustrating step 2 of the method for manufacturing a wooden decorative board according to the first embodiment. FIG. 2B(b) is an enlarged cross-sectional view of the transfer film 100 and the projecting plate 4 (partially enlarged view 2-2). FIG. 2C is a schematic cross-sectional view illustrating step 3 of the method for manufacturing a wooden decorative board according to the first embodiment. 2A, 2B, and 2C, the same components as those in FIGS. 1A to 1E, 5 and 6 are denoted by the same reference numerals and the description thereof will be omitted. 2A, 2B, and 2C are schematic cross-sectional views illustrating a process of manufacturing a wood decorative board by bonding the transfer film 100 and the projecting plate 4 by using hot pressing.

(1) First, in Step 1 shown in FIG. 2A (a), the first press die 200 and the second press die 201 for press working are heated to a predetermined temperature in advance, and the transfer film 100 of the sheet is preliminarily set. The single-sided protruding plate 4 having the support 3 attached to one surface of the protruding plate 4 is sandwiched (FIG. 2A(a)). Thereby, the adhesive layer 107 for the projecting plate of the transfer film 100 and the projecting plate 4 are heated and pressure-bonded. As the support body 3, the projection plate 4 having the support body 3 attached to one side of the projection plate 4 in advance may be used. Further, in the case of the projecting plate 4 which is not provided with the supporting body 3 in advance, the supporting body 3 may be bonded to the projecting plate 4 at the same time in the step of adhering the single transfer film 100 to the projecting plate 4. That is, the support 3 which can be bonded to the projection plate 4 or the support 3 having an adhesive applied to one surface thereof is arranged on the side opposite to the surface of the projection plate 4 on which the transfer film 100 is arranged, or the projection plate 4 and the support. A hot melt sheet or the like may be arranged between the sheet 3 and the sheet. This allows the support 3 to be bonded to the projecting plate 4 at the same time in the step of bonding the transfer film 100 and the projecting plate 4. A non-woven fabric, a film, or a porous non-woven fabric layer having an adhesive function may be formed on the support 3. The support 3 may be selected according to the application. Further, in the case where the projecting plate 4 is a continuous sheet, the transfer film 100 may be supplied by a roll instead of a sheet and adhered thereto. In the first embodiment, the non-woven fabric is used for the support 3 this time.

The mold used for the hot pressing may be a metal mold, a wooden mold, or a resin mold, and it is not limited if it is made of any other material as long as the same effect can be obtained.
A partially enlarged view 2-1 (FIG. 2A(b)) of Step 1 is an enlarged cross-sectional view of the transfer film 100 and the projecting plate 4. As shown in the partially enlarged view 2-1, an air layer may be included between the transfer film 100 and the projecting plate 4 when sandwiched between the first press die 200 and the second press die 201. When the protrusion plate 4 is pressed from the transfer film 100 side by the first press die 200, the air layer between the transfer film 100 and the protrusion plate 4 is formed along the surface of the protrusion plate 4 by the pressure of the first press die 200. Exit to the outside. At that time, the air existing inside the conduit 13 existing on the surface of the projecting plate 4 also escapes. The inside of the conduit 13 of the veneer 4 is a portion where the wood fibers are sparse and has a porous shape. In addition, the surface of the mold used for hot pressing may be embossed in order to facilitate the escape of air, and may be provided with irregularities of a size for facilitating the escape of air. Further, in the transfer film 100, the convex portion on the surface of the mat release layer 103 is formed as a convex portion on the surface of the final adhesive layer 107 for veneer in a similar shape. Therefore, during hot pressing, a structure in which air easily passes through between the fine protrusions on the surface of the adhesive layer 107 for a veneer plate is obtained, and a good adhesive surface is obtained without air being caught between the transfer film 100 and the veneer plate 4. Can be done.

(2) When the veneer adhesive layer 107 of the transfer film 100 and the veneer 4 are heat-bonded by the pressure of the first press die 200, the veneer adhesive layer 107 of the transfer film 100 is removed from the first press die 200. Softens due to heat conduction. As a result, part of the adhesive layer 107 for the protrusion plate of the transfer film 100 enters the conduit 13 of the protrusion plate 4. At this time, the air inside the conduit 13 of the veneer 4 is also activated and activated by the heating of the first press die 200 and the second press die 201, and the veneer adhesive layer 107 of the transfer film 100 enters. As a result, a part of the air in the conduit 13 of the projecting plate 4 is pushed out. At this time, as shown in the partially enlarged view 2-1 (FIG. 2A(b)), the air in the conduit 13 moves from the conduit 13 in the direction of the arrow →, and the air from the side of the second press die 201 of the projecting plate 4 moves. Part of As a result, in each layer of the transfer film 100 on the conduit 13 of the projecting plate 4, a part of the projecting plate adhesive layer 107 gradually enters the inside of the conduit 13 of the projecting plate 4 starting from the projecting plate adhesive layer 107.

After sufficient heat and pressure have been applied to the transfer film 100 and the projecting plate 4 in Step 1 shown in FIG. 2A, the first press die 200 is operated in Step 2 shown in FIG. 2B to move it onto the transfer film. At this time, as a result of the hot press working of Step 1, in the partially enlarged view 2-2 of the transfer film 100 and the protruding plate 4 shown in the partially enlarged view 2-2 (FIG. 2B (b)) of Step 2, the inside of the conduit 13 of the protruding plate 4 is shown in FIG. A part of the adhesive layer 107 for the veneer of the transfer film 100 is inserted. In other words, each of the other layers of the transfer film 100 is also pulled by the shape of being inserted into the conduit 13 of the projecting plate 4 of the projecting plate adhesive layer 107 and is slightly deformed. As a result, the concavo-convex shape formed by the conduit 13 on the surface of the projecting plate 4 is formed in a similar shape to the transfer layer of the transfer film 100.

(3) The final Step 3 is a step of taking out the wood decorative board in a state where the transfer film 100 and the projecting plate 4 are integrated.

Further, on the surface of the mat release layer 103 in the transfer film 100 using the manufacturing process, there are a plurality of convex portions smaller than the size of the conduit 13 of the projecting plate 4 not shown. Therefore, it is not shown in the figure that is formed on the surface of the mat release layer 103 of the transfer film 100 when the projecting plate 4 is indirectly heated and pressed from the base film 102 of the transfer film 100 by the first press die 200. The convex portion disperses the pressure applied to the surface of the projecting plate 4 by the convex portion of the mat release layer 103. As a result, the concavo-convex shape formed by the conduit 13 on the surface of the projecting plate 4 is unlikely to be crushed by the pressure applied by the hot press. Since the uneven shape formed by the conduit 13 on the surface of the projecting plate 4 is difficult to be crushed, the transfer layer 101 of the transfer film 100 follows the uneven shape formed by the conduit 13 of the projecting plate 4. That is, the concavo-convex shape along the conduit 13 of the projecting plate 4 is transferred onto the surface of the transfer layer 101 in a similar shape. Further, in order to improve the followability of the transfer film 100 to the projecting plate 4, the first press die 200 and the second press die 201 are made of a material other than metal such as Teflon (registered trademark) material or heat resistant resin material. The press die may be used during hot pressing. As a result, the flexibility of the press die is increased as compared with the case of using a metal material, and the followability of the transfer film 100 to the projecting plate 4 at the time of heating/pressurizing is improved. Further, by preliminarily subjecting the veneer plate 4 to resin impregnation, the wooden fibers inside the veneer plate 4 are loosened by the impregnating resin, and the flexibility of the veneer plate 4 itself is improved, and the transfer film 100 and the veneer plate 4 are subjected to hot pressing. Will be easier to follow. The resin for impregnating the veneer 4 includes water-based polyethylene glycol (PEG), acrylic, polyvinyl alcohol, etc., but an appropriate resin may be selected according to the application. For example, a thermoplastic resin, a thermosetting resin, a two-component curable resin, an ultraviolet/EB curable pre-cure resin, or an ultraviolet/EB curable after-cure resin may be used as long as it can be impregnated into the veneer 4. Resin impregnation is not essential, and the presence or absence of resin impregnation may be determined as necessary. As a processing method other than the hot press processing, the transfer film 100 may be adhered to the projecting plate 4 or the support 3 by a vacuum heat laminator, a vacuum forming method, a pressure forming method, or a heating and pressurizing method by vacuum pressure forming.

In the case of a vacuum heat laminator, air or a transfer film in the conduit 13 of the projecting plate 4 described in the partially enlarged view 2-1 (FIG. 2A(b)) and the partially enlarged view 2-2 (FIG. 2B(b)) by evacuation. Air between 100 and the projecting plate 4 is more likely to escape due to reduced pressure, and a part of the projecting plate adhesive layer 107 of the transfer film 100 is more easily drawn into the inside of the conduit 13 of the projecting plate 4. As a result, the transfer film 100 more easily follows the uneven shape of the conduit 13 on the surface of the projecting plate 4, and the similar uneven shape of the conduit 13 formed on the surface of the transfer layer 101 of the transfer film 100 is more significantly formed. It

3A is a cross-sectional view showing the layer structure of the wooden decorative board according to Embodiment 1, and FIG. 3B shows the surface of the hard coat layer 104, which is the outermost surface of the transfer layer 101, 200 times larger. It is an enlarged SEM image (partial enlarged view 3-1). In FIG. 3, the same components as those in FIGS. 1A to 2C, FIGS. 5 and 6 are designated by the same reference numerals, and description thereof will be omitted. The wooden decorative board 109 shown in FIG. 3A is in a state where the base film 102 and the mat release layer 103 of the transfer film 100 are removed. That is, on the unevenness 108 formed by the conduit 13 on the surface of the projecting plate 4, the transfer layer 101 of the transfer film 100 has an uneven shape similar to the uneven shape formed by the conduit 13 of the projecting plate 4 on the outermost surface of the transfer layer 101. It is formed as unevenness 108. The size of the unevenness 108 is H1. Explaining with a partially enlarged view 3-1 of FIG. 3B, a concave portion having a pattern opposite to that of the convex portion formed on the mat peeling layer 103 is formed between the similar concave and convex portions (H1) of the conduit 13. .. As a result, in the wooden decorative board 109, recesses smaller than the recesses and projections of the conduit 13 are randomly (irregularly) formed on the surface of the hard coat layer 104. The size of this recess is H2. In FIG. 3B, the size of the light-scattering concave portion formed of an even smaller filler is H3. Therefore, the texture of the surface of the hard coat layer 104 and the external light are scattered on the surface of the hard coat layer 104 while leaving the unevenness 108 due to the original conduit of the veneer 4 and the hard coat layer 104 serving as a matte surface is formed. As a result, a wooden decorative board that maintains reliability while maintaining the original touch and matte surface of the veneer 4 is obtained.

Moreover, the average thickness of the protruding plate 4 used is 0.1 mm or more and 0.7 mm or less, and more preferably 0.2 mm or more and 0.6 mm or less. If the thickness is less than 0.1 mm, the protruding plate 4 is thin and easily cracks during handling. Further, if the thickness is more than 0.7 mm, the followability at the time of molding as a sheet deteriorates. However, there is no problem with the thickness of the veneer outside the above range as long as the desired effect is obtained.

<Manufacturing process to transfer the wooden decorative board to the surface of the molded product by insert molding>
4A-1 to 4D, each step of the manufacturing method of transferring the wooden decorative board 109 according to the first embodiment to the surface of the molded product by insert molding will be described. 4A-1 to 4D, the same components as those in FIGS. 1 to 3, 5 and 6 are designated by the same reference numerals and the description thereof will be omitted.
(A) In the step shown in FIG. 4A-1, first, the wooden decorative board 109 is arranged between the fixed press die 2A for preform and the movable press die 1A. At this time, the wooden decorative board 109 is a single sheet. At this time, the wooden decorative board 109 is arranged with the transfer layer 101 side facing the fixed mold 2A.
(B) Next, in the step shown in FIG. 4A-2, the movable die 1A is moved and clamped to preform the wooden decorative board 109.
(C) Thereafter, in the step shown in FIG. 4A-3, the movable die 1A is returned to its original state and the preformed wooden decorative board 109 is taken out from the die. At this time, water may be included in the wood decorative board 109 in advance to loosen the wood fibers in the veneer 4 of the wood decorative board 109 with water so that the wood decorative board 109 can easily follow the preform mold during preforming. .. At the same time as preforming, water or steam may be applied to the wooden decorative board 109 to loosen the wood fibers in the veneer 4 in the wooden decorative board 109 or to make the wooden decorative board 109 flexible. If water or water vapor cannot be used due to problems with the wooden decorative board 109 or the molding process, resin can be impregnated into the inside of the veneer 4 in advance to improve the flexibility of the veneer 4 without using water. Good.

(D) Next, the wooden decorative board 109 is trimmed with an exclusive cutter 110 at an unnecessary portion of the end surface of the wooden decorative board 109 in the step shown in FIG. 4B-1.
(E) In the step shown in FIG. 4B-2, the trimming is completed, and the wood veneer board 109 for insert molding is completed.

(F) Next, in the step shown in FIG. 4C-1, the preformed wood decorative board 109 is placed in the movable mold 2B and the fixed mold 1B for insert type. At this time, the wooden decorative board 109 is arranged with the transfer layer 101 side facing the movable mold 2B side where suction holes are formed in a portion not shown in the drawing. At this time, the wooden decorative board 109 preformed through the suction holes not shown in the figure is sucked.
(G) In the step shown in FIG. 4C-2, the movable mold 2B is moved to perform mold clamping.
(H) In the step shown in FIG. 4C-3, injection molding resin is poured into the mold from the gate 111 vacant in the fixed mold 1B, and a second bonding is provided beforehand on the surface of the wooden decorative board 109 opposite to the transfer layer 101. Adhere to the layers.
(I) In the step shown in FIG. 4C-4, the mold is opened, and the insert-molded product 112 integrally molded with the wooden decorative board 109 is taken out from the mold by a protruding pin (not shown). This process is repeated for mass production. In the insert molding process as well, similar to the preform process, moisture may be applied to the wooden decorative board to increase flexibility and improve followability to the insert molding die. In addition, the veneer 4 impregnated with resin in advance may be used to improve the flexibility of the wooden decorative board 109.

FIG. 4D is a SEM image showing a state in which the hard coat layer 104 on the surface of the insert-molded product 112 is magnified 200 times (partially enlarged view 4-1). As shown in the partially enlarged view 4-1, if the wooden decorative board 109 is used, the fine recesses on the surface of the hard coat layer 104 after molding are unlikely to be crushed. Therefore, the fine recesses on the surface of the hard coat layer 104 are likely to remain, and the fine recesses that scatter the diplomatic relation are likely to remain, and the state in which the matte surface is maintained can be maintained.

The tactile concave portion formed by the matte release layer 103 on the surface of the hard coat layer 104 is difficult to be crushed by the pressure during injection molding because of the concave shape. Further, fine recesses for scattering light are also randomly arranged on the surface of the hard coat layer 104, and there are irregularities 108 formed by conduits on the surface of the veneer plate and a concave shape for tactile feel smaller than that. Not a uniform surface. Therefore, the pressure at the time of injection molding is easily dispersed on the surface of the hard coat layer 104, and the fine recesses for maintaining the matte surface are not easily crushed and are easily maintained.

Further, when it is desired to maintain the uneven shape of the surface of the wooden decorative board 109 more precisely, and when the shape of the molded product is relatively flat and the amount of deformation of the wooden decorative board 109 is relatively small, the veneer 4 and the transfer film The deformation of 100 is small, and the difference in expansion and contraction between the materials is unlikely to occur. Therefore, it is difficult for wrinkles to occur due to the expansion and contraction of the transfer film 100. Therefore, wrinkles are not formed on the surface of the veneer 4 and the transfer film 100 and the veneer 4 are bonded by hot pressing, and then the base film 102 and the matte release layer 103 of the transfer film 100 are left without being peeled off. The plate 109 may be insert-molded. Alternatively, the base film 102 with the mat release layer 103 may be peeled off from the insert-molded article after the insert-molding is completed. Thus, the shape of the recess formed on the transfer layer 101 on the surface of the insert-molded product 112 with the wooden decorative plate 109 does not directly contact the surface of the transfer layer 101 and the surface of the insert mold during insert molding. Therefore, the recess formed on the surface of the transfer layer 101 is less likely to be crushed, and it is possible to obtain the insert-molded product 112 with the wooden decorative board 109 in which a fine recess is left on the surface.

Further, the wooden decorative board 109 is decorated by performing trimming processing as needed after preform processing other than insert molding, and pasting it on the surface of the molded product by post-processing by hand pasting or vacuum pressure forming. You may.

(Embodiment 2)
As another method for more effectively maintaining the uneven shape of the surface of the wooden decorative board 109, the step shown in FIG. 4A-1 to the step shown in FIG. 4A-3, or the step shown in FIG. 4C-1. 4C-4, in the insert molding step or both steps of the step shown in FIG. 4C-4, even if a die having an arbitrary grain on the surface of the die 2A or die 2B on the side of the projecting plate 4 to which the transfer layer 101 is transferred is used Good.

This method is effective when the base film 102 and the mat release layer 103 of the transfer film 100 are first peeled off in the preform step or the insert molding step, and only the transfer layer 101 is formed on the wooden decorative board 109 for use. Is. In particular, when the curvature of the molded product is large or when the molded product has a complicated three-dimensional shape, there is a large difference in expansion/contraction ratio between the projecting plate 4 and the base film 102, which are molded without peeling the base film 102, and wrinkles are large. When the wrinkles are generated and the wrinkles are transferred to the surface of the wooden decorative board 109, resulting in a defective appearance, it is an effective means.

The wrinkles formed on the surface of the mold may be appropriately formed by etching or sandblasting so that the surface has the same roughness and gloss as the surface of the matte release layer 103 of the transfer film 100. The etching process is mainly used for forming large-sized unevenness for touch, and the sandblasting process is used for forming fine unevenness for obtaining a matte surface. The size of the sand particles used in the sandblasting may be divided into plural times depending on the processing conditions to randomly form fine irregularities having the same size as the matte release layer 103. Alternatively, it may be formed only by sandblasting without using etching. Further, other processing methods are not limited to etching processing and sandblasting processing as long as the same effect can be obtained.

By this method, the grain surface of the mold surface not shown in FIGS. 4A to 4C-4 is applied to the surface of the transfer layer 101 by heating/pressurizing at the time of preforming or the injection pressure of the insert molding process. A part or all of the texture can be formed on the transfer layer 101. As a result, it becomes possible to manufacture the insert-molded product 112 in which the textured surface and the matte surface are maintained on the surface of the hard coat layer 104 of the final molded product.

It should be noted that the present disclosure includes appropriate combination of any of the various embodiments and/or examples described above, and each of the embodiments and/or The effects of the embodiment can be achieved.

According to the wood decorative board and the method for manufacturing the same and the method for manufacturing a molded article using the same according to the present invention, the original uneven texture of the veneer produced by slicing natural wood, the matte feeling, and the appearance feeling are impaired. In addition, the durability required for industrial products can be imparted to the surface of the veneer. Further, according to this method, it is possible to manufacture a wooden decorative board which retains the texture of the real wood at low cost and with stable quality. This technique can be widely used as a technique for imparting a woody design using real wood to resin components such as exterior casings of home electric appliances and mobile devices and interior components for automobiles.

1 Injection Molding Resin Layer 2 First Adhesive Layer 3 Support 4 Veneer 5 Second Adhesive Layer 6 Transparent Film 7 Hard Coat Layer 8 Wood Decorative Board 9 Insert Molded Product 10 Protective Layer of Surface Irregularity 11 Wood Decorative Board 12 Insert Molding Product 13 Conduit 100 Transfer film 101 Transfer layer 102 Base film 103 Release layer 104 Hard coat layer 105 Anchor layer 106 UV cut layer 107 Veneer adhesive layer 108 Concavo-convex 109 Wooden decorative board 110 Cutter 111 Gate 112 Insert molded product 200 First press Mold 201 Second press mold

Claims (18)

A veneer made from natural wood with multiple irregularities formed by wooden conduits on the surface,
A hard coat layer or a protective layer in which irregularities having different sizes are formed on the surface of the veneer;
Equipped with
On the surface of the hard coat layer or the protective layer, a plurality of recesses formed on the surface of the hard coat layer or the protective layer, and a plurality of smaller than the recesses formed on the surface of the hard coat layer or the protective layer. A wooden decorative board having a recess. The height difference or the depth relationship of the uneven shape of the surface of the hard coat layer or the protective layer is H1, the height or depth of the uneven shape of the similar shape of the conduit of the projecting plate is H1, the hard coat layer or the The height or depth of the recesses formed on the surface of the protective layer is H2, and the height or depth of a plurality of recesses smaller than the recesses formed on the surface of the hard coat layer or the protective layer is H3, The wooden decorative board according to claim 1, wherein the respective magnitude relationships satisfy the relational expression of H1>H2>H3. The wood makeup according to claim 2, wherein the plurality of recesses formed on the surface of the hard coat layer or the protective layer on the surface of the wooden decorative board are transferred via fillers having different sizes. Board. The wood decorative board according to claim 3, wherein the height or depth H2 of the recess formed on the surface of the hard coat layer or the protective layer is 15 μm or more and 30 μm or less. The height or depth H3 of the recesses smaller than the recesses formed on the surface of the hard coat layer or the protective layer is 0.5 μm or more and 8 μm or less, The claim 3 or 4, characterized in that Wood veneer. The glossiness of the surface of the hard coat layer or the protective layer on the surface of the wooden decorative board is 10% or less at an angle of 20°, 60°, and 85°, respectively. The wooden decorative board as described in 1 above. 7. The hard coat layer or the protective layer formed on the surface of the wooden decorative board is made of an after-cure type ultraviolet curable resin or an electron beam curable resin. The wooden decorative board according to item. The layer structure of the film formed on the surface of the wooden decorative board is composed of a plurality of layers including at least one layer of an ultraviolet ray blocking layer, an anchor layer and an adhesive layer in addition to the hard coat layer or the protective layer. The wooden decorative board according to any one of claims 1 to 7. The wood decorative board according to any one of claims 1 to 8, wherein a total thickness of the film formed on the surface of the wood decorative board is 4 µm or more and 80 µm or less. The wooden veneer according to claim 1, wherein the veneer used in the wooden veneer has a resin impregnated inside the veneer. A step of preparing a veneer made of natural wood on the surface of which a plurality of irregularities are formed by wooden conduits,
A transfer film having at least a base film, a peeling layer, a hard coat layer or a protective layer, wherein two or more kinds of fillers having different sizes are added to the peeling layer, and the surface of the peeling layer has the above-mentioned size. A plurality of convex shapes of different sizes formed by different fillers are formed, and further formed on the release layer on the surface of the hard coat layer or the protective layer formed on the release layer thereon. There are a plurality of concave shapes of different sizes, the surface of the release layer and the unevenness are formed in a reversed state, the step of preparing a transfer film,
Using the transfer film, a step of transferring the hard coat layer or the protective layer of the transfer film to the surface of the veneer,
And a method for manufacturing a wooden decorative board. The transfer layer side of the transfer film and the veneer are overlapped, and the hard coat layer or the protection of the transfer film is formed by a method selected from the group of hot pressing, vacuum heat lamination, vacuum forming, pressure forming, and vacuum pressure forming. The method for manufacturing a wood decorative board according to claim 11, wherein a transfer layer including a layer is adhered to the surface of the veneer, and the transfer layer including the hard coat layer or the protective layer is formed on the surface of the veneer. By changing the surface roughness and the matte feeling of the release layer formed on the side on which the transfer layer including the hard coat layer or the protective layer is formed on the transfer film, it is transferred to the surface of the veneer plate. The surface roughness and the matte feeling of the surface of the hard coat layer or the protective layer can be adjusted, and
A method for changing the surface roughness and matte feeling of the release layer is to add a plurality of fillers of different sizes to the release layer, and adjust the size of the filler and the addition amount of each filler. Item 13. A method for manufacturing a wooden decorative board according to item 11 or 12. The depth of the convex portion on the surface of the release layer formed on the transfer film is smaller than the height difference or the depth of the unevenness due to the conduit on the surface of the projecting plate, or the depth of the convex portion according to any one of claims 11 to 13. A method for producing a wooden decorative board as described above. A preforming step of preforming the veneer into a shape close to a final product by hot pressing using the wood decorative board manufactured by the manufacturing method according to any one of claims 11 to 14,
The hard coat layer or the transfer layer including the protective layer is injection-molded on the adhesive layer or the adhesive functional surface formed on the surface of the veneer on the side where the transfer is not performed to form a molding resin layer, and the transfer layer is An insert molding step of manufacturing a resin part in which the applied veneer is formed on the surface,
A method for producing a molded article including: In one or both of the preform step or the insert molding step, a grain surface is formed on the mold surface in contact with the projecting plate side on which the transfer layer is formed, and the preform step or the insert molding step is performed. The production of the molded article according to claim 15, wherein a part or all of the grain on the die surface is transferred to the surface of the hard coat layer or the protective layer formed on the surface of the veneer by either one or both. Method. The method for producing a molded product according to claim 15 or 16, wherein the base film of the transfer film is peeled off from the surface of the wooden decorative board in the final step of completing the molded product in the insert molding process. A molded article using the wooden decorative board according to any one of claims 1 to 10, wherein a plurality of uneven shapes having different sizes are formed on the surface of the hard coat layer or the protective layer. A molded product having a concavo-convex shape transferred other than the concavo-convex shape due to the conduit of the projecting plate, and the concavo-convex having the largest size among the transferred concavo-convex shapes is a concave shape.