JP2524564B2 - Veneer manufacturing method - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a method for manufacturing a decorative board, and more specifically, it has excellent surface physical properties such as surface hardness, scratch resistance, and abrasion resistance, and the depth of a printed pattern. The present invention relates to a method for manufacturing a decorative board having excellent design properties such as feeling and three-dimensional effect.

(Prior Art) Conventionally, many decorative boards have been used as surface finishing materials for various furniture and building materials. These decorative boards are generally formed by laminating decorative polyester-based or diallyl phthalate-based or other thermosetting resin-impregnated decorative paper on a decorative board base material and heating and pressurizing it.

(Problems to be Solved by the Invention) The surface of the conventional decorative board as described above is composed of a thermosetting resin layer, but the surface hardness is insufficient and the scratch resistance and abrasion resistance are insufficient. For the same reason, there is a problem that the stain resistance is insufficient.

Further, from a decorative point of view, there is a problem in that the printed pattern is flat and has a poor three-dimensional effect, and there are many points that the design is not satisfactory.

As a method for solving the above problems, a method of further forming a film having good surface properties on the surface of the decorative plate is considered, but the method of forming these films on the surface is the coating of a paint on the surface. And complicated steps such as curing are required and there are many problems of adhesion between the surface layer and the decorative paper surface, which is not preferable. Further, as a method of making a printed pattern three-dimensional, there is a method of giving unevenness by embossing, but it is not economical because it requires a separate step.

Therefore, there is a demand for the development of a technique capable of easily providing a decorative board having excellent surface properties and design effects.

(Means for Solving Problems) The present inventor has completed the present invention as a result of earnest research to solve the above-described problems of the prior art.

That is, the present invention relates to a decorative board base material, a decorative paper having a printed pattern treated with a thermosetting resin, and an ionizing radiation curable composition that is solid at room temperature in the uncured state on the release surface of the releasable film. A transfer sheet having a resin layer is heat-cured in a state where the resin layer and the decorative paper are in contact with each other to cure the thermosetting resin so that the decorative board base material and the decorative paper are adhered and the release film is peeled off. Then, the ionizing radiation is then irradiated to cure the ionizing radiation-curable resin layer.

(Function) In the production of a decorative plate, by forming a surface layer using a transfer sheet having an ionizing radiation curable resin layer, excellent physical properties, design properties and delamination free of delamination can be achieved without complicated steps. The boards are provided economically.

(Preferred Embodiment) Next, the present invention will be described in more detail with reference to the accompanying drawings that schematically show preferred embodiments of the present invention.

1 to 3 are diagrams schematically showing the method of the present invention. The method of the present invention is a thermosetting resin having a decorative board substrate 1 and a printed pattern 2 as shown in FIGS. The resin-impregnated decorative paper 3 and the transfer sheet 6 having the ionizing radiation curable resin layer 5 which is solid at room temperature in the uncured state on the release surface of the peelable film 4, the resin layer 5 and the decorative paper 3 Are laminated so that they are in contact with each other, and the laminate is placed between the heating plates A and A ', preferably with the mirror plate 9 interposed between the heating plate A and the transfer sheet 6, and is heated and pressed to apply heat to the decorative paper 3. After the thermosetting resin is cured and each element is adhered, the releasable film 4 is peeled off from the obtained molded body as shown in the second drawing, and the ionizing radiation 7
Then, the resin layer 6 is cured by irradiating with, and the decorative plate 100 as the target product is obtained.

In another example, another printed pattern 8 can be provided on the resin layer 5 of the transfer sheet 6 used above.

The heating and pressurizing conditions, the ionizing radiation irradiation conditions, and the like used in the present invention as described above may be in accordance with conventionally known techniques, and are not particularly limited.

Next, the materials used in the present invention will be described in more detail.

The transfer sheet 6 used in the present invention is a releasable film 4.
The ionizing radiation-curable resin layer 5 that is solid at room temperature in the uncured state is formed on the release surface of the release sheet, and the material of the release film used for the transfer sheet is, in principle, a transfer sheet of this type. The thickness is usually 5 to 200 μm, more preferably 12 to 50 μm.

Specific examples are films of synthetic resins such as polyethylene terephthalate (so-called polyester), polypropylene, polyethylene and polyamide, paper, synthetic paper and the like. These can be used by laminating if necessary.

The surface condition of the releasable film determines the condition of the surface of the transfer layer 5 after transfer, and when the surface of the transfer layer after transfer is desired to be a mirror (mirror) surface, these releasable films are used. The surface of must be a mirror surface. In addition, in decorative applications, a matte surface is often required.In that case, use a matte film with a matte agent kneaded as a releasable film, the gloss state of which has been adjusted by sandblasting or chemical etching. Good to do.

The releasable film may be made of a material other than the above-mentioned materials, or may have a releasable layer separately provided to make the surface releasable.

This releasable layer has a component that enables the transfer resin layer to be separated from the base sheet of the transfer sheet at the time of transfer, and specifically, an appropriate vehicle (an example of the vehicle is a vehicle of an ordinary ink composition). The same as those described below) may be used alone or if necessary, a releasing material such as wax or silicone may be added.

The resin layer formed on the releasable film is solid at room temperature in an uncured state and has a thermoplastic property and a solvent solubility property, but is apparently or touched by coating and drying. It is preferable to form a resin layer using an ultraviolet curable resin or an electron beam curable resin that gives a coating film that is non-fluid and non-adhesive even when exposed, and forms such a resin layer. By doing so, it is easy to handle, and an arbitrary printing layer 8 can be formed on the surface thereof, and by further integrating with the decorative paper 3 and curing the resin layer, the adhesiveness with the decorative paper is optimized. Can be

As such a resin, there are the following two thermoplastic resins having a radically polymerizable unsaturated group.

(1) A polymer having a glass transition temperature of 0 to 250 ° C. and a radically polymerizable unsaturated group in the polymer.

More specifically, a method (a) described below is applied to a compound obtained by polymerizing or copolymerizing the following compounds (a) to (h)
Those introduced with radically polymerizable unsaturated groups in accordance with (b) to (b) can be used.

(A) a monomer having a hydroxyl group; N-methylol (meth) acrylamide, 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate,
2-hydroxybutyl (meth) acrylate, 2-hydroxy-3-phenoxypropyl (meth) acrylate and the like.

(B) A monomer having a carboxyl group; (meth) acrylic acid, (meth) acryloyloxyethyl monosuccinate and the like.

(C) Epoxy group-containing monomer; glycidyl (meth)
Acrylate etc.

(D) Monomers having an aziridinyl group; 2-aziridinylethyl (meth) acrylate, allyl 2-aziridinylpropionate and the like.

(E) Amino group-containing monomer; (meth) acrylamide, diacetone (meth) acrylamide, dimethylaminoethyl (meth) acrylate, diethylaminoethyl (meth) acrylate and the like.

(F) Monomers having sulfone groups; 2- (meth) acrylamido-2-methylpropanesulfonic acid and the like.

(G) Monomer having isocyanate group; diisocyanate such as 1 mol to 1 mol adduct of 2,4-toluene diisocyanate and 2-hydroxyethyl (meth) acrylate and adduct of radically polymerizable monomer having active hydrogen etc.

(H) Furthermore, in order to control the glass transition point of the above copolymer or the physical properties of a cured film, the above compound and the following monomer copolymerizable with this compound And can be copolymerized. Examples of such a copolymerizable monomer include methyl (meth) acrylate, ethyl (meth) acrylate, propyl (meth) acrylate, butyl (meth) acrylate, isobutyl (meth) acrylate, and t-butyl (meth) acrylate. ) Acrylate, isoamyl (meth) acrylate, cyclohexyl (meth) acrylate, 2-ethylhexyl (meth) acrylate and the like.

Next, the polymer obtained as described above is reacted by the methods (a) and (b) described below to introduce a radically polymerizable unsaturated group, whereby an ultraviolet or electron beam curable resin is obtained. .

In the case of (a) a polymer or copolymer of a monomer having a hydroxyl group, a monomer having a carboxyl group such as (meth) acrylic acid is subjected to a condensation reaction.

(B) In the case of a polymer or copolymer of a monomer having a carboxyl group or a sulfone group, the above-mentioned monomer having a hydroxyl group is subjected to a condensation reaction.

(C) In the case of a polymer or copolymer of a monomer having an epoxy group, an isocyanate group or an aziridinyl group,
The above-mentioned monomer having a hydroxyl group or monomer having a carboxyl group is added.

(D) In the case of a polymer or copolymer of a monomer having a hydroxyl group or a carboxyl group, a monomer having an epoxy group, a monomer having an aziridinyl group or a diisocyanate compound and a hydroxyl group-containing (meth) acrylic acid Addition reaction is performed with an adduct of 1 mole of ester monomer.

In order to carry out the above reaction, it is desirable to add a trace amount of a polymerization inhibitor such as hydroquinone and to carry out by sending dry air.

(2) A compound having a melting point of normal temperature (20 ° C.) to 250 ° C. and a radically polymerizable unsaturated group. Specific examples include stearyl (meth) acrylate, triacryl isocyanurate, cyclohexanediol di (meth) acrylate, and spiroglycol (meth) acrylate.

Further, in the present invention, the above (1) and (2) may be mixed and used, and a radical polymerizable unsaturated monomer may be added to them. This radically polymerizable unsaturated monomer improves the crosslink density and the heat resistance upon irradiation with ionizing radiation, and in addition to the above-mentioned monomers, ethylene glycol di (meth) acrylate and polyethylene. Glycol di (meth) acrylate,
Hexanediol di (meth) acrylate, trimethylolpropane tri (meth) acrylate, trimethylolpropane (meth) acrylate, pentaerythritol tetra (meth) acrylate, pentaerythritol tri (meth) acrylate, dipentaerythritol hexa (meth) acrylate, Ethylene glycol diglycidyl ether di (meth) acrylate, polyethylene glycol diglycidyl ether di (meth) acrylate, propylene glycol diglycidyl ether di (meth) acrylate, polypropylene glycol diglycidyl ether di (meth) acrylate, sorbitol tetraglycidyl ether tetra ( (Meth) acrylate or the like can be used, and the solid content of the above-mentioned copolymer mixture can be used.
It is preferable to use 0.1 to 100 parts by weight with respect to 100 parts by weight. Further, although the above-mentioned ones can be sufficiently cured with an electron beam, when they are cured by irradiation with ultraviolet rays, benzoinones such as benzoquinone, benzoin and benzoin methyl ether, halogenated acetophenones and biacetyls are used as sensitizers. Those that generate radicals by irradiation with ultraviolet rays, such as the above, can also be used.

Ultraviolet rays and electron beams are typical examples of ionizing radiation.

As the electron beam, Cockloft-Walton type, Van de Graaff type, resonance transformer type, insulating core transformer type, linear type, 50-1000 KeV emitted from various electron beam accelerators such as dynamitron type frequency type, preferably 100 to An electron beam having an energy in the range of 300 KeV can be used, and as the ultraviolet rays, those emitted from an ultraviolet ray source using a light source such as an ultrahigh pressure mercury lamp, a high pressure mercury lamp, a low pressure mercury lamp, carbon arc, xenon arc, and a metal halide lamp are used. be able to.

The decorative paper used in the present invention is in a state in which a thermosetting resin is applied to the surface of the printed pattern paper and dried, or the printed pattern paper is impregnated with the thermosetting resin and dried.

As the decorative paper base paper for these decorative papers, thin paper, bleached kraft paper, titanium paper, linter paper, paperboard, gypsum board paper, polyethylene film, polypropylene film, polyvinyl chloride film, polyvinyl chloride film, polyvinyl chloride, etc. Alcohol film, polyethylene terephthalate film, polycarbonate film,
Nylon film, polystyrene film, ethylene-
Examples thereof include vinyl acetate copolymer film, ethylene-vinyl alcohol copolymer film, and plastic films such as ionomer.

Applying a print pattern to the base paper or the transfer sheet 6
The printed pattern is applied to the resin layer 5 by, for example, a cellulose derivative, a styrene resin, an acrylic resin, a rosin ester resin, a vinyl chloride resin, an alkyd resin, a butyral resin, a polyurethane resin, a polyester resin, a polyamide resin, or the like. Gravure printing, gravure offset printing, flat plate offset printing, dilitho printing, letterpress printing, intaglio printing, jet printing using a printing ink consisting of a kneaded material of vehicle, pigment or dye, plasticizer, stabilizer, solvent, etc. It is carried out by an ordinary printing means such as silk screen printing, electrostatic printing or the like.

Examples of the thermosetting resin to be applied to or impregnated on the decorative paper include phenol resin, urea resin, melamine resin, unsaturated polyester resin, polyurethane resin, aminoalkyd resin, melamine-urea co-condensation resin, diacrylic phthalate. A thermosetting resin such as a base resin or a silicon resin, or a resin liquid containing an initial condensation product thereof as a main component can be used.

Further, the base material for the decorative board in the method for producing a decorative board of the present invention includes, for example, wood-based base materials such as plywood, particle board, hard board, insulation board, gypsum board, asbestos perlite board, and silicic acid. Inorganic base materials such as calcium board, glass wool, rock wool,
Metal substrates such as iron plate, zinc plate, amyl plate and lead plate, foam polyethylene plate, polystyrene foam plate, urethane foam, foam substrate such as phenol foam, phenol resin plate, melamine resin plate, polyester resin plate, acrylic A synthetic resin plate such as a resin plate or a vinyl chloride resin plate, or a composite material of these is used.

In the present invention, the adhesive that may be used for adhering the decorative board base material to the decorative paper is a type of decorative board base material used or a decorative pattern paper printed with a thermosetting resin. The adhesive is appropriately selected according to the type of the thermosetting resin in the paper, but in general, a versatile adhesive such as vinyl acetate type, urethane type, epoxy type, urea type is used. It

(Effect) The decorative board of the present invention obtained as described above is very excellent in that the surface thereof is covered with a cured layer of an ionizing radiation curable resin, and these cured layers are highly crosslinked cured layers. Since the cured layer has excellent surface physical properties and the cured layer has excellent transparency, the printed pattern in the basement has excellent three-dimensional effect and depth feeling.

Further, in a preferred embodiment of the present invention, by making the ionizing radiation curable resin layer of the transfer sheet used above an uncured but solid layer at room temperature, cosmetics with more excellent surface physical properties and excellent interlayer adhesion are obtained. A board is provided.

That is, the present invention is carried out using such a transfer sheet, and after the release film is peeled off, the adhesiveness between the cured layer and the decorative paper is further improved by irradiating with ionizing radiation to cure the ionizing radiation curable resin. improves.

Further, in another preferred embodiment of the present invention, by using the cured sheet of the transfer sheet provided with an optional colored printing layer, the present invention can be carried out to obtain a printed pattern of a decorative sheet. Provided is a decorative board that is superposed and has more excellent designability, three-dimensional effect, and depth feeling.

(Example) Next, an Example is given and this invention is demonstrated still more concretely.

Example 1 A decorative paper having a printed pattern was obtained by printing gravure printing on a base paper for decorative paper (PAC-100RS manufactured by Sanyo Kokusaku Pulp) with gravure printing ink (Chemical L manufactured by Showa Ink).
An unsaturated polyester resin (manufactured by Mitsui Toatsu, Ester) was applied to the surface of this printed pattern at a rate of 200 g / m ² (Wet) to impregnate the resin to obtain a thermosetting resin-impregnated decorative paper.

On the other hand, polyester film (Toray, Lumirror X-
44) UV curable resin (Mitsubishi Yuka, Yupimer LZ)
-075) was applied at a rate of 7 g / m ² (dry) and dried at 80 ° C. for 1 minute, and then gravure ink (SA, Showa Ink Co., Ltd.) was used for gravure printing to obtain a transfer sheet.

This transfer sheet was laminated on the above-mentioned decorative paper impregnated with the thermosetting resin so that the curable resin layer of the transfer sheet was in contact with each other, and heat-treated at 100 ° C. to be integrated. Next, the integrally molded product was adhered onto a plywood for decorative board using a polyvinyl acetate adhesive (Rikabond AC-315 manufactured by Chuo Rika). After that, the release film is peeled off, and the high pressure mercury lamp (type with ozone, output 80 W / cm below 5 m from the peeled surface)
The ionizing radiation curable resin layer was cured by passing it 10 times at a speed of / min to obtain a decorative board of the present invention.

The surface of this decorative plate is not scratched even if it is rubbed with steel wool # 1000, and it has excellent scratch resistance and abrasion resistance.
Moreover, even when writing with an oil-based felt-tip pen, the characters could be easily wiped off and had excellent stain resistance.

In addition, the printed pattern had an excellent three-dimensional effect and design because of the transparent cured layer on the surface.

Example 2 At the same time as in Example 1, except that the resin layer of the transfer sheet used in Example 1 was previously cured with an electron beam and the final ultraviolet ray irradiation was not performed. An excellent decorative board was obtained.

[Brief description of drawings]

1 to 3 schematically show the method of the present invention. 1: Base material for decorative plate, 2, 8: Printed pattern 3: Decorative paper, 4: Release film 5: Resin layer, 6: Transfer sheet 7: Ionizing radiation, 9: Mirror surface plate 100: Decorative plate, A, A ' : Hot plate

Claims (2)

(57) [Claims] 1. A decorative board base material, a decorative paper having a printed pattern treated with a thermosetting resin, and an ionizing radiation curable resin which is solid at room temperature in an uncured state on a release surface of a releasable film. A transfer sheet having a layer is heat-cured in a state where the resin layer and the decorative paper are in contact with each other to cure the thermosetting resin to adhere the decorative board base material and the decorative paper, and peel off the release film. ,
Next, a method for producing a decorative board, which comprises irradiating ionizing radiation to cure the ionizing radiation-curable resin layer. 2. The method for producing a decorative board according to claim 1, wherein a printed pattern is provided on the ionizing radiation curable resin layer.