JP2712483B2 - Cosmetic material manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION <Industrial Application Field> The present invention relates to a method for producing a decorative material. More specifically,
In the production of decorative materials such as melamine decorative board, while forming a predetermined uneven pattern on the surface of the decorative material, it is possible to transfer the colored ink to only the concave portions of the unevenness with high accuracy, It relates to a manufacturing method.

<Prior art> In the case of melamine decorative boards, in order to reproduce three-dimensional designs such as conduit holes possessed by natural wood, a decorative sheet having irregularities on the surface is formed by stacking a molding sheet on the surface during the manufacture of decorative boards. Has been manufactured.

Further, since such a conduit hole has a different hue from other portions, for example, a spring member, it is desirable to color only the concave portions of the concavities and convexities formed by embossing with another color with high accuracy.

As a method of manufacturing such a decorative material, after forming irregularities on the surface of the decorative material, applying a coloring ink to the entire surface thereof,
There is a method (wiping method) in which the colored ink on the convex portions is scraped to leave the colored ink only on the concave portions. However, this method is uneconomical because unevenness forming and coloring steps are separate steps,
With a decorative material having a curved surface, it is practically impossible to scrape the colored ink.

In addition, a method is also known in which coloring ink is applied to convex portions of irregularities on the surface of a shaping sheet, and irregularities are formed on the surface of a decorative material using the shaping sheet, and the colored ink is transferred to concave portions of the decorative material. ing. According to this method, there are no disadvantages caused by the wiping method described above, the formation of irregularities and coloring can be performed in one step, and the method can be applied to a curved surface.

Two methods are known for producing such a shaped sheet in which only the convex portions are colored.

One of them is a method in which an inking roll is brought into contact with a shaping film having irregularities and is pressed so that the concave portions are not colored so that only the convex portions are colored. However, the conduit is generally very fine, having a depth of 2 to 100 μ, and it is difficult and practically impossible to distinguish between the inlaid portion and the non-inlaid portion due to such a small height difference. .

Another method is to use a shaped film with irregularities,
This is a method of printing in alignment with the convex portions. But,
Also in this method, it is very difficult to print in alignment with the fine conduit hole. Since the shaping sheet expands and contracts somewhat even on a printing press, the expansion and contraction further makes alignment difficult.

<Problems to be Solved by the Invention> Under such circumstances, the present invention provides a method of manufacturing a decorative material using a shaping sheet in which only the convex portions of the irregularities formed on the surface are accurately colored. Aim.

<Means for Solving the Problems> In order to achieve this object, the present invention relates to an embossed film (1) having irregularities on the surface, and having a transferable colored ink in the concaves of the irregularities, and a base sheet. By laminating the laminated sheet (2) having a synthetic resin layer in a state where the synthetic resin layer is softened, an unevenness is formed on the synthetic resin layer and a colored ink is transferred to produce a shaped sheet, The present invention provides a method for producing a decorative material, characterized by forming irregularities on the surface of a decorative material using the shaping sheet and transferring colored ink to recesses of the decorative material.

<Effect> The embossed film (1) has irregularities on the surface, and has a transferable colored ink in the concaves of the irregularities. Unlike the case where only the convex portions of the irregularities are colored, if the coloring ink is applied to the entire surface of the irregularities and the colored ink of the convex portions is scraped off with a doctor or the like,
Since the coloring ink can be left only in the concave portions, only the concave portions can be colored with high accuracy.

By embossing the embossed film (1) on the laminated sheet (2) having a softened synthetic resin layer, irregularities having a shape obtained by inverting the irregularities of the embossed film (1) are formed on the synthetic resin layer, and the coloring ink is formed. It is transferred to the surface of the synthetic resin layer. The embossed film of the synthetic resin layer is embossed (1)
Since the irregularities are exactly inverted, the colored ink is accurately transferred to the irregularities on the surface of the synthetic resin layer.

The embossed film (1) is peeled off to obtain a shaped sheet. The imprinting sheet has irregularities on the surface, and has colored ink only on the convex portions with high accuracy.

By using such a shaping sheet, for example, by imparting irregularities to the surface of a decorative material such as a melamine decorative board and transferring a color ink, irregularities which are exactly the reverse of the irregularities of the shaping sheet are provided on the surface. In addition, it is possible to manufacture a decorative material in which only the concave portions are provided with the coloring ink.

<Example> Hereinafter, the present invention will be described with reference to the drawings. The drawings show an embodiment of the present invention.

Embossed film (1) FIG. 1 is a sectional view of the embossed film (1).

The embossed film (1) is a film that accurately imparts irregularities and coloring to the surface of the laminated sheet (2), and includes a thermoplastic resin film (11) having irregularities (1a) formed on the surface and concave portions of the irregularities (1a). And a colored ink layer (12) formed only on the colored ink layer (12).

The thermoplastic film (11) determines the unevenness of the surface of the imprinting film, that is, the unevenness of the surface of the decorative material. It is necessary that the surface of the thermoplastic film (11) is smooth and can form unevenness.
For example, a polyvinyl chloride film, a polypropylene film, a polyethylene film, an acrylic resin film, a polycarbonate film and the like can be used.

The irregularities (1a) can be formed by a conventional method. That is, the embossing roll or the embossing plate is bonded to the thermoplastic resin film (1
The projections and depressions (1a) can be formed by superimposing on 1) and applying heat and pressure.

The coloring ink (12) is intended to improve the design by coloring concave portions on the surface of the decorative material, which is the final product, and is easy to peel off from the thermoplastic resin film (11) and can be transferred to the surface of the laminated sheet (2); In addition, transfer from the surface of the imprinting sheet to the surface of the decorative material, that is, transferability is required. Examples of such a coloring ink (12) include, depending on the material of a thermoplastic resin film (11), a laminated sheet (2), and a cosmetic material, a nitrified cotton type, a cellulose acetate type, a vinyl chloride type, an acrylic type, and a butyral type. And chlorinated polyolefin-based, urethane-based, polyester-based and chlorinated rubber-based inks.

In order to apply the coloring ink (12) only to the concave portions, after applying the coloring ink to the entire uneven surface of the thermoplastic resin film (11), before drying, the coloring ink attached to the convex portions is scraped off by a doctor. Or just wipe it off. If desired, it may be partially applied. It is necessary to apply the coloring ink (12) to a thickness smaller than the depth of the concave portion. Preferably is less than _^1/2 of the depth of the recess. It should be noted that the thickness of the colored ink becomes thinner with shrinkage due to drying, and the uneven shape is not substantially affected.

Thus, the embossed film (1) can be manufactured.

Laminated sheet (2) FIG. 2 is a sectional view of the laminated sheet (2).

The laminated sheet (2) is used as a material for the shaping sheet.
It is composed of a base sheet (21) and a synthetic resin layer (22).

The base sheet (21) serves as a support for the synthetic resin layer (22) and prevents the synthetic resin layer (22) from breaking or expanding and contracting. As the base sheet (21), the heat during the formation of the synthetic resin layer (22), or the heat and pressure when the unevenness is formed by overlapping the embossed film (1), and the unevenness is formed on the decorative material by overlapping with the decorative material. Tears by the heat pressure at the time,
It is required not to melt or substantially expand and contract. As such a base sheet (21),
Paper, polyester film, or a laminated sheet thereof can be used.

The synthetic resin layer (22) reproduces the unevenness (1a) of the surface of the embossed film (1) in a softened state to impart the unevenness to the surface of the decorative material, and receives the colored ink layer (12) from the embossed film (1). Transfer to the surface of the decorative material. For this reason, the synthetic resin layer (22) can be easily peeled off from the thermoplastic resin film (11) or the surface of the decorative material, and can be softened when superimposed on the embossed film (1) to accurately reproduce irregularities. It is necessary to maintain the shape during material production. For example, polyethylene resin, polypropylene resin, ethylene-vinyl acetate copolymer resin, polymethylpentene resin and the like can be used.

The synthetic resin layer (22) can be formed on the base sheet (21) by any method. However, a method of extruding a synthetic resin in a molten state from an extrusion die and laminating the synthetic resin on the base sheet (21) (an extrusion laminating method) Is preferred. Subsequently, the embossed film (1) is laminated to form a synthetic resin layer (22) and to form irregularities on the surface thereof, and to form a colored ink layer (12).
Is possible in a series of steps. The synthetic resin is extruded from the die at a temperature of 150-330 ° C. depending on its material. The thickness may be 5 to 300 μm depending on the depth of the unevenness.

The shaping sheet The shaping sheet (3) is for imparting irregularities to the surface of the decorative material and transferring the coloring ink (12).

The shaping sheet (3) is formed by laminating an embossed film (1) on the above-mentioned synthetic resin layer (22) in a state where the synthetic resin layer (22) is heated and softened, and pressurizing the embossed film (1a) to form the surface of the synthetic resin layer (22). The colored ink layer (12) and the synthetic resin layer (22)
Transferred onto top. FIG. 3 is a cross-sectional view of a state where the embossed film (1) and the laminated sheet (2) are overlaid and pressed.

The synthetic resin layer (22) must be in a softened state in order to faithfully reproduce the irregularities on the surface of the embossed film (1). The synthetic resin layer (22) is softened by heating,
It need not be molten. It is sufficient to heat the synthetic resin layer (22) to 50 to 150 ° C. depending on the material and the depth of the unevenness.

Heating can be performed with a heating roll, an oven, an infrared lamp, or the like, but it is not easy to uniformly heat the synthetic resin layer (22). As described above, following the step of extruding and laminating the molten synthetic resin onto the base sheet (21), a method of superimposing the embossed film (1) on the synthetic resin layer (22) and pressing it is simple, The uniformly softened synthetic resin layer (22) can be used. The embossed film (1) may be stacked when the molten synthetic resin is cooled to a temperature of 50 to 150 ° C., and the pressure is applied between two nip rolls or between the nip roll and the cooling roll.

After the synthetic resin layer (22) is sufficiently cooled and solidified, the thermoplastic resin film (11) is peeled off to obtain a shaped sheet (3) (FIG. 4).

In addition, on the surface of the shaping sheet (3), a surface protective layer (41), a picture printing layer (42), and an adhesive layer (43) having better releasability can be provided. (FIG. 5) The surface protective layer (41), the pattern printing layer (42), and the adhesive layer (43) are transferred to the surface of the decorative material during the production of the decorative material.

Method of using the shaping sheet (3) The shaping sheet (3) is used to produce a decorative board that requires heating and pressurization, such as a melamine decorative board or diallyl phthalate decorative board, and is superimposed on the surface thereof, and the decorative sheet surface Can be used to provide irregularities and a colored ink layer on the surface.

FIG. 6 is a sectional view of a step of manufacturing a melamine decorative board.

That is, in FIG. 6, the following items are laminated in order from the top between the upper and lower hot plates (61). (62) is a heat-resistant cushion sheet. (64) is a mirror-finished plate, but the lower surface is not directly in contact with the melamine resin, and is sufficiently polished because there is a shaping sheet (3) between it and the melamine resin-impregnated paper (52). Need not be. (53) in the overlay paper, a melamine resin impregnated 40-100% rayon pulp or nonwoven fabric having a basis weight of 25 to 45 g / m ^2, a dry transparent resin impregnated paper, may be omitted in some cases. (52) is a melamine resin impregnated paper, which may be omitted in some cases. (52) is a melamine resin impregnated paper having a basis weight of 55 to 16
A pattern is printed on titanium paper of 0 g / m ² in some cases, impregnated with 40 to 100% of melamine resin, and dried. (Five
1) is a core paper, which is a paper having a basis weight of 140 to 180 g / m ² , impregnated with 30 to 60% of a phenol resin, and dried. The core paper (51) is used to determine the thickness of the melamine resin decorative board, and is generally used by stacking four to five sheets. (54) 4 melamine resin in the titanium paper is backer sheet basis weight 55~160g / m ²
It is a dry impregnated paper impregnated with 0 to 100%, and is a melamine resin impregnated paper (52) or overlay paper (5
It balances with 1) and plays the role of preventing warping of decorative panels.

A release sheet (63) prevents adhesion of the melamine resin to the lower heat-resistant cushion sheet (62).

Laminated in the state shown in Fig. 5, maximum temperature 140-150 ° C, pressure 80
100100kg / cm ² , heat and pressure molding for 15 to 30 minutes, cooling with cold water for 15 to 60 minutes while pressing (51)
(57) can be cured to obtain an integrated melamine decorative board. During curing, the unevenness is reproduced by the flowing resin.

Further, when a liquid curable resin is applied to a substrate and cured to produce a decorative board, the decorative board can be used for providing irregularities and a colored ink layer on the surface thereof. Examples of such decorative panels include polyester decorative panels. That is, a substrate obtained by laminating a supporting substrate such as a plywood and a printing paper is used as a substrate, a shaping sheet (3) is laminated on the resin surface, defoamed, and the resin is cured under a sufficient pressure. A sheet obtained by applying a liquid unsaturated polyester resin to the printing paper, stacking the shaping sheet (3), defoaming, and curing the resin may be adhered to the supporting substrate. A case where a liquid ultraviolet curable resin is used in place of the unsaturated polyester resin can be similarly used.

Further, a cosmetic material whose surface is made of a vinyl chloride resin sol can be used in the same manner. What is necessary is just to apply a vinyl chloride resin to the supporting substrate, stack the shaping sheet (3), defoam, and heat gelate.

Further, the surface of the molded product may be provided with irregularities and colored ink by heating and pressing the plastic molded product. As the plastic molded product, for example, a molded product composed of acrylonitrile-butadiene-styrene copolymer (ABS) can be used. The heating is performed to a temperature at which the surface of the molded product is softened.

(Test Example 1) Embossed film (1) Unevenness having a maximum depth of 20 µm was formed on a surface of a polyvinyl chloride film having a thickness of 120 µm by using heat and pressure using an embossed plate having an oak wood grain conduit pattern.

A vinyl acetate dark brown ink was applied to the entire surface of the uneven surface by gravure printing so as to have a thickness of 3 μ (wet), and the ink on the convex portion was scraped off with a doctor before drying the ink. Subsequently, it was air-dried to produce an embossed film (1).

The obtained embossed film (1) had a concave / convex pattern composed of a concave portion of an oak wood grain conduit pattern and a dark brown ink layer with high accuracy only in the concave portion.

Forming Sheet Polymethylpentene resin was extruded to a thickness of 20 μm on a high-quality paper having a basis weight of 60 g / m ² at an extrusion temperature of 320 ° C. When the polymethylpentene resin reached approximately 70 to 110 ° C., the embossed film (1) was pressure-bonded, pressed between a nip roll and a cooling roll, and cooled.

After cooling sufficiently, only the polyvinyl chloride film was peeled off to produce a shaped sheet.

In the polymethylpentene resin layer of the imprinting sheet, the irregularities of the shape obtained by inverting the irregularities of the embossed sheet (1) were faithfully reproduced, and the dark brown ink adhered to the projections with high accuracy.

Melamine decorative board As shown in FIG. 6, heat-resistant cushion sheet, release sheet, backer paper, four core papers,
Print the oak pattern titanium paper having a basis weight of 80 g / m ^2, impregnated paper impregnated with melamine resin, overlaid overlay paper, further shaping the sheet, the mirror plate, stacked heat cushion sheet, heating and pressing by the upper heating plate did. Heating up to 140 ° C, pressure 8
0 kg / cm ² , time is 20 minutes. Next, the mixture was cooled with cold water for 40 minutes while being pressurized, and the melamine decorative board was taken out.

The melamine decorative board is made by integrating backer paper, core paper, resin-impregnated paper, and overlay paper by curing melamine resin or phenolic resin. Moreover, only the concave portion was provided with the dark brown ink with high accuracy.

(Test Example 2) Embossed film (1) On a surface of a polyvinyl chloride film having a thickness of 70 µm, irregularities having a depth of 4 µm were formed by hot pressing using a grained embossing plate.

A chlorinated polypropylene-based gray ink was applied to the entire surface of the uneven surface by gravure printing so as to have a thickness of 2 μ (wet), and the ink on the convex portions was scraped off by a doctor before drying the ink. Subsequently, it was air-dried to produce an embossed film (1).

The obtained embossed film (1) had a gray ink layer only in the irregularities of the grain pattern and the concave portions.

Molding sheet Extruding temperature 29 on polyester film 25μ thick
At 0 ° C., a polypropylene resin was extruded and laminated to a thickness of 15 μm.

Thereafter, a shaped sheet was manufactured in the same manner as in Test Example 1. In the polypropylene resin layer of the obtained shaped sheet,
Grained irregularities were formed, and gray ink was accurately attached to the concaves.

Transfer sheet On the surface of the polypropylene resin layer of the molding sheet, a surface protective layer (entire surface) made of an acrylic resin layer having a thickness of 5 μm, a printing ink layer having a stone pattern, and a light gray ink layer are successively formed by gravure printing. A 2 μm-thick acrylic heat-sensitive adhesive layer was formed to obtain a transfer sheet.

Cosmetic material The transfer sheet was superimposed on an ABS molded product, pressed with a heating roll at 220 ° C, and then the polypropylene resin layer and the polyester film were peeled off to produce a cosmetic material.

The obtained decorative material had sand-grained irregularities together with a stone pattern on the surface of the ABS molded product, and only the concave portions were accurately colored in gray, which was very similar to natural stone.

<Effects> As described above, according to the present invention, it is possible to manufacture a cosmetic material having an excellent three-dimensional effect, having a concave-convex surface and a coloring ink applied to only these concave portions with high accuracy.

In addition, the embossed film can be reused, mass production of the imprint sheet is easy, and mass production of the decorative material can be performed at low cost.

[Brief description of the drawings]

The drawings show an embodiment of the present invention, FIG. 1 is a cross-sectional view of an embossed film, FIG. 2 is a cross-sectional view of a laminated sheet, and FIG. FIG. 4 is a cross-sectional view of a shaping sheet, FIG. 5 is a cross-sectional view of a transfer sheet, and FIG. 6 is an explanatory view of manufacturing a melamine resin decorative board. (1) Embossed film, (11) Thermoplastic resin film (12) Colored ink layer, (1a) Unevenness (2) Laminated sheet, (21) Base sheet (22) ) Synthetic resin layer (3) Molding sheet (4) Transfer sheet (41) Surface protective layer (42) Picture printing layer (43) Adhesive layer (51) Core paper, (52) Melamine resin impregnated paper (53) Overlay paper, (54) Backer paper (61) Upper and lower hot platen, (62) Heat resistant cushion sheet (63) … Release sheet, (64) …… Mirror plate

Claims (1)

(57) [Claims] 1. An embossed film (1) having irregularities on the surface and having a transferable colored ink in the concaves of the irregularities, and a laminated sheet (2) having a synthetic resin layer on a substrate sheet,
The synthetic resin layer is overlapped in a softened state, thereby forming irregularities on the synthetic resin layer and transferring a coloring ink to produce a shaping sheet. And a method for producing a decorative material, wherein a colored ink is transferred to a concave portion of the decorative material.