JP2789962B2 - Manufacturing method of decorative board - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a decorative plate having a pattern on its surface, and more particularly to a method for producing a decorative plate having a large embossment on its surface, having a pattern in harmony with this, and further having a gross synchronized with them. The present invention relates to a method for efficiently producing a decorative board having a very high design property on which a coat and a mat coat are applied.

[0002]

2. Description of the Related Art Conventionally, various decorative panels have been used for exterior and interior of a house or as a furniture member. In recent years, products having embossed surfaces have been favored along with the trend toward higher quality and higher design. It has become Conventionally, in the case of a product having a flat surface, as a method of providing a pattern on the surface, for example, a method of laminating a sheet on which a pattern is printed on the surface was possible, but when there is embossing on the surface, There were only simple decoration methods such as applying a single color paint or sprinkling sand.

[0003] However, the design effects obtained by these methods are limited to some extent and are not very effective. Also, depending on the place where the decorative board is used, a top coat is often applied for the purpose of protecting the surface.However, a single top coat such as a gloss coat only for a gloss coat or a mat coat only for a mat coat Was used in most cases. When applying a high-design gloss coat or matte coat, such as that used for wallpaper, to these decorative plates, first apply one of the top coats to the entire surface, and then apply again using masking tape or the like. Such an extremely complicated operation is required.

[0004]

SUMMARY OF THE INVENTION The present invention has been made in view of such a conventional problem, and provides a decorative plate having a complicated embossed surface with a complicated unevenness to give a desired pattern synchronized therewith. Another object of the present invention is to propose a method for efficiently producing a decorative plate having a very high design property having a different top coat.

[0005]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, the present invention provides a decorative plate having a large embossed surface with large irregularities and fine irregularities in the concaves. The transfer sheet having the following is pressed by a flexible heat roll, thermally transferred, a top coat is applied to the entire surface, and then a different top coat is applied only to the convex portions of the large irregularities. The present invention provides a method, wherein a screen printing method or a roll coater is used to apply a top coat only to the convex portion of the large-sized uneven portion.

Hereinafter, the present invention will be described in detail. FIG. 1 shows the configuration of a transfer sheet used in the present invention. Base sheet 1
Has a structure in which a release layer 2, a picture layer 3, and an adhesive layer 4 are sequentially provided on the surface of the substrate.

As the substrate sheet 1, a thermoplastic resin film capable of following irregularities on the surface of the substrate by heat during molding is used. Specifically, films of vinyl chloride, polyethylene, polypropylene, nylon, polyester and the like can be used. The type and thickness of the resin may be appropriately selected depending on the degree of surface irregularities and the balance with the transfer temperature.
A vinyl chloride resin film having a thickness of 0 μm or less is most preferable.

As a method for forming the following layers on the substrate sheet, gravure printing, screen printing, offset printing, and the like can be used.

Although any varnish or the like can be used as the material of the release layer, an appropriate material is selected according to the material of the base sheet. For example, when the substrate sheet is a vinyl chloride resin film, polyvinyl butyral is suitable.

As the printing ink for the printing layer, a weather-resistant printing ink such as a pigment-based printing material can be used. The synthetic resin binder used for the printing ink is determined in consideration of elongation during heating, durability of the final product, and the like. For example, an acrylic resin, a styrene resin, an alkyd resin, polyamide, polyester, polyvinyl chloride, polyvinyl acetate, or a mixture or copolymer of these combinations can be used.

The adhesive for the adhesive layer is appropriately selected depending on the material of the substrate on which the transfer is performed. For example, when a fiber reinforced cement board is used, urethane is preferable.

FIG. 2 schematically shows the transfer method of the present invention.
The adhesive layer surface of the transfer sheet 22 shown in FIG.
Press 3 to transfer the desired picture.

The heat roll used at this time is a soft roll which follows the unevenness of the plate. Silicon rubber having a rubber hardness of 30 ° and a wall thickness of 20 mm or more is suitable, though depending on the size of the unevenness of the plate.

FIG. 3 shows a sectional structure of a decorative board according to the present invention. An emboss plate 31, an adhesive layer 32, a picture layer 33, a gloss coat 34, and a mat coat 35 to be decorated are sequentially laminated. At this time, the gloss coat and the mat coat may be reversed depending on a desired design.

As a method of forming the gloss coat 34, an air spray, a flow coater, a curtain coater or the like may be used. The synthetic resin binder used for the gloss coat is appropriately determined depending on the environment in which the product is used. For example, when high durability such as an exterior is required, fluorine or acrylic silicon may be used.

After the gross coat 34 is completely cured,
A mat coat 35 is provided. Or vice versa. To form the mat coat 35, a screen printing method or a roll coater is used. In the screen printing method, it is possible to print only the convex portions of the concave and convex portions of the plate to be decorated. When using a roll coater, due to its coating structure,
The mat coat is applied only to the convex portions of the concave and convex portions. The synthetic resin binder used for the mat coat is appropriately determined as described above, but it is preferable to use the same type of binder in consideration of the close contact with the already applied gloss coat.

[0017]

As described above, according to the present invention, it is possible to provide a desired pattern by printing on a substrate having irregularities by a simple method, and conventionally, a complicated process such as masking with a tape is required. Gloss and mat coat can also be easily formed.

[0018]

EXAMPLES Hereinafter, the present invention will be described more specifically with reference to examples of the present invention.

Example 1 A substrate sheet having a thickness of 50
A release layer composed of polyvinyl butyral, a printing ink layer composed of colored pigments (alamide yellow, phthalocyanine blue, diansuraquinonidyl red) and polyvinyl chloride on gravure semi-rigid vinyl chloride sheet using gravure printing (A checkered pattern of light and shade granite) and an adhesive layer made of urethane were sequentially laminated to obtain a transfer sheet.

With the adhesive layer of the obtained transfer sheet facing down,
The printed pattern was embossed in synchronization with a checkered pattern, placed on a fiber reinforced cement board having a large uneven pattern, and pressed from the surface with a hot roll having a surface temperature of 160 ° C. and a rubber hardness of 30 °. The pressure was 10 kg / cm and the speed was 5 m
/ Min.

After the substrate sheet was peeled off, an acrylic silicon-based gloss clear top coat was applied to the obtained surface by spraying. The coating amount was 80 g / m ² . This was dried in an oven at 120 ° C. for 15 minutes and left at room temperature for one day.

An acrylic silicon-based mat clear top coat was applied to the surface of the gloss clear top coat only by screen printing to only the convex portions having a large uneven pattern. The obtained product had an embossed shape, a pattern conforming to the embossed shape, and a gloss mat top coat, which was extremely high in design.

Example 2 50 μm thick base sheet
m on a semi-rigid vinyl chloride sheet, using gravure printing, a release layer composed of polyvinyl butyral, a printing ink layer composed of colored pigments (alamide yellow, phthalocyanine blue, diansuraquinonidyl red) and polyvinyl chloride (Stripe pattern of light and dark granite), an adhesive layer made of urethane, and each layer were sequentially laminated to obtain a transfer sheet.

With the adhesive layer of the obtained transfer sheet facing down,
The embossing is performed in advance in synchronization with the stripes of the printed pattern, and then placed on a fiber-reinforced cement board having a large uneven pattern and a finer uneven pattern in the concave portion. The surface temperature is 160 ° C. and the rubber hardness is 30 °. It was pressed with a hot roll. The pressure was 10 kg / cm, and the speed was 3 m / min.

After the substrate sheet was peeled off, an acrylic silicon-based mat clear top coat was applied to the obtained surface by spraying. The coating amount was 80 g / m ² . This was dried in an oven at 100 ° C. for 15 minutes and left at room temperature for one day.

An acrylic silicon-based gloss clear top coat was applied to only the convex portions having a large uneven pattern using a roll coater on the surface on which the mat clear top coat was applied. The obtained product had an embossed pattern, a picture synchronized with the embossed pattern, and a gloss mat top coat, and had extremely high designability.

[0027]

As described above, according to the present invention, an embossed decorative board having a beautiful gloss matte pattern can be easily prepared, compared to a decorative board having a large embossed shape on the surface and fine irregularities formed on the concave. Obtainable. Further, when a top coat is applied only to the concave portions having large irregularities, by using a screen printing method or a roll coater, complicated steps such as masking with a conventional tape are not required.

[0028]

[Brief description of the drawings]

FIG. 1 is a sectional view showing one embodiment of a transfer sheet according to the present invention.

FIG. 2 is a schematic view illustrating a transfer method according to the present invention.

FIG. 3 is a schematic view showing a decorative board according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Base sheet 2 ... Release layer 3 ... Picture layer 4 ... Adhesive layer 21 ... Emboss board 22 ... Transfer sheet 23 ... Heat roll 31 ... Emboss board 32 ... Adhesive layer 33 ... Picture layer 34 ... Gloss coat 35 ... Mat coat

──────────────────────────────────────────────────続 き Continued on the front page (58) Fields surveyed (Int. Cl. ⁶ , DB name) B32B 1/00-35/00 B44C 1/16-1/175 B29C 59/00-59/18

Claims (3)

(57) [Claims] 1. A transfer sheet having a pattern layer tuned to the embossed shape is thermally transferred to a decorative plate having a large embossed surface having large irregularities and fine irregularities in the concaves by pressing with a flexible heat roll. After applying the top coat on the entire surface,
A method for manufacturing a decorative board, characterized in that a different top coat is applied only to the convex portion of a large uneven portion. 2. The method for manufacturing a decorative board according to claim 1, wherein a screen printing method is used to apply a top coat only to the convex portions of the large irregularities. 3. The method for producing a decorative board according to claim 1, wherein a roll coater is used to apply a top coat only to the projections of the large irregularities.