JP2998483B2 - 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 manufacturing a decorative plate having a surface having irregularities and a pattern, and more particularly to a method for efficiently producing a decorative plate having a design and a pattern in conformity with the irregularities.

[0002]

2. Description of the Related Art Conventionally, various decorative panels have been used for exteriors and interiors of houses and as furniture members. In recent years, products with embossed surfaces have been preferred along with the trend toward higher grades and higher designs. It has come to be. In particular, a decorative board imitating a very high-grade brick or tile as a wall material can perform much simpler and cheaper construction than actual brick and tile construction.

[0003] However, since these decorative boards are manufactured mainly for embossed decoration, the color design is currently lagging behind. In other words, most products are painted with a single-color paint on the entire surface, or simply painted with two colors using different colors at joints. The design effects obtained by these methods were limited and not very satisfactory compared to real bricks and tiles.

In the case where the transfer is not performed to the concave portions of the decorative board base material, it is possible to use a hard roll. However, the decorative board base has a large pattern of irregularities and fine irregularities in the convex portions. In the case of a material, it is difficult to completely transfer to fine irregularities, and conversely, if a soft roll is used, it can be completely transferred to fine irregularities, but it will transfer to large concaves, It is extremely difficult to select the rubber hardness of the rubber roll.

[0005]

SUMMARY OF THE INVENTION The present invention has been made to solve such a problem, and it is an object of the present invention to provide a method for forming large irregularities on the surface and fine irregularities on the convex portions. An object of the present invention is to propose a method for efficiently manufacturing a decorative board having a very high design, having a desired pattern only on a large convex portion of a decorative board base material having a shape.

[0006]

In order to solve this problem, the present invention provides a two-part curable urethane-based resin on a decorative board substrate having large irregularities on its surface and fine irregularities on its convex portions. An undercoat layer of paint is provided, and after curing, an adhesive layer of a two-component cured urethane-based paint of the same type as the undercoat layer is provided only on the protrusions of the large irregularities, and a transfer sheet is provided thereon, and a flexible sheet is provided. It is characterized in that the base sheet of the transfer sheet after transfer is peeled off by pressing with a heat roll, and the print layer of the transfer sheet is transferred only to the convex portions of the large pattern.

Hereinafter, the present invention will be described in detail with reference to the drawings. FIG. 1 shows an example of the configuration of a transfer sheet used in the present invention. The structure is such that a release layer 12 and a printed layer 13 are sequentially provided on the surface of a base sheet 11.

FIG. 2 shows a decorative plate on which an adhesive has been applied. The undercoat layer 22 is provided on the entire surface of the decorative board substrate 21, and the adhesive layer 23 is provided only on the convex portions having large irregularities.

The undercoating layer is determined by the adhesion of the adhesive layer to be used next with the adhesive and the site where the decorative board is used, for example, for interior or exterior use. In the present invention, the two-component cured urethane is used. Use a system paint. As a coating method, a known method such as an air spray or various coaters may be used.

The adhesive used for the adhesive layer is determined by the paint used for the undercoat, the adhesion to the printed layer to be transferred, and the site where the decorative board is used. After the undercoat layer is cured, an adhesive layer is formed. In order to form the adhesive layer 23, screen printing or a roll coater is used. In screen printing, only the projections of the irregularities on the plate to be decorated can be printed. When a roll coater is used, the adhesive is applied only to the convex portions of large irregularities due to its coating structure.

The adhesive used is one whose viscosity is adjusted so as to adapt to fine irregularities, and the synthetic resin binder to be used is appropriately determined as described above. In the present invention, the undercoat layer which has already been coated is used. Considering the close contact with the undercoat layer, a two-component curable urethane-based paint of the same type as the undercoat layer is used. that is,
This is because both properties of the paint and the adhesive can be obtained, which is preferable.

FIG. 3 shows an example of a transfer sheet transfer method. Decorative plate substrate 31 provided with an undercoat layer and coated with an adhesive
It is installed so as to be in contact with the printing layer side of the transfer sheet 32 shown in FIG.
Transfer the printing layer. At this time, the roll used is a soft roll that follows the fine irregularities of the decorative board substrate.
The rubber hardness is 30mm,
Silicon rubber having a thickness of 20 mm or more is preferable.

FIG. 4 shows an example of a cross section of the decorative board obtained by the present invention. The decorative board base material 41, the undercoat layer 42, the adhesive layer 43, and the print layer 44 are sequentially laminated. Furthermore, when used for a part requiring durability such as an exterior, a top coat may be appropriately applied.

As described above, according to the present invention, after the undercoat layer applied to the entire surface including the concave portion of the decorative board substrate is cured, the adhesive layer is provided on the convex portion, and then the transfer is performed. Since the undercoat layer is hardened and loses adhesiveness, it is possible to provide a desired pattern by printing only on the convex portion provided with the adhesive layer by a simple method, and a decorative board closer to a real tile or brick Alternatively, a decorative plate having a design feeling that can be expressed only by printing can be obtained. In addition, since a similar two-component curable urethane-based paint is used for the undercoat layer and the adhesive layer, a decorative plate excellent in adhesion, heat resistance, and weather resistance can be obtained.

[0015]

【Example】

<Example 1> A semi-cured vinyl chloride sheet having a thickness of 50 µm was used as a base sheet, and a release layer composed of polyvinyl butyral and a coloring pigment (alamide yellow, phthalocyanine blue, dianthraquinoni) were formed thereon by gravure printing. Drill Red) and a printing layer (brick pattern) made of polyvinyl chloride (vinyl chloride) were sequentially laminated to obtain a transfer sheet.

As a decorative board base material, a brick-like embossed one is used, and as a subbing layer, a white two-component curing urethane paint using titanium oxide as a pigment is used, and this is air-sprayed. 50 g / m ² . This was dried in an oven at 80 ° C. for 30 minutes and left at room temperature for one day.

As an adhesive layer, the same paint as that of the undercoat layer was applied only to the convex portions having large irregularities by screen printing. This was dried in an oven at 80 ° C. for 9 minutes, the transfer sheet was placed on a decorative sheet substrate with the print layer facing down, 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 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.

The obtained decorative board had an extremely high design effect in which the joints were white and the bricks had a fine pattern transferred by printing.

Example 2 50 μm thick base sheet
m, a release layer made of polyvinyl butyral and a coloring pigment (alamide yellow, phthalocyanine blue,
A printing layer (sandstone pattern) composed of dianthraquinonidyl red) and polyvinyl chloride (vinyl chloride) was sequentially laminated to obtain a transfer sheet.

As a decorative board base material, a brick-like embossed one is used, and as a undercoat layer, a white two-component curable urethane paint using titanium oxide as a pigment is used.
This was applied at 50 g / m ² using an air spray.
This was dried in an oven at 80 ° C. for 30 minutes and left at room temperature for one day.

As an adhesive layer, the same paint as that for the undercoat layer was applied only to the convex portions having large irregularities using a roll coater. This was dried in an oven at 80 ° C. for 9 minutes, the transfer sheet was placed on a decorative sheet substrate with the print layer facing down, 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 silicone mat clear top coat was applied 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.

The obtained decorative board had an extremely high design effect in which the joints were white and the bricks had a fine pattern transferred by printing.

[0025]

As described above, according to the present invention, a desired pattern harmonized with the irregularities is formed only on the large irregularities of the decorative board substrate having a large irregularity on the surface and its convexities having finer irregularities. It is possible to efficiently manufacture a decorative plate having extremely high designability. Further, these methods are suitable methods for imparting a beautiful pattern only to the convex portion of a decorative plate imitating a brick or a tile.

[0026]

[Brief description of the drawings]

FIG. 1 is an explanatory view showing an example of a cross-sectional structure of a transfer sheet used in the present invention.

FIG. 2 is an explanatory view showing a cross-sectional structure after application of an adhesive layer in one embodiment of a process of a method for manufacturing a decorative board according to the present invention.

FIG. 3 is an explanatory view showing one embodiment of transfer of a transfer sheet in a process of a method for manufacturing a decorative board according to the present invention.

FIG. 4 is an explanatory view showing an example of a cross-sectional structure of the decorative board of the present invention.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 11 ... Base sheet 12 ... Release layer 13 ... Printing layer 21 ... Decorative board base material 22 ... Undercoat layer 23 ... Adhesive layer 31 ... Decorative board base material after adhesive application 32 ... Transfer sheet
33: heat roll 41: decorative board substrate 42: undercoat layer 43: adhesive layer 4
4 ... Printed layer

Claims (3)

(57) [Claims] To 1. A decorative board substrate shape the surface has a big irregularities and fine irregularities on the convex portion, the entire surface is provided with a subbing layer of two-component curing urethane-based paint, the after curing, said a big An adhesive layer of a two-component curable urethane-based paint similar to the undercoat layer is provided only on the protrusions of the irregularities, and a transfer sheet is placed thereon, and pressed with a flexible heat roll to form a base sheet of the transfer sheet after transfer. Wherein the printed layer of the transfer sheet is transferred only to the projections of the large pattern. 2. The method for manufacturing a decorative board according to claim 1, wherein an adhesive is applied only to said large convex portion by using screen printing. 3. The method for producing a decorative board according to claim 1, wherein an adhesive is applied only to said convex portion using a roll coater.