JP3155100B2 - 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 high glitter and rich texture.

[0002]

2. Description of the Related Art Conventionally, as a method of forming an uneven pattern on a polyester decorative board, as disclosed in Japanese Patent Application Laid-Open No. Hei 3-97555, an uneven resin layer is formed using an embossed film. As the shaping film, a film having no oxygen permeability is used alone, or a film obtained by combining a film having no oxygen permeability and a film having oxygen permeability is used. For example, as shown in FIG. 5, an unsaturated polyester resin layer 42 containing a brilliant pigment is laminated on a base material 41, and is used for forming a concavo-convex pattern formed of a composite material of a film having no oxygen permeability and a film having an oxygen permeability. Is applied to the metal frame 44 and pressurized from above the resin layer 42 to transfer irregularities to the surface of the resin layer 42.

[0003]

Incidentally, the above-mentioned concavo-convex molding film including the above-mentioned conventional film having no oxygen permeability does not swell, the gas of styrene monomer is hardly permeated, and the resin layer does not move in the direction of the film or mold. There is no internal pressure in the flow or direction, and no force is applied to the brilliant pigment against the film or mold. Therefore, random orientation as shown in FIG. The incident light 51 is irregularly reflected, and when viewed from the surface of the uneven resin layer, a brilliant portion is present as being uneven, and the brilliancy is extremely impaired. The present invention has an uneven pattern faithful to the original,
Moreover, it is an object of the present invention to provide a method for producing a decorative plate having high glitter and deeperness without unevenness in glitter.

[0004]

According to the present invention, an unsaturated polyester resin layer containing a brilliant pigment is laminated on a substrate, and the unsaturated polyester resin layer is provided with a gas permeability for forming irregularities.
Pressurizing using a large silicone rubber die, a method for manufacturing a decorative plate, characterized in that the glittering pigment particles and the uneven polyester resin layer is oriented in parallel along the uneven surface of the unsaturated polyester resin layer , Further, there is provided a method for manufacturing a decorative board, further comprising laminating a mirror surface layer on the uneven resin layer.

[0005]

The decorative plate of the present invention is obtained by pressing an unsaturated polyester resin layer containing a brilliant pigment with a silicone rubber stamping die having an extremely large oxygen permeability, which is formed with irregularities, and the brilliant pigment particles are formed on the resin layer. The particles are oriented in parallel along the plane, the light incident on each pigment particle is regularly reflected in a certain direction, and the uneven polyester resin layer has no glitter unevenness and has high glitter. Further, if a mirror surface layer is laminated on the uneven polyester resin layer, a mirror surface decorative plate having a more three-dimensional appearance can be obtained.

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described with reference to the drawings. In FIG. 1, paper 3 such as thin paper, titanium paper or the like is placed on a base material 1 such as MDF, plywood, particle board or the like via an adhesive layer 2.
To form an unsaturated polyester resin layer 4 mixed with a brilliant pigment on the surface of the paper 3. As brilliant pigments,
Natural fish scale foil, basic lead carbonate, lead acid arsenate, bismuth oxychloride, inorganic pearl pigments whose surface is coated with high refractive index metal oxides such as titanium oxide and iron oxide, gold powder,
There are metal powders such as silver powder, aluminum powder, brass powder, and copper powder, and glitters obtained by finely cutting a metal-deposited plastic film, all of which have a flat flake shape. In the case of using a pigment in which the surface of natural mica is coated with titanium dioxide (TiO ₂ ), the mica titanium particles have a thickness of about 1 μm and a size of 40 to 60 μm, and each of the glitter pigments has a size of 40 to 60 μm. Light is reflected multiple times on the surface of titanium dioxide and the interface between titanium dioxide and mica, and each particle is transparent or translucent, and multiple reflections occur between pigments, resulting in a soft, deep pearlescent luster. Emits.
Next, a metal frame 5 is placed on the unsaturated polyester resin layer 4.
The silicone rubber stamping die 6 for forming the concavo-convex shape, which is stuck on the surface, is placed thereon, and the resin is uniformly spread while pressing with a rubber roll as in the related art. Oxygen permeability of this silicone rubber and PET and other films used in the conventional film method (unit:
(cc / m ² / mil / 24 hr / atm) is as follows. Silicone rubber sheet 1,650,000 PET 100 Cellophane 70 Vinylon 1,500 Low density polyethylene 7,700 Polypropylene 3,800 Thus, silicone rubber has a rubber-like elastic structure and a siloxane bond (Si-O-Si) Have a large intermolecular distance and a very large gas permeability. Therefore, while the unsaturated polyester resin layer 4 is pressed through the silicone rubber mold 6, a part of the resin is absorbed by the mold 6, and the gas of the styrene monomer mixed in the unsaturated polyester resin is slightly discharged from the mold 6. However, the resin layer 4 penetrates to the outside, and a micro-flow direction is generated in the resin layer 4 from the base material 1 toward the die 6 or an internal pressure is applied to the direction, so that the resin The brilliant pigment is pressed against the mold 6, and as shown in FIG. 2, the pigment particles 51 are oriented in parallel along the surface of the mold 6, and the regular reflection of incident light in a certain direction as described above. Is carried out to obtain a decorative plate having a high glitter. Although the silicone rubber stamp 6 swells with a styrene monomer, it has rubber-like elasticity, and when it is pasted on the metal frame 5 with strong tension in advance, even if it swells, no sagging occurs and the decorative board obtained There is no problem.

The unsaturated polyester resin is roughly classified into a wax type and an air-curable non-wax type. Both types can be used. However, since silicone rubber has a large oxygen permeability, the wax type resin has a solid surface. May remain, in which case an air-curable non-wax unsaturated polyester resin is desirable. In the case of manufacturing by curing at room temperature, an air-curable non-wax unsaturated polyester resin is used.

As described above, a decorative plate having a high glitter can be obtained, but the glitter can be further enhanced by performing the following surface treatment on the surface of the decorative plate. That is, as shown in FIG. 3, for example, a clear paint is formed on the uneven resin layer 4 of the decorative plate by spray coating or dry coating with a rubber roll coater or a sponge roll coater to form a clear paint layer 7 of 5 to 100 g / m ² . . In this case, the uneven shape is almost left on the surface. The clear paint layer 7 increases the regular reflection efficiency of the bright layer on the uneven surface, and further increases the light brightness. In addition, a clear mirror layer of a clear synthetic resin is laminated in place of the clear paint layer 7 so that the clear paint layer 7 is formed.
In the same manner as described above, the light brightness can be increased, and the three-dimensional effect can be further enhanced. For example, when an unsaturated polyester resin is applied by the conventional film method, the number of steps is extremely small compared with other application methods (spray method, roll coating method, flow coating method, etc.), and smoothness and gloss are excellent. A mirror surface layer is obtained. When an epoxy resin is used as the resin for the mirror surface layer, a mirror surface layer having excellent smoothness can be obtained.

When the thickness of the mirror surface layer is large, the three-dimensional appearance is increased and a decorative board with a rich texture can be obtained.
It is preferably about 00 μm. However, in the film method, a considerably thick mirror layer can be formed by one coating, but if the thickness of one coating is 500 μm or more, it is difficult to sufficiently remove bubbles in the resin. Therefore, it is desirable to form the mirror surface layer by a two or three degree film method. For example,
As shown in FIG. 4, a base mirror surface layer 8 is first formed on the uneven polyester resin layer 4. A finishing mirror surface layer 9 is formed on the base mirror surface layer 8. Before forming the finishing mirror surface layer 9, irregularities appearing on the surface of the base mirror surface layer 8 due to volume shrinkage are removed and smoothed. In order to improve the adhesion of 9, the surface of the base mirror layer 8 is polished with a polishing sheet such as # 400. After that, the finish mirror surface layer 9 is formed,
A hard coat paint can be applied on the finish mirror surface layer 9 by a spray method, a roll coat method, or the like, and can be UV-cured.

Further, concrete examples of the material of the present invention are as follows. 1. Decorative board A. Transparent resin decorative board Base material: MDF, 3 to 20 mm thick Decorative paper: Titanium paper (60 g / m ² or 80 g / m ² ) or thin paper (23 g / m ² ) Polyester resin layer: Unsaturated polyester resin GOSELAC 500B (Nihon Gosei) Chemical) 100 parts Curing accelerator Cobalt naphthenate 0.5 part Bright pigment Iriodin 100 (Merck) 0.2-5 parts Catalyst Permec N (Nippon Oil & Fat) 1.5 parts B. Colored resin decorative board Base material: Plywood, 2.5 to 20 mm thick Decorative paper: Same as A Polyester resin layer: Unsaturated polyester resin Gothrac 770 (Nippon Synthetic Chemical) 100 parts Curing accelerator Same as A 0.5 part Color pigment PCN toner (Tokyo Ink) 1-10 parts Bright pigment Super White (R) 5-20 parts Catalyst Permec H (Nippon Oil & Fats) 1 part 2. 2. Stamping die for forming irregularities (silicone rubber type) For curing at room temperature KE10RTV, KE1300TRTV (Shin-Etsu Chemical) For heat curing KE931-U, KE951-U (Shin-Etsu Chemical) Clear paint layer Acrylic polyol Polyurex # 548 Clear A solution (Washin Chemical) 4 parts Isocyanate polyurex # 548B solution (Washin Chemical) 1 part 4. Base mirror surface layer Unsaturated polyester resin Gothrac 500B (Nippon Gohsei) 100 parts Curing accelerator 6% cobalt naphthenate 0.5 part Catalyst Permec N (Nippon Yushi) 1.5 parts Coating amount 500 g / m ² 5. Finish mirror surface layer A. Unsaturated polyester resin Gothrac 500B (Nippon Gohsei) 100 parts Curing accelerator 6% cobalt naphthenate 0.5 part Ultraviolet absorber Sandouwa 3212 (Sand) 2 parts Catalyst Permec N (Nippon Yushi) 1.5 parts Coating amount 410 g / m ² Surface hardness Pencil hardness 2H B. Unsaturated polyester resin GOHSELAC 7161 (Nippon Gohsei) 100 parts Curing accelerator Same as A 0.5 part UV absorber Same as A 2 parts Catalyst same as A 1.5 parts Coating amount 410 g / m ² Surface hardness Pencil hardness 4H C.I. Unsaturated polyester resin Diovar CN-740 (Dainippon Ink and Chemicals) 50 parts Gothrac 510A (Nippon Synthetic Chemical) 50 parts Curing accelerator Same as A 0.5 part Ultraviolet absorber Same as A 2 parts Same as catalyst A 1.5 Part Coating amount 410 g / m ² Surface hardness Pencil hardness 3H Hard coat paint applied to finish mirror surface layer A UV acrylic resin 59-W-2804 Swift gloss clear, NY
(Union Paint Co.) Coating amount 30-100 g / m ² (dry coating) Surface hardness Pencil hardness 3H

[0011]

As described above, according to the present invention, since the silicone rubber stamp can form a desired original with extremely high fidelity, the surface of the uneven resin layer is also very realistic and faithful to the original. The glitter pigment particles contained in the uneven resin layer are oriented in parallel along the resin layer surface, and the light incident on each pigment particle is regularly reflected in a certain direction, It is possible to obtain a decorative plate having a uniform appearance and a high glitter, and by further stacking a mirror surface layer, it is possible to obtain a decorative plate having a three-dimensional appearance and a mirror surface.

[Brief description of the drawings]

FIG. 1 is a sectional view illustrating a manufacturing method according to an embodiment of the present invention.

FIG. 2 is an enlarged view of an orientation state of glitter pigment particles in the uneven resin layer of FIG.

FIG. 3 is a cross-sectional view when a decorative plate is subjected to surface treatment by the manufacturing method of FIG. 1;

FIG. 4 is a cross-sectional view when the decorative board is subjected to a surface treatment by the manufacturing method of FIG. 1;

FIG. 5 is an explanatory view of a manufacturing method showing an example of a conventional method.

FIG. 6 is an enlarged view of an orientation state of glitter pigment particles in the uneven resin layer of FIG. 5;

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Base material 2 Adhesive layer 3 Paper 4 Unsaturated polyester resin layer 5 Metal frame 6 Silicone rubber stamping 7 Clear paint layer 8 Base mirror surface layer 9 Finish mirror surface layer 41 Base material 42 Unsaturated polyester resin layer 43 Composite molding film 44 Metal Frame 51 Bright pigment particles

Continuation of the front page (56) References JP-A-3-79555 (JP, A) JP-B1-114827 (JP, B2) JP-B1-39350 (JP, B2) JP-B4-30348 (JP) , B2) (58) Field surveyed (Int. Cl. ⁷ , DB name) B32B 1/00-35/00

Claims (2)

(57) [Claims] 1. An unsaturated polyester resin layer containing a brilliant pigment is laminated on a base material, and the unsaturated polyester resin layer is pressurized using a silicone rubber stamping die having a large gas permeability for forming irregularities. Brilliant pigment particles with unsaturated polyester
A method for manufacturing a decorative board, comprising a textured resin layer oriented in parallel along a textured surface of a tellurium layer. 2. The method for manufacturing a decorative board according to claim 1, wherein a mirror surface layer is further laminated on the uneven resin layer.