JP3237911B2 - Polyester decorative panel having shine of natural wood and method for producing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative panel made of natural wood having a three-dimensional appearance and high design quality and a method of manufacturing the same.

[0002]

2. Description of the Related Art Decorative polyester veneers having a design property are:
For example, it is obtained by transferring a picture at the time of molding, and it is also possible to provide irregularities with a shaping film. However, in these conventional methods, since only one layer of the polyester resin layer is formed, only those having a poor three-dimensional effect are obtained.

For the purpose of solving the above-mentioned disadvantages, the present applicant has previously made a decorative board comprising a decorative board base material, a concealing paper thereon, and a polyester resin layer thereon, wherein the polyester resin layer comprises two or more layers. And at least one layer other than the uppermost layer has irregularities formed on the surface thereof.
No. 46632). The polyester decorative board disclosed in the above-mentioned application has at least one uneven surface and a printed pattern inside.
By arranging the individual resin layers, a design rich in a three-dimensional effect, in particular, unevenness and shine of the grain of a natural tree are well reproduced.

[0004] The present applicant has further researched the "shine" of natural wood in decorative boards, and since the wood fibers draw complicated curves in the wavy grain of natural wood and around the nodes, Due to the change of the position of the viewer, the brightly illuminated part and the darkly shaded part of the natural wood grain pattern change subtly, thereby expressing the characteristic illuminance of each wood, When creating a decorative material with a woodgrain pattern, it is difficult to express such a glow on a normally printed woodgrain pattern, which makes it difficult for viewers Perceives that it gives an unconscious distinction between natural wood and a decorative material with a printed grain pattern on the other hand, and based on such knowledge, based on such knowledge, fine irregularities consisting of a group of unique curve patterns Patterns and trees A decorative board or a decorative sheet that further enhances the shine of natural wood by placing a pattern in a specific relationship has already been proposed (Japanese Patent Application Laid-Open No. 4-64443, Japanese Patent Application No. 4-100009). .

[0005]

SUMMARY OF THE INVENTION The present invention is a further improvement of the prior art polyester decorative board in which the above-mentioned polyester resin layer is composed of two or more layers, which has a more three-dimensional appearance and a more natural design. An object of the present invention is to obtain a polyester decorative board faithfully reproducing a feeling of "shine" and a method for producing the same.

[0006]

In order to achieve the above-mentioned object, the present invention provides a decorative board comprising a decorative board base material, a concealing paper thereon, and a polyester resin layer thereon, wherein the polyester resin layer comprises And a fine embossed concavo-convex pattern composed of a parallel curve group of wavy curves having a width of 1 to 100 μm is formed on at least one surface other than the uppermost layer. Disclosed is a polyester decorative panel having the shine of natural wood.

The running direction of the printed grain pattern is substantially perpendicular to the running direction of the fine embossed concavo-convex pattern composed of parallel curves, and a printed pattern is formed on at least one surface of the polyester resin layer. The fact that at least one of the polyester resin layers is colored is a preferred embodiment of the present invention. The present invention also provides a wood grain print pattern on a releasable support, and embossing a fine uneven pattern consisting of a parallel curve group of wavy curves having a width of 1 to 100 μm on the pattern. The transfer molding sheet thus obtained is placed on a concealable paper impregnated with an unsaturated polyester resin adhered to a decorative sheet substrate, and the uneven surface and the resin layer come into contact with each other. And so on
The laminate is heated and pressurized, and then the releasable support is peeled off to hide the woodgrain pattern layer having a fine uneven pattern composed of a parallel curve group of wavy curves having a width of the concave portion and the convex portion of 1 to 100 μm. Also disclosed is a method for producing a shining polyester decorative board of natural wood, which comprises transferring onto a base paper, then applying an unsaturated polyester resin onto the transfer layer and integrally forming the same.

Hereinafter, the present invention will be described in more detail with reference to the accompanying drawings. 1 and 2 show the configuration of the decorative board of the present invention and the outline of the manufacturing process thereof. The decorative board base material 1 provides the required thickness and strength to the decorative board. As the base material, for example, plywood or particle board is appropriately selected and used. As the concealing paper 2 to be laminated on the base material, a pattern was printed by a known method such as gravure printing, offset printing or silk screen printing on paper called "titanium paper" mixed with an opaque pigment such as titanium oxide. Can be used. The lamination of the base material and the concealing paper is performed using the adhesive 3.

The first unsaturated polyester resin layer 4 is formed by coating an unsaturated polyester resin solution on a concealing sheet with a generally 250 μm liquid.
It is formed by applying and impregnating an amount of up to 350 g / m ² , curing and molding. A polymerization initiator and, if necessary, a polymerization accelerator and other ordinary additives can be added to the resin liquid. As the polymerization initiator, for example, peroxides such as methyl ethyl ketone peroxide, benzoyl peroxide and hydroperoxide, and radical initiators such as azobisisobutyronitrile are appropriately selected and used. Generally, the amount of the polymerization initiator to be added is 0.5 to 3% by weight. As the polymerization accelerator, for example, a cobalt compound such as cobalt naphthenate,
Metal compounds such as vanadium compounds and manganese compounds,
An amine compound such as dimethyl nitrile is preferably used at a ratio of 0.1 to 2.0% by weight based on the resin. Furthermore, in order to adjust the viscosity by crosslinking the resin,
A compound having a vinyl group such as a styrene monomer may be added in an amount occupying 10 to 40% by weight of the resin.

Further, the first unsaturated polyester resin layer 4
Contains titanium dioxide-coated mica, aluminum powder,
A glitter pigment composed of a foil piece may be added and dispersed. This is preferable because the uneven pattern 6 at the interface between the first resin layer 4 and the second resin layer 8 can be clearly seen, and at the same time, the shine unique to the wood grain can be more effectively reproduced. Further, in the polyester decorative board of the present invention, the polyester resin layer has 2
At least one layer 4 has a fine embossed uneven pattern composed of a wood grain print pattern 5 and a parallel curve group of wavy curves having a width of a concave portion and a convex portion of 1 to 100 μm, as described in detail later. 6. The grain pattern 5 and the wave-shaped curve group 6 can be particularly preferably formed by a transfer method.

For transfer, for example, a releasable support 7 (see FIGS. 1 and 2) in which a polyethylene film is adhered to a polyethylene terephthalate film with a releasable adhesive, and a wood grain pattern 5 is formed on the resin layer. After printing by a known printing method, preferably a gravure method, the printed surface has a fine embossed concavo-convex pattern 6 composed of a parallel curve group of wavy curves having a width of a concave portion and a convex portion described later of 1 to 100 μm. Use a transfer sheet. . The grain pattern 5 and the corrugated curve group 6 are shaped by, for example, embossing. As the printing ink, a nitrocellulose-based ink is preferable.

Alternatively, after shaping the waveform curve group 6 on the releasable surface side in advance, the grain pattern 5 may be printed thereon. In addition, when the second resin layer 8 is formed on the transferred layer, the first and second resin layers are generally hard to adhere to the unsaturated polyester resin layer once cured. In order to strengthen the adhesion between the unsaturated polyester resin layer and the grain pattern, it is preferable that the transfer sheet has a structure of "releasing support / adhesive resin layer / grain pattern". By doing so, the second resin layer 8 adheres to the first resin layer via the easily adhesive resin layer, so that the adhesion between both resin layers is improved. Examples of the easily adhesive resin layer include those having excellent adhesion to the unsaturated polyester resin layer, for example, vinyl chloride / vinyl acetate copolymer, acrylic, polystyrene, cellulose resin, or a mixture thereof. The thickness is about 1 μm or more so that the unsaturated polyester resin does not penetrate to the back surface.

[0013] Embossing refers to shaping the embossed plate under heat and pressure into a target material, and can be performed using various known embossing machines such as a press machine and a roll embossing machine. . In the present invention, during processing of the embossed concavo-convex pattern, for example, as shown in FIG. 3, the direction (see FIG. 3a, L ₁₎ and parallel curves of the wave-shaped curve which runs the grain of wood grain print pattern has already been made running direction may be processed as (Fig. 3b, L ₂ reference) and are substantially orthogonal, it may be processed so as to be parallel substantially as shown in FIG.

Next, the first unsaturated polyester resin layer 4
The fine embossed concavo-convex pattern 6 formed of a parallel curve group of wavy curves having a width of 1 to 100 μm, which is formed on the resin layer of the releasable support 7, that is, formed on the resin layer, will be described. The fine embossed concavo-convex pattern composed of the parallel curve group of the wavy curves serves as an element for expressing the illuminance and the movement of the shine peculiar to the above-described natural wood, and the parallel curve group of the wavy curve is shown in FIG. an example of a preferably width d ₂ of the width d ₁ and the convex portion of the concave portion is a component of unevenness is 1 to 100 [mu] m, these curves as shown in,
Is a curve unit 1 such as sine wave curve, cycloid curve, and arc
2 (FIG. 6a) and a combination of the parallel curve group 12 and the parallel straight line group 13 as appropriate (FIG. 6b), which are arranged by moving a plurality of them in parallel. Further, as shown in FIG. 6C, a set of line groups each having a parallel curve group 12 in each area surrounded by the contour line, and the shape or line direction of the contour line and the parallel curve group is set to each contour line area. It may be configured to be different every time.

The parallel curve group of the wavy curve may be a function line group. In this case, a pattern group is formed as a curve group expressed by a mathematical expression (that is, as a curve group in which function parameters of the function curve are sequentially changed) and x- Drawing can also be performed using a computer device such as a y-plotter. Using the parallel curve group of the wavy curves drawn in this manner as an original plate, an embossed plate is prepared by a usual method, for example, by corroding a copper plate using a photo-etching method.
The shape of the plate may be flat or cylindrical.

The following sinusoidal function curve can be given as an example of a preferred embodiment of a wave-like curve group that can be patterned and formed using a computer as a curve group that has been made into a mathematical expression (function). That is, assuming that the amplitude is A, the wavelength is λ, and the phase is α, two sine waves represented by formulas in which one or more of the function parameters, amplitude, wavelength, and phase, and the Y-axis intercept are different. Wavelength difference of the curve,
It is composed of (n + 1) curves shown when i of a curve represented by an equation obtained by dividing the difference between the phase difference, the period difference, and the Y coordinate difference into n equals 0, 1,..., N-1, n. Such a curve group. FIG. 7 shows an example of a diagram in which the uneven pattern embossing the curve group is viewed from above.

X _O = A _O sin (2π / λ _O ) y... X _n = A _N sin (2π y / λ _N + α) + Δx... X _i = ((A _n −A _O ) i / n + A _O ) sin ｛ ((2π / λ _N −2π / λ _O ) i / n + 2π / λ _O ) y + αi / n｝ + Δxi / n The natural wood grain pattern is more in the mind of a person than a geometric pattern such as a simple striped pattern. It is thought that the reason why the user is familiar, liked, and does not feel uncomfortable is in harmony with the rhythm of ecology such as an electrocardiographic waveform having a so-called 1 / f-type spectrum (Reference: The World of Fluctuation, Toshimitsu Musha, Kodansha Co., Ltd.).
Therefore, in order to reproduce “shine” that is familiar to the mind of the viewer and more similar to natural wood, the curve shape (period, amplitude, phase) of the concave grooves in the parallel curve group of the wavy curves and the interval between the grooves are modulated. However, it can be said that it is a very preferable mode to make the spatial frequency spectrum intensity P (f) of the curve group approximate to 1 / f or 1 / f.

[0018] The above is an example of changing the amplitude or period between the curves, the addition, amplitude modulation at an appropriate function each individual curve itself _{(x i = A i (y} i) sin (k i y + α _i )
+ Δx _i ) or frequency modulation (x _i = A _i sin (k
_{i (y) y + α i} ) + Δx i) may be parallel to arranging such a those. Further, the wavy curve is not limited to a sine wave, but may be basically any bounded (variable in a finite range) curve and a continuous curve. As such an example, bounded curve (f _i (x)
Is a curve of a function having a finite value) and has a certain period λ, that is, a curve satisfying f _i (x + λ) = f _i (x). Specifically, trigonometric functions sinx, cos
x, the first-class cylindrical function Jn (x) among the Bessel functions, the Jacobian elliptic function sn (x, k), cn (x, k), dn
(X, k), Legendre polynomial Pn (x), Chebyshev polynomial Tn (x), other curves sinx / x, Jn
(X) / x, and so on.

In this case, if the value is too large and is inconvenient in terms of plate making dimensions or gloss appearance, such an inconvenient section may be interpolated by a curve or a straight line having another appropriate value. . In addition, such a curve can be appropriately modulated by the same method as described above so as to give a feeling of fluctuation of the 1 / f spectrum, which is a preferable mode.

The transfer molding film thus produced is superimposed on the unsaturated polyester resin layer 4 impregnated on the concealing paper 2 as described above, heated and pressurized by a conventional method, and then released. The fine embossed concavo-convex pattern 6 composed of a group of parallel curves of a wood grain pattern 5 and a wavy curve is transferred to the first resin layer 4 by peeling off. Next, the second unsaturated polyester resin layer 8 is formed by applying and integrally molding an unsaturated polyester resin on the transferred wood pattern 5 and the fine embossed concavo-convex pattern 6 composed of a group of parallel curves of wavy curves. . First and second resin layers 4 and / or 8
May be colored.

When the unsaturated polyester resin is cured, the resin is generally covered with an air (oxygen) blocking film 9.
As shown in FIG. 2, when an embossed shaping film 10 is used as this film, it is possible to shape irregularities corresponding to the surface. Note that the release support 7 and air
(Oxygen) The blocking film 9 and the shaping film 10 have good oxygen gas shielding properties such as polyethylene terephthalate, ethylene-vinyl alcohol copolymer, polypropylene, and vinylon, and releasability from a cured unsaturated polyester resin. And a good synthetic resin film.

In addition, a pattern may be transferred onto the second resin layer 8, and in this case, it is preferable to use a transparent ink for printing the pattern so that the lower layer can be seen through. Further, an unsaturated polyester resin layer can be formed on the picture layer in the same manner as described above. The surface of the outermost resin layer may be smooth, but it is also possible to form appropriate irregularities.

In the above description, both the grain pattern printing and the fine embossed concavo-convex pattern composed of a parallel curve group of wavy curves having a width of 1-100 μm are formed on the releasable support 7 side. And the first unsaturated polyester resin layer 4
Although it was described that the pattern was transferred to the side, the grain print pattern was printed on the first unsaturated polyester resin layer 4 side or the second unsaturated polyester resin layer 8 side, and the releasable support 7 Only the fine embossed concavo-convex pattern may be formed.

As described above, the polyester decorative board of the present invention has a grain print pattern and a width of the concave and convex portions of 1 to 1 inside.
By forming a fine embossed concavo-convex pattern consisting of a parallel curve group of a wavy curve of 00 μm, a design rich in three-dimensional effect is reproduced. The expression of the shine and the movement of the shine of the grain of the natural tree is particularly well expressed for the viewer.

[0025]

EXAMPLES Examples of the present invention will be described, but the present invention is not limited by these examples. Example 1 Polyethylene terephthalate film having a thickness of 16 μm
(Toyobo, E-5101) with 20μ of polyethylene
m to obtain a raw film for a shaped film (A).

The raw material (A) was solid-printed (7 g / m ² ) with a nitrocellulose-based transparent ink, and then a wood grain pattern was printed with a nitrocellulose-based ink and further solid-printed with a nitrocellulose-based pearl ink. For the obtained film, the width of each curve was 30 μm from the printing surface,
They are arranged at intervals of 30 μm, using an embossing roll on which a fine uneven pattern composed of a parallel curve group pattern having a concave portion and a convex portion alternately having a width of 30 μm is formed, and the running direction of the parallel curve group (curve equation is y = f X in the case of (x)
An embossing process was performed so that the direction of movement of the grain pattern was perpendicular to the running direction of the grain pattern to obtain a transfer molding sheet.

The embossing plate used at this time has a radius of 17.
An embossed plate having a parallel curve group of curves obtained by sequentially repeating a quarter of a 0 cm circle was used. On the other hand, the base material (4m
m plywood) and titanium paper printing paper, and 1% of hardening agent Kayamake is added to unsaturated polyester resin (Rigolac, manufactured by Showa Polymer Co., Ltd.) and stirred well and applied in an amount of 500 g per 3 m × 6 m. Then, the printed surface of the above-mentioned imprinting transfer sheet was coated so as to be in contact with the resin, left at room temperature for 1 hour, and then the imprinting film was peeled off to transfer the printed pattern and the unevenness. Then, by a general polyester molding method,
Molding was performed using a mold embossed film with a conduit.

The pattern of the polyester decorative board thus obtained is as shown in FIG. 3C, which has a three-dimensional wood grain pattern, and the illuminance of the wood grain of natural wood and the sense of movement of the shine to the viewer. Was well expressed.

[0029]

Since the present invention is constructed as described above, the obtained decorative board has fine embossed irregularities in which a concave and a convex portion have a width of 1 to 100 μm and a parallel curve group of wavy curves. By arranging at least one resin layer having a pattern and a wood grain print pattern, a design rich in a three-dimensional effect, particularly the unevenness and shine of a wood grain of a natural tree is well reproduced, and is extremely useful in industry.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing a configuration of a decorative board as one embodiment according to the present invention and an example of a manufacturing process thereof.

FIG. 2 is an explanatory diagram showing an example of a configuration of a decorative board as another embodiment according to the present invention and a manufacturing process thereof.

FIG. 3 is a view showing a combination of a wood grain print pattern and a fine embossed concavo-convex pattern on the decorative board of the present invention.

FIG. 4 is a diagram showing another combination of a wood grain print pattern and a fine embossed concavo-convex pattern in the decorative board of the present invention.

FIG. 5 is a diagram showing an example of a cross section of a fine embossed concavo-convex pattern.

FIG. 6 is a view showing another example of a fine embossed concavo-convex pattern.

FIG. 7 is a view showing still another example of the fine embossed concavo-convex pattern.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Base material for decorative boards 2 Concealing paper 3 Adhesive 4 First unsaturated polyester resin layer 5 Wood grain printing pattern 6 Fine embossed uneven pattern 7 Releasable support 8 Second unsaturated polyester resin layer

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) B32B 1/00-35/00 B05D 1/00-7/26

Claims (5)

(57) [Claims] 1. A decorative board comprising a decorative board substrate, a concealing paper thereon, and a polyester resin layer thereon, wherein the polyester resin layer comprises two or more layers, and at least one surface other than the uppermost layer thereof Characterized by a wood grain printed pattern and a fine embossed uneven pattern consisting of a parallel curve group of wavy curves having a width of the concave portion and the convex portion of 1 to 100 μm, the decorative polyester plate having the shine of natural wood. . 2. The printed grain pattern is provided in a direction substantially perpendicular to a running direction of the printed grain pattern and a running direction of the fine embossed concavo-convex pattern composed of parallel curves.
A decorative polyester veneer having the shine of the natural wood according to claim 1. 3. The decorative polyester panel according to claim 1, wherein a printed pattern is formed on at least one surface of the polyester resin layer. 4. The decorative polyester panel having the shine of natural wood according to claim 1, wherein at least one of the polyester resin layers is colored. 5. A wood grain print pattern is printed on a release support,
A concave and convex pattern is formed by embossing a fine concavo-convex pattern composed of a parallel curve group of wavy curves having a width of a concave portion and a convex portion of 1 to 100 μm to form irregularities. On the concealing paper impregnated with the unsaturated polyester resin adhered to the base material, so that the uneven surface and the resin layer are in contact with each other, and then pressurize or heat-press the laminate and then release. By peeling the mold support, a woodgrain pattern layer having a fine uneven pattern consisting of a parallel curve group of wavy curves having a width of the concave portion and the convex portion of 1 to 100 μm is transferred onto the concealing paper. A method for producing a shining polyester decorative panel of natural wood, comprising applying an unsaturated polyester resin thereon and integrally forming the same.