JP3953538B2 - Manufacturing method of decorative sheet - Google Patents

Description

[0001]
[Industrial application fields]
The present invention relates to a decorative material for interior materials, furniture and cabinets.
[0002]
[Prior art]
Conventional decorative sheets used in the above-mentioned fields are provided with a printed pattern on a base sheet made of plastic sheet mainly made of vinyl chloride, paper, wood, metal or their combination, and overlaid with polyurethane resin. Many are coated.
Further, a decorative sheet in which a printed pattern is provided on a vinyl chloride sheet or the like and a transparent vinyl chloride sheet is double-embossed thereon is generally used mainly for furniture and cabinets. Recently, by using an ionizing radiation curable resin to laminate a concavo-convex transparent layer that reproduces the concavo-convex pattern of natural wood, stone, etc., on a printed pattern of the same natural material, more realistic texture and superior design feeling are reproduced. A decorative sheet is used.
[0003]
[Problems to be solved by the invention]
However, a substrate sheet provided with a printed pattern and overcoated with a polyurethane-based resin or the like is a representation of only the printed pattern, so that there is a problem that the design is poor.
Further, the decorative sheet embossed with doubling cannot express fine unevenness, and it is difficult to synchronize the uneven shape with the lower handle.
A laminated layer of a concavo-convex transparent layer that reproduces the concavo-convex pattern of natural wood or stone using an ionizing radiation curable resin is surely superior if the synchrony is perfect. However, there is a problem that it is difficult to completely synchronize due to various factors during the machining process. As a result, process loss increases and it becomes difficult to stably supply a finished sheet at an economic cost.
The present invention has been made in view of the above problems, and even if the uneven pattern and the printed pattern are not synchronized, the glossiness, that is, the multi-directional fine shine of a natural product, particularly stone, is reproduced in harmony with the printed pattern. The object of the present invention is to provide a decorative sheet with a good texture and a good design at an economical cost.
[0004]
[Means for Solving the Problems]
The present invention made to solve the above problems comprises a fine concavo-convex pattern layer, a transparent or translucent plastic film layer, a printed pattern layer, and a base sheet layer formed by curing ionizing radiation curable resins sequentially from the surface. A method for producing a laminated decorative sheet , comprising a transparent or translucent plastic film layer having a fine uneven pattern layer formed by curing an ionizing radiation curable resin on a surface, and a substrate on which a printed pattern layer is formed . In the manufacturing method of laminating a material sheet layer on its printed surface, the concavo-convex pattern is composed of a set of irregularly shaped regions separated by a closed curve, and has a line-shaped groove in the region, The gist of the manufacturing method of the decorative sheet is that the two lines adjacent to each other through any of the sides have different traveling directions.
[0005]
[Action]
According to the present invention, it is possible to reproduce excellent texture, glossiness, wood texture and the like without synchronizing the printed pattern and the uneven pattern, and to give scratch resistance to the surface.
[0006]
【Example】
Hereinafter, the present invention will be described in detail with reference to the drawings.
FIG. 1 is a schematic diagram showing a basic layer configuration of a decorative sheet 10 according to the present invention.
A pattern such as a stone pattern is printed on the surface of the substrate sheet 1 to provide a printed pattern layer 2. In addition to patterns such as stone, wood, abstract, cloth, and grain, the printed pattern that is the subject includes geometric patterns. Among these, it is desirable to enhance the synergistic effect of the concave / convex pattern 6 and the decoration described later in detail.
On the other hand, the transparent uneven | corrugated layer 5 by an ionizing radiation curable resin is formed in the surface of the transparent film 4 by the method mentioned later, and is laminated | stacked on the printing surface of the said base material sheet 1. FIG. In this case, if the base material sheet 1 and the transparent film 4 are both vinyl chloride-based, they can be laminated by thermal lamination, but if they are different materials, a urethane-based adhesive layer 3 is provided for dry lamination. Laminate.
[0007]
In general, a thermoplastic plastic sheet such as vinyl chloride is suitably used for the base sheet 1, but may be a wood-based, metal-based, paper-based, or glass-based sheet depending on the use of the decorative sheet.
[0008]
The printing pattern layer 2 is composed of a printing ink layer, and is a printing ink in which known pigments, colorants such as dyes, extender pigments, solvents, stabilizers, plasticizers, catalysts, curing agents, and the like are appropriately mixed in the vehicle as necessary. Can be formed by printing. As the vehicle, those appropriately selected from thermoplastic resins, thermosetting resins, ionizing radiation curable resins and the like according to necessary physical properties, printability and the like can be used. As the pigment, a commonly used organic or inorganic pigment can be used. As a diluent solvent, a liquid solvent having the ability to dissolve and disperse vehicle colorants, colorants such as pigments, and other additives, and has an appropriate drying property is generally used. However, the solubility parameter is generally similar to that of the vehicle. A liquid solvent is preferably selected from the viewpoint of solubility.
A printing pattern can be provided on the base material sheet 1 using well-known printing methods, such as gravure printing and silk screen printing.
[0009]
Moreover, the transparent film 4 may be translucent or colored.
The thickness of the transparent film is polyethylene terephthalate, polyethylene naphthalate, polyarylate, polyetheretherketone, polyimide, etc. in the range of 12-200 μm, with sufficient sheet strength, dimensional stability, heat resistance, ionizing radiation transparency Some can be selected and used as appropriate.
[0010]
FIG. 2 is an explanatory view of the thermal lamination lamination method of the decorative sheet 10.
The back surface of the transparent film 2 formed with the uneven layer 5 on the surface and the printed surface of the base sheet 1 are overlapped, and sandwiched between the upper and lower hot plates 9 via the mirror plate 7 and the cushion material 8 and subjected to thermocompression bonding. Laminate.
[0011]
A method for forming the fine uneven pattern 6 on the surface of the transparent film 4 is performed by a drum printing system (hereinafter referred to as DPS) applying a roll intaglio printing system. The DPS will be described below with reference to FIG. 3 which is a conceptual diagram of the DPS.
As shown in FIG. 3, ionizing radiation curable resin liquid 5 ′ is applied to the plate surface of roll intaglio 11 on which concave portions 12 are formed by etching so as to form desired uneven pattern 6 on a roll coater. The applicator roll 13 is applied so that at least the recess 12 is filled. The recess 12 actually has a complicated cross-sectional shape as shown in FIGS. 1 and 2, but is conceptually shown as a simple triangle. Next, while supplying the transparent film 4 to the coated ionizing radiation curable resin liquid 5 ′ at a traveling speed synchronized with the peripheral speed of the roll intaglio 11, the transparent film 4 is ionized radiation curable by the pressing roll 14. The surface of the roll intaglio 11 is brought into contact with the concave surface of the roll intaglio 11 through the resin liquid 5 ′, and the ionizing radiation curable resin liquid 5 ′ is ionized from the back surface of the transparent film 4 with the transparent film 4 being held between the roll intaglio 11. After the ionizing radiation curable resin liquid 5 ′ is cured by irradiating with ionizing radiation by the radiation irradiation device 15, the roll intaglio 11 is transferred in a state where the ionizing radiation curable resin 5 cured by the feed roll 16 is transferred to the transparent film 4. Release from the mold.
According to the DPS described above, the fine and sharp recess 12 formed on the roll intaglio 11 can be faithfully reproduced on the film substrate.
[0012]
A T-shaped nozzle coating apparatus may be used instead of the roll coater.
Further, in order to prevent air bubbles from being mixed into the ionizing radiation curable resin liquid 5 ′ and to faithfully reproduce the concave and convex shape of the concave portion 12, it is desirable that the coating is on the roll intaglio 11 side. The uneven pattern 6 can also be provided by applying the ionizing radiation curable resin liquid 5 ′ to the side and then pressing the coating surface of the resin liquid 5 ′ on the roll intaglio 11.
[0013]
Further, when the ionizing radiation curable resin liquid 5 ′ is applied to the roll intaglio 11, a solvent diluted ionizing radiation curable resin can be used in order to control the fluidity of the resin liquid 5 ′ to some extent. In this case, it is necessary to dry the solvent in the resin liquid 5 ′ before irradiating the ionizing radiation from the ionizing radiation irradiation device 15 by using a drying device such as hot air or an infrared heater (not shown). However, when such a solvent-diluted resin is used, the range of resins that can be used is widened, and in addition, the coating property can be easily adjusted.
[0014]
The ionizing radiation curable resin 5 released from the roll intaglio 11 and cured is the concavo-convex layer 5 itself and forms the concavo-convex pattern 6, but is installed separately from the ionizing radiation irradiating device 15 in order to sufficiently cure this. Further, ionizing radiation may be further irradiated from an ionizing radiation irradiation apparatus (not shown).
[0015]
The roll intaglio 11 is made of a metal such as chrome-plated copper or iron, ceramics such as glass, quartz or PLZT, or a synthetic resin such as silicon resin, and is used for photo-corrosion, electroforming, milling, etc. The concave portion 12 can be engraved by a known method. In order to prevent thermal damage of the transparent film 2 and the ionizing radiation curable resin liquid 5 'to be applied during ionizing radiation irradiation, or to adjust the viscosity, the inside of the roll intaglio 11 is a hollow or double wall, It is preferable to adjust the temperature of the plate surface of the roll intaglio 11 by supplying cold water or hot water, cold air or hot air to the inside.
[0016]
In general, the irradiation of ionizing radiation is performed from the back side of the transparent film 2 as shown in the figure, but the roll intaglio 11 is formed of an ionizing radiation transmissive material such as quartz or glass, and the inner side of the intaglio 6 (specifically, Can be irradiated by an irradiation device installed in the roll hollow), or may be irradiated from both sides of the back side of the transparent film and the inside of the roll intaglio 11.
[0017]
The ionizing radiation curable resin used in the present invention is a resin that undergoes a cross-linking polymerization reaction upon irradiation with ionizing radiation and becomes a polymer to be solidified (cured). For example, one or more acryloyl groups, It is preferable to use a polymer having a polymerizable group such as an acryloyl group, an acryloyloxy group, a methacryloyloxy group or a thiol group, a prepolymer, or a monomer alone or a mixture thereof as a main component.
[0018]
Examples of the polymer include acrylates such as polymethyl acrylate and polystearyl acrylate, and methacrylates such as polymethyl methacrylate and polystearyl methacrylate. Examples of the prepolymer include acrylates such as urethane acrylate, polyester acrylate, and epoxy acrylate, methacrylates such as urethane methacrylate, polyester methacrylate, and epoxy methacrylate, and unsaturated polyester. Furthermore, examples of monomers include acrylates such as 2-phenoxyethyl acrylate, tripropylene glycol diacrylate, trimethylolpropane triacrylate, dipentaerythritol hexaacrylate, 2-phenoxyethyl methacrylate, tripropylene glycol dimethacrylate. And methacrylates such as acrylate, trimethylolpropane trimethacrylate, and dipentaerythritol hexamethacrylate.
[0019]
In the present invention, ionizing radiation means an electromagnetic wave or charged particle beam having an energy quantum capable of polymerizing or cross-linking molecules, such as an electromagnetic wave such as visible light, ultraviolet light, and X-rays, or an electron. There are particle beams such as rays, but usually ultraviolet rays or electron beams are used, and when ionizing radiation curable resins as described above are cured with visible light or ultraviolet rays, acetophenones, benzophenones, A photoreaction initiator such as thioxanthone is added in advance.
[0020]
The ionizing radiation irradiation device used to cure the ionizing radiation curable resin should use a light source such as an ultra high pressure mercury lamp, a high pressure mercury lamp, a low pressure mercury lamp, a carbon arc, a black light lamp, or a metal halide lamp when irradiating ultraviolet rays. Can do. When irradiating with an electron beam, various electron beam accelerators such as a Cockloft Walton type, a bandegraph type, a resonant transformer type, an insulated core transformer type, a linear type, a dynamitron type, and a high frequency type are used. In addition, when irradiating an electron beam, it is preferable to irradiate the electron with energy of 100-1000 keV normally, Preferably it is 100-300 keV with the irradiation amount of about 0.1-30 Mrad.
[0021]
The concavo-convex pattern 6 formed on the decorative sheet 10 of the present invention faithfully reproduces the concavo-convex pattern engraved on the roll intaglio 11 (indicated by the concave portion 12). Is possible.
Among the above-mentioned various uneven patterns, the most effective uneven pattern 6 for the decorative sheet 10 according to the present invention is a line-shaped groove in an irregularly shaped region 18 defined by a closed curve 17 as shown in FIG. And a plurality of lines adjacent to each other through any side are connected to each other so that the traveling directions are always different. In FIG. 4A, there are gaps between the regions, and in FIG. 4B, they are adjacent to each other without a gap. In any case, the lines in each region form parallel grooves, but may be curved.
[0022]
When such a concavo-convex pattern 6 is provided on a specific printed pattern such as a granite pattern, terrazzo, etc., the adjacent irregularly shaped regions 18 exhibit different glossiness, and the glossiness of each section changes depending on the parallax. The design can be created so that it can match the granite pattern of the lower pattern well and reproduce the natural granite pattern and texture very close to terrazzo.
What should be noted here is that since the uneven pattern 6 as shown in FIG. 4 is used, there is no need for tuning as in the case of a combination of a normal grain pattern and a conduit embossed plate. According to the decorative sheet according to the present invention, the texture of the natural stone material can be realistically reproduced without synchronization, so that the defective product due to the poor synchronization is eliminated and the yield as the decorative sheet is greatly improved.
Such a matching effect may be a combination of a wood grain pattern and a grainy uneven pattern in addition to stone, and in this case, the texture of natural wood is reproduced. Further, even if the uneven pattern shown in FIG. 4 is combined with an appropriate abstract pattern, a decorative sheet whose gloss changes depending on the viewing angle can be obtained.
[0023]
Example 1
Transparent thermoplastic vinyl chloride sheet W-500, 0.08mm, 23 parts (manufactured by Riken Vinyl Industry Co., Ltd.) with DPS on urethane acrylate ionizing radiation curable resin P-EX-36 (Daiichi Seika Co., Ltd.) )) Was used to form the concavo-convex pattern shown in FIG. The average size of the irregularly deformed region of this uneven pattern was 20 μm, and the number of lines in each region was 120 / inch. Moreover, the average depth of the grooves of the line was 20 μm.
Note that an ozone high-pressure mercury lamp (manufactured by Nippon Batteries Co., Ltd.) 160 W / 2 lamp was used for the radiation of the DPS ionizing radiation.
On the other hand, a gravure pattern is printed on a thermoplastic vinyl chloride sheet VS, 0.1 mm, 23 parts (manufactured by Riken Vinyl Industry Co., Ltd.). Thermal lamination was performed at 140 ° C. and a press pressure of 10 kg / cm ² for 30 minutes so as to be the outermost layer. In addition, it took 50 minutes when temperature increase from room temperature and temperature decrease time were added.
If this example is used, not only laminating by the press described above, but also 150 ° C., line speed 6 m / min. Doubling is also a process.
The decorative sheet obtained in this way reflected external light in many polygons, and thus a glossy and textured texture of a natural granite pattern was reproduced well, and a decorative sheet having excellent scratch resistance was obtained.
[0024]
【The invention's effect】
According to the present invention, the texture, luster and natural wood texture of natural stone materials are reproduced very well, and the surface of the decorative sheet has an uneven layer of ionizing radiation curable resin. Therefore, it can have excellent scratch resistance.
Furthermore, since it is not necessary to synchronize the concave / convex pattern with the printed pattern, productivity is improved, the production loss rate can be lowered, and supply can be performed at an economic cost.
[Brief description of the drawings]
[Fig. 1] Basic layer configuration diagram [Fig. 2] Explanatory diagram of thermal lamination method [Fig. 3] Conceptual diagram of DPS [Fig.
DESCRIPTION OF SYMBOLS 1 Substrate sheet 2 Print pattern layer 3 Adhesive layer 4 Transparent film 5 Concavity and convexity layer, cured ionizing radiation curable resin layer 5 'Uncured ionizing radiation curable sap 6 Concavity and convexity pattern 7 Mirror surface plate 8 Cushion material 9 Hot press plate DESCRIPTION OF SYMBOLS 10 Decorative sheet 11 according to the present invention Roll intaglio 12 Recess 13 Applicator roll 14 Press roll 15 Ionizing radiation radiating device 16 Feed roll 17 Closed curve 18 Compartment area

Claims (1)

A method for producing a decorative sheet in which a fine concavo-convex pattern layer, a transparent or translucent plastic film layer, a printed pattern layer, and a base sheet layer are formed by curing an ionizing radiation curable resin sequentially from the surface, ,
A transparent or translucent plastic film layer having a fine uneven pattern layer formed by curing an ionizing radiation curable resin on the surface and a substrate sheet layer having a printed pattern layer are laminated on the printed surface . In the method for manufacturing a decorative sheet ,
The concavo-convex pattern is composed of a set of irregularly shaped regions partitioned by a closed curve, and has a line-shaped groove in the region, and two regions adjacent to each other through any side of the region A method for producing a decorative sheet, wherein the traveling directions are different.

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