JP4249836B2 - Manufacturing method of decorative board - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing a decorative board, and more particularly, to a decorative laminate manufacturing method for efficiently obtaining decorative plate having a pattern patterns a deep feeling is excellent in smoothness.
[0002]
[Prior art]
A decorative board made of an architectural board as a base material and coated on its surface or bonded with a decorative sheet is widely used as a building material for interior and exterior. As being among them recently most widely used, the decorative layer formed by coating on the substrate surface, further, there is a decorative laminate to form a top clear layer by clear coating or the like to the decorative layer (e.g. KOKOKU 4 -63037).
[0003]
[Problems to be solved by the invention]
However, although such a conventional decorative board has a certain degree of design, there is still room for improvement in that a so-called pattern pattern cannot provide a deep sense of depth.
Accordingly, an object of the present invention is to provide a production method for efficiently obtaining a decorative board having excellent smoothness and having a deep sense of depth in the pattern .
[0004]
[Means for Solving the Problems]
In order to achieve the above object, the invention according to claim 1 is based on a ceramic inorganic board provided with an uneven shape having a thickness difference of 150 μm or less from the bottom of the concave portion to the top of the convex portion, A first decorative layer in which a resin paint containing a color pigment is cured is formed on the substrate, and then a transparent ultraviolet curable resin paint is cured on the first decorative layer, and the total light transmittance is 85. % Of a first transparent layer having a thickness of 20 to 80 μm and a second decorative layer obtained by curing a resin paint on the first transparent layer, and a clear paint or a color clear paint on the second decorative layer. It is a method for producing a decorative board, characterized in that a top clear layer having a translucency with a total light transmittance of 40% or more is formed by applying and curing by a flow coater method .
The invention according to claim 2 has a total light transmittance of 85% or more and a thickness of 20 to 80 μm obtained by curing a transparent ultraviolet curable resin coating on the second decorative layer in the invention according to claim 1. After forming transparent layers and decorative layers with cured resin paints alternately and making the decorative layers into three or more layers, apply clear paint or color clear paint on the topmost decorative layer by the flow coater method. And a hardened top clear layer having a total light transmittance of 40% or more is formed .
The invention according to claim 3 is the method for manufacturing a decorative board according to claim 1 or 2, wherein at least one of the decorative layers is partially provided on the transparent layer.
Furthermore, the invention which concerns on Claim 4 is a manufacturing method of the decorative board of any one of Claims 1-3 in which the translucency of a top clear layer is 50% or more of total light transmittance. .
[0005]
DETAILED DESCRIPTION OF THE INVENTION
As the base material of the decorative board used in the production method of the present invention, ceramic-based inorganic board, specifically , fiber reinforced cement board, calcium silicate board, slag gypsum board, perlite board, gypsum board, wood chip cement board, etc. Moreover, a volcanic glassy multilayer board etc. are mentioned. To reinforce the surface of these substrates, it may be carried out to become by applying curing the impregnating sealer to the substrate surface impregnation sealer treatment. Moreover, when it is necessary to improve the smoothness of the substrate surface, a sealing process is performed. The sealing process can be performed by a conventionally known method. For example, by grinding the surface of the substrate with a polishing machine, there is dried by applying a moisture-curable sealer diluted with a thinner, an ultraviolet curable resin sealers were applied to the application surface, irradiated with ultraviolet rays Then, the sealing agent is cured and the surface is polished to complete the sealing treatment. In this case, when the difference in thickness of the base material from the bottom of the concave portion to the top of the convex portion is 150 μm or less, the surface is excellent in smoothness when the below-described top clear layer is formed, and a plurality of decorative layers and Ru more to obtain a further effect on the handle pattern I deep sense coupled with with depth by the transparent layer which arranged during this time. In addition, even if the uneven surface shape is given to the base material surface, the difference in the thickness of the base material from the bottom of the concave portion to the top of the convex portion is 150 μm or less. A so-called deep depth feeling can be given to the pattern.
[0006]
Decorative plate according to the production method of the present invention is provided with a decorative layer of a plurality of layers on said substrate, and a transparent layer the total light transmittance has 85% or more light-transmitting between each facing layer those were set only.
FIG. 1 is a cross-sectional view of a decorative board obtained by the production method of the present invention.
In FIG. 1, the decorative board 10 is provided with a first decorative layer 201 on a base material 11 of a ceramic inorganic board , on which a first transparent layer 301, a second decorative layer 202, a second transparent layer 302, The third decorative layers 203 are sequentially stacked alternately . Further, on the uppermost third decorative layer 203 , a translucent top clear layer 41 having a total light transmittance of 40% or more formed by a clear paint or a color clear paint is provided.
[0007]
The first decorative layer 201, since to the role of the base coat layer was result, the color pigment by those obtained by curing including resin coatings, hiding the appearance color that unwanted underlying substrate, the pattern design A base hue can be formed. The first transparent layer 301 provided on the first decorative layer 201 and the second transparent layer 302 provided on the second decorative layer 202 each have a total light transmittance obtained by curing a clear paint of a transparent ultraviolet curable resin. by as having 85% or more light transmittance, it is capable of giving a deep sense of depth to handle pattern consisting of the decorative layer 201, 202, 203. In the decorative board disclosed in, for example, Japanese Patent Publication No. 4-63037, which is a conventional technique, the transparent layer is provided only on the decorative board surface, and does not have a transparent layer sandwiched between the decorative layers.
[0008]
The decorative layer of the decorative board according to the production method of the present invention can be provided by applying a paint. Although it does not restrict | limit especially as a coating material, For example , an acrylic resin, an acrylic urethane type, a urethane type resin coating material etc. are mentioned. The method for applying the coating material for the decorative layer is not particularly limited, and examples thereof include a roll coater method, a flow coater method, a spray method, a screen printing method, and a transfer method, all of which are known techniques. In the case of forming a decorative layer by painting, a plurality of paint I rows may form one of the decorative layers.
The thickness of the decorative layer is usually 3 to 100 μm, although it varies depending on the type of coating material forming the decorative layer and the application method.
[0009]
In the production method of the present invention, when the transparent layer is formed, it can be provided by curing a transparent ultraviolet curable resin, which is a clear paint. As the ultraviolet curable resin, for example, it can be mentioned unsaturated polyester resins, acrylic resins and the like. A method for applying the coating material for the transparent layer is not particularly limited, and examples thereof include a known roll coater method, a flow coater method, and a spray method. The thickness of the transparent layer is usually 20 to 80 μm.
Note that the transparent layer in the present invention, but is intended to encompass a transparent or translucent layer, the total light transmittance are those with 85% or more. This total light transmittance can be measured by a conventionally known method using a haze meter or the like.
[0010]
The top clear layer 41 having translucency in the production method of the present invention serves as a protective layer for the uppermost decorative layer and imparts further design properties to the decorative board. The top clear layer 41 can be provided by applying and curing the same ultraviolet curable resin as the transparent layer. The coating method of the top clear layer 41 is a known flow coater method. The thickness of the top clear layer is usually 20 to 100 μm. However, since the uneven | corrugated shape is provided to the base-material surface, it cannot be overemphasized that the whole thickness of a top clear layer may partially exceed 100 micrometers.
In addition, by using a color clear containing a coloring pigment for the top clear layer 41, a desired color combined with the color of the lower decorative layer can be imparted to the decorative board. In this case, the coloring pigment is 0.3 to 4% by weight, preferably 0.8 to 2% by weight, based on the top clear layer 41.
The top clear layer 41 in the present invention preferably has a total light transmittance of, for example, 40% or more, and more preferably 50% or more.
[0011]
The hardness of the transparent layer and the top clear layer is preferably 2H or more as pencil hardness.
[0012]
In the decorative board 10 according to the manufacturing method of the present invention, the one shown in FIG. 1 is provided with three decorative layers, but may be three or more decorative layers. Also in this case , a transparent layer having a total light transmittance of 85% or more obtained by curing a transparent ultraviolet curable resin coating is provided between the decorative layers. Moreover, at least one layer of the decorative layer may have a pattern different from that of the other decorative layers. According to this embodiment, since the other of the handle pattern through the transparent layer is visible, so that the increase even more depth feeling to the handle design.
Apart from this, at least one layer of the decorative layer may be partially provided on the transparent layer. FIG. 2 is a cross-sectional view for explaining a mode in which the third decorative layer 203 is partially provided on the transparent layer. 2, third decorative layer 203 is not cover the entire upper surface of the second transparent layer 302 is partially provided. The first decorative layer 201 serves as a base coat layer as described above, to conceal the appearance color that undesired underlying substrate, since those forming the underlying color of the handle design, the first decorative layer not the subject of the case partially provided. By providing the decorative layer partially, the basic hue of the first decorative layer 201 as the base coat layer is emphasized, and the design of the decorative plate becomes clear.
[0013]
Next, the manufacturing method of this invention is demonstrated.
Decorative plate 10 according to the manufacturing method of the present invention, as described above, the decorative layer is made of a plurality of layers, and total light transmittance of 85% or more curing the transparent ultraviolet-curable resin coating material in each decorative layers A transparent layer is provided. Several embodiments of the method for forming each layer are described below.
(1) from the recess bottom on the base material 11 is the difference in thickness of up to protrusion top is 150μm or less of the surface, is cured by applying a resin coating material containing a coloring pigment, a first cosmetic comprising a colored pigment forming a layer 201, then cured the clear paint was coated on the first decorative layer 201, the total light transmittance is formed a first transparent layer 301 of 85% or more, further, the first transparent layer 301 above after forming the second decorative layer 202, on the second decorative layer 202 to form the top, the clear coating or a color clear coating material was applied and cured, the total light transmittance of 40% or more translucent A top clear layer 41 is formed. In this description, decorative layer forming the uppermost part is a second decorative layer 202, as shown in FIG. 1, may be provided decorative layers 3 layers or more. Adhesion between the layers may be thermal bonding or an adhesive may be used as necessary.
(2) FIG. 3 is a cross-sectional view of a decorative board for explaining a method of forming each layer in the production method of the present invention. As shown in Figure 3, first, it is cured by applying a resin coating containing a color pigment on the substrate 11, to form the first decorative layer 201. Separately from this, a resin sheet 501 composed of a first transparent layer 301 and a second decorative layer 202 having a total light transmittance of 85% or more obtained by curing a transparent ultraviolet curable resin coating is prepared. And the 1st transparent layer 301 of this resin sheet 501 is adhere | attached on the 1st decorative layer 201 on a base material . In addition, the 2nd and 3rd decorative layer can be provided by producing the several resin sheet 501 and laminating | stacking this sequentially . Finally, a clear paint or a color clear paint is applied on the decorative layer forming the uppermost portion and cured to form a top clear layer having translucency with a total light transmittance of 40% or more . This is the same as (1) above. It should be noted that the adhesive of the resin sheet and the adhesion between the layers may be performed by thermal bonding or, if necessary, an adhesive.
(3) FIG. 4 is a cross-sectional view of a decorative board for explaining another method of forming each layer in the production method of the present invention. As shown in Figure 4, first, a first decorative layer 201 by Rukoto cured by applying a resin coating containing a color pigment on the substrate 11. Separately, two or more first and second transparent layers 301 and 302 having a total light transmittance of 85% or more obtained by curing a transparent ultraviolet curable resin paint, and the same number of second and third makeups. A laminated resin sheet 502 in which the layers 202 and 203 are alternately arranged and integrated is prepared. Next , the first decorative layer 201 and the first transparent layer 301 of the laminated resin sheet 502 are bonded. Then, the decorative layer to form a top, a clear coating or a color clear coating material was applied and cured, the total light transmittance to form a top clear layer having 40% or more of light-transmitting property, the ( Same as 1) . Adhesion between the layers may be thermal bonding or an adhesive may be used as necessary.
(4) FIG. 5 is a cross-sectional view of a decorative board for explaining another method of forming each layer in the production method of the present invention. Figure 5 As shown, first, two or more layers of the decorative layer and the transparent ultraviolet-curable resin coating material total light transmittance curing the transparent one layer or more than 85% comprising a first decorative layer 201 layer and (FIG. 5, the decorative layer is a three-layer, a transparent layer is two layers.) are integrated by arranging alternately, and to prepare a laminated resin sheet 503 consisting of front and back surface with the decorative layer. Then, the first decorative layer 201 is bonded onto the base material 11. Then, the decorative layer to form a top, to form a top clear layer of clear coating or a color clear coating material by coating and curing a total light transmittance of having 40% or more of light-transmitting property, the (1 ) . Adhesion between the layers may be thermal bonding or an adhesive may be used as necessary.
[0014]
【Example】
Hereinafter, the present invention will be described in more detail with reference to examples.
Example 1
Using calcium silicate plate having a thickness of 6mm at a bulk density 1.1 as a base material, an isocyanate-based impregnating sealer to the surface of the substrate (Nippon Paint Co., Ltd., trade name E-100 sealer) be cured by applying a The impregnation sealer treatment was carried out. Next , the substrate surface is polished with a polishing machine, and a moisture curable urethane sealer diluted by 50% with a urethane thinner is applied at a rate of 90 g / m ² and dried. the bonding agent using a roll coater and coated at a rate of 90 g / m ^2, UV curing the sealer is irradiated with, further, by polishing the surface to complete the sealing treatment.
Next , an acrylic urethane resin paint (manufactured by Nippon Paint Co., Ltd.) containing a white pigment is applied at a rate of 60 g / m ² by a flow coater method, dried and cured, and then thickened. A white first decorative layer having a thickness of 30 μm was provided.
Subsequently, a transparent acrylic UV curable resin clear (manufactured by Nippon Paint Co., Ltd.) was applied on the first decorative layer at a rate of 30 g / m ² by the flow coater method, and the substrate was moved at 6 m / min. Then, the resin was cured by irradiating with ultraviolet rays at 120 W / cm to provide a first transparent layer having a thickness of 30 μm and a total light transmittance of 90.6%.
Next, an acrylic ultraviolet curable resin paint (manufactured by Nippon Paint Co., Ltd.) is printed on the first transparent layer by a screen printing method, and ultraviolet rays are 120 W / cm while moving the substrate at 6 m / min. The second decorative layer having a thickness of 8 μm composed of a sandstone-like pattern based on dark gray was provided as a pattern by performing two steps of irradiating under conditions and curing the resin. The color tone of the paint used in the first plate and the color of the paint used in the second plate are slightly different, and the sandstone-like pattern was formed by overlapping these two plates.
Subsequently, an ultraviolet curable resin (manufactured by Nippon Paint Co., Ltd.) is applied on the second decorative layer at a rate of 45 g / m ² by the flow coater method, and ultraviolet light is 120 W while moving the substrate at 6 m / min. The resin was cured by irradiation under the conditions of / cm, and a top clear layer having a thickness of 45 μm was provided. The top clear layer is a translucent layer containing a pale yellow coloring pigment at a content of 1.5% by weight (total light transmittance is 52.1%).
Pattern pattern veneer of the present invention obtained in this way are those excellent in enhanced color depth of the conventional shadow compared with that, also, was smoothness also good.
[0015]
(Example 2)
In the decorative board manufactured in Example 1, Example 1 was repeated except that the following points were changed. Ie:
A transparent acrylic UV curable resin clear (manufactured by Nippon Paint Co., Ltd.) is applied on the second decorative layer at a rate of 30 g / m ² by the flow coater method, and the substrate is moved while moving at a rate of 6 m / min. Was cured under a condition of 120 W / cm to cure the resin, and a second transparent layer having a thickness of 30 μm and a total light transmittance of 90.6% was provided. Further, acrylic ultraviolet-curable resin coating on the second transparent layer by (Nippon Paint Co.) to a screen printing method to print a pattern of sandstone tone that tones and light gray as pattern design, 6 m substrate / Ultraviolet rays were irradiated under the condition of 120 W / cm while moving in minutes to cure the resin, and a third decorative layer having a thickness of 5 μm was provided. Further, the same top clear layer as in Example 1 was provided on the third decorative layer.
Pattern pattern thus obtained of粧板are those excellent in further enhanced color depth of shade than that of Example 1, was also smoothness also good.
[0016]
【The invention's effect】
According to the present invention, a method for efficiently obtain veneer handle design that have a deep sense of depth with excellent smoothness can be provided.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a decorative board for explaining a mode of forming a decorative layer and a transparent layer according to the present invention.
FIG. 2 is a cross-sectional view of a decorative board for explaining an embodiment in which one layer of a decorative layer is partially provided on a transparent layer.
FIG. 3 is a cross-sectional view of a decorative board for explaining a mode of forming a decorative layer and a transparent layer according to the present invention.
FIG. 4 is a cross-sectional view of a decorative board for explaining another embodiment of forming a decorative layer and a transparent layer according to the present invention.
FIG. 5 is a cross-sectional view of a decorative board for explaining another embodiment of forming a decorative layer and a transparent layer according to the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 Decorative board 11 Base material 201,202,203 Decorative layer 301,302 Transparent layer 41 Top clear layer 501 Resin sheet 502,503 Laminated resin sheet

Claims (4)

A ceramic inorganic board provided with a concave-convex shape having a thickness difference of 150 μm or less from the bottom of the concave portion to the top of the convex portion was used as a base material, and a resin paint containing a color pigment was cured on the base material. Forming a first decorative layer, and then curing a transparent UV-curable resin coating on the first decorative layer; a first transparent layer having a total light transmittance of 85% or more and a thickness of 20 to 80 μm ; A second decorative layer obtained by curing a resin coating is formed on the first transparent layer, and a clear coating or a color clear coating is applied and cured on the second decorative layer by a flow coater method, so that the total light transmittance is 40. A top clear layer having a translucency of at least% is formed. A ceramic inorganic board provided with a concave-convex shape having a thickness difference of 150 μm or less from the bottom of the concave portion to the top of the convex portion was used as a base material, and a resin paint containing a color pigment was cured on the base material. Forming a first decorative layer, and then curing a transparent UV-curable resin coating on the first decorative layer; a first transparent layer having a total light transmittance of 85% or more and a thickness of 20 to 80 μm; A second decorative layer obtained by curing a resin coating is formed on the first transparent layer, and a total light transmittance of 85% or more is obtained by curing a transparent ultraviolet curable resin coating on the second decorative layer. A transparent layer of 20 to 80 μm and a decorative layer obtained by curing a resin coating are alternately formed. After the number of the decorative layer is three or more , a clear coating or a color clear coating is applied to the topmost decorative layer. Apply and cure by the method, total light transmittance is 40% or more Method for manufacturing a decorative laminate, characterized in that to form a top clear layer having a light-transmitting property.   The method for producing a decorative board according to claim 1 or 2, wherein at least one of the decorative layers is partially provided on the transparent layer.   The manufacturing method of the decorative board of any one of Claims 1-3 whose translucency of the said top clear layer is 50% or more of total light transmittance.

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