JP4297260B2 - Cosmetic material and method for producing the same - Google Patents

Description

  The present invention is a decorative material suitably used for top plates and doors of kitchen equipment, dining tables, desks, shelves, etc., and more specifically, a thick plate shape having a top surface portion and a side surface portion and having a mirror surface on the surface. It relates to a certain cosmetic material.

  Conventionally, as this type of decorative material, for example, MDF (medium density fiberboard) is used as a base material, and a decorative sheet is attached to the surface of the base material via an adhesive. And the base material is a thick plate-like plate having a rectangular shape in plan view consisting of an upper flat top surface part and a side part surrounding the periphery, and usually the boundary part between the top surface part and the side part is from the top surface part. The chamfered or curved surface is processed over the side surface.

In this way, since the surface of the base material has a three-dimensional shape, in order to attach the decorative sheet to the base material, the decorative sheet is placed along the surface of the base material by vacuum forming, pressure forming, or vacuum / pressure forming. And sticking with an adhesive. In other words, a decorative sheet made of a thermoplastic resin with excellent three-dimensional formability, such as polyolefin and polyvinyl chloride, is used, and it is further necessary by vacuum suction from the substrate side in a state where it is softened by heating. In response to this, pressure is applied from above the decorative sheet, or pressing by a rubber film is used to follow and adhere to the base material (see, for example, Patent Documents 1 to 3). When a decorative sheet is attached to the surface of the base material by such a molding method, the decorative sheet is laminated from the top surface portion to the side surface portion, so the portion from the top surface portion to the side surface portion is stretched and three-dimensionally. By being molded, it follows the three-dimensional surface of the substrate. When applying this molding method, the material of the base material may be a porous material such as MDF for reasons such as workability into a three-dimensional shape, air permeability during vacuum forming, anchoring effect during bonding, and price. Absorbent materials are used.
Japanese Examined Patent Publication No. 56-45768 JP-A-6-42269 Japanese Patent Publication No. 60-58014

  The decorative material produced by the above molding method is obtained by directly laminating a decorative sheet on a porous or absorbent base material with an adhesive layer interposed therebetween. Therefore, there is a problem that fine skin-like or streak-like irregularities are formed on the surface of the decorative sheet after lamination, the surface specularity (flat smoothness) is lowered, and the appearance design is deteriorated. That is, usually the adhesive is often applied on a base material, but since the surface of this base material is a three-dimensional shape, when applying the adhesive, a uniform thickness such as roll coat, comma coat, etc. This is because a coating method capable of coating cannot be applied.

  When a coating method such as spray coating or brush coating adapted to a three-dimensional surface is applied, the surface of the applied adhesive becomes a streaky, fine uneven or uneven surface. In such a coating method, the coating film itself first becomes uneven, and the base material is porous or absorbent, so that the applied adhesive is non-uniform at a different speed depending on the location with respect to the base material. The surface roughness of the adhesive is further amplified.

  Moreover, in order to stack a decorative sheet on such a three-dimensional base material so as to follow the three-dimensional shape, the decorative sheet must be stacked in a heat-softened state. Therefore, the decorative sheet is molded or follows the shape of the surface irregularity of the adhesive layer, and the specularity of the surface of the laminated decorative sheet is lowered. This is somewhat inconspicuous when an uneven pattern such as embossing is present on the surface of the decorative sheet, but is very conspicuous when the surface is a mirror-like decorative sheet.

  On the other hand, a method of applying an adhesive to the surface side of the decorative sheet has also been attempted, but when the decorative sheet is laminated on the base material in a hard state at a low temperature, the decorative sheet extends from the top surface portion to the side surface portion of the base material. If the three-dimensional shape is not followed or forcedly followed, the decorative sheet will be wrinkled or broken. At first, when the decorative sheet is softened by heating and sufficient shape followability is obtained, the softened decorative sheet is deformed, the uneven surface shape of the base material is picked up, or the adhesive is applied to the base material. If the decorative sheet follows uneven penetration, the surface of the decorative sheet will be uneven and deformed.

  Moreover, in order to solve the above problems, a decorative sheet is placed on the base material via an adhesive layer, and a heat insulating sheet having a mirror-like surface and a releasable surface is placed only on the top surface portion. In addition, a molding method in which vacuum press molding is performed is proposed in Japanese Patent Laid-Open No. 5-57786. According to this method, the decorative sheet on the top surface portion can maintain the mirror surface by suppressing the heat softening of the decorative sheet by the rubber film by the interposition of the heat insulating sheet. On the other hand, the decorative sheet on the side surface portion is sufficiently softened without being suppressed by heat softening, and is formed following an uneven shape. At that time, the specularity is deteriorated, but the specular deterioration of the side surface portion is not conspicuous or not noticeable in design. However, the mirror surface is maintained by this method when the thickness of the decorative sheet is large, but when the thickness is small, the surface unevenness of the base material and the surface unevenness of the adhesive are still sufficiently raised on the surface of the decorative sheet. It cannot be suppressed. In addition to this, as a newly generated problem, there is a problem that the contour of the end portion of the heat insulating sheet is formed on the decorative sheet and the design property is lowered.

  The present invention has been made in view of such problems, and the object of the invention is a thick plate made of a porous or absorbent material and having a top surface portion and a side surface portion curved and connected thereto. Another object of the present invention is to provide a decorative material excellent in specularity and a method for producing the same, although it is a decorative material obtained by sticking a decorative sheet to a substrate.

In order to achieve the above object, the decorative material of the present invention is a decorative material obtained by attaching a decorative sheet to the surface of a thick plate-like base material made of a porous or absorbent material, It has a top surface portion and a side surface portion that is curvedly connected to the top surface portion, and has a first adhesive layer partially penetrated in the vicinity of the surface of the base material only on the top surface portion of the base material, and the first adhesion It has a mirror surface imparting sheet made of a resin sheet on the surface of the agent layer that is flat and smooth on at least the viewer side of the front and back surfaces. A decorative sheet formed by decorating a thermoplastic resin base sheet is laminated following the surface shape of the top surface and side surfaces. It is characterized by being.

  And in the decorative material of the said structure, it is preferable that the periphery of the mirror surface provision sheet | seat is reducing gradually from the top | upper surface part to the side part. Moreover, it is preferable that the 2nd adhesive bond layer is formed in the top | upper surface part and the side part from another adhesive bond layer.

And the decorative material of this invention can manufacture the thing of a preferable form by performing each next process in order.
(1) A mirror surface imparting sheet comprising a resin sheet having a flat and smooth film formed on at least the viewer side of the front and back surfaces is prepared, and a room temperature solid heat-sensitive fusion resin is applied to the surface of the mirror surface imparting sheet. A first step of laminating a second adhesive layer and a peelable protective sheet in this order, and forming a first adhesive layer on the back surface.
(2) A thick plate made of a porous or absorptive material is prepared as a base material, and a mirror surface imparting sheet is placed on the surface of the base material so that the first adhesive layer side is the base material side. And the second step of laminating.
(3) The periphery of the base material is polished or cut from the protective sheet to the side surface, and the base material is formed into a three-dimensional shape including a top surface portion formed by laminating a mirror surface imparting sheet on the surface and a side surface portion formed by exposing the base material. 3rd process to shape | mold.
(4) A fourth step of forming a second adhesive layer directly on the side surface of the substrate.
(5) The 5th process which peels a protective sheet from the surface of a mirror surface provision sheet | seat.
(6) A decorative sheet formed by decorating a thermoplastic resin base material sheet is prepared, the decorative sheet is heated and softened, and the decorative sheet is attached to the base material by vacuum suction from the base material side. A sixth step of adhering and laminating the entire surface of the mirror surface imparting sheet on the side surface portion and the base material top surface portion of the base material while following the surface shapes of the side surface portion and the top surface portion.

  The decorative material of the present invention has a decorative sheet laminated on the top surface portion of the base material via a mirror surface imparting sheet, so that the unevenness of the base material is not reflected on the surface of the decorative sheet, and the decorative sheet is attached. Since the 2nd adhesive bond layer which exists on a mirror surface provision sheet | seat is flat, it becomes the thing excellent in the mirror surface property of the top | upper surface part. And since the decorative sheet is stuck by the 2nd adhesive bond layer over the side part, the mirror surface fall in a side part does not stand out.

  FIG. 1 is a cross-sectional view schematically showing an example of a decorative material according to the present invention.

  As shown in FIG. 1, the decorative material C is obtained by attaching a decorative sheet 2 to the surface of a base material 1. The base material 1 is a thick plate made of a porous or absorbent material, and has a shape having a top surface portion and a side surface portion curved and connected thereto. And it has the 1st adhesive bond layer 3 which one part osmose | permeated the surface vicinity of the base material 1 only in the top | upper surface part in the base material 1, and the surface is flat and smooth mirror surface provision on the 1st adhesive bond layer 3 The sheet 4 is provided, and the second adhesive layer 5 is provided over the entire side surface of the base material 1 and the specular surface imparting sheet 4, and the decorative sheet 2 is placed on the second adhesive layer 5. It is laminated following the surface shape of the surface portion and the side surface portion.

  The decorative material C shown in FIG. 1 is manufactured by the following procedure. That is, after providing the first adhesive layer 3 on the back surface of the mirror surface imparting sheet 4 and laminating the mirror surface imparting sheet 4 only on the top surface portion of the substrate 1 so that the adhesive layer 3 side is the substrate 1 side, By providing the second adhesive layer 5 over the upper surface of the mirror surface imparting sheet 4 and the side surface of the substrate 1, placing the decorative sheet 2 on the second adhesive layer 5, and sticking it by vacuum forming A decorative sheet 2 is laminated on the surface of the substrate 1.

  The decorative material C produced by this procedure is such that the unevenness of the base material 1 is not reflected on the surface of the decorative sheet 2, and the second adhesive layer 5 for adhering the decorative sheet 2 is on the mirror surface imparting sheet. Since it is flat, it has excellent specularity at the top surface. However, in the vicinity of the boundary between the top surface portion and the side surface portion of the substrate 1, a step due to the presence or absence of the mirror surface imparting sheet 4 occurs. Therefore, a more preferable manufacturing method for obtaining a decorative material having no step will be described with reference to FIGS.

  First, as shown in FIG. 2, a mirror surface imparting sheet 4 having a flat and smooth surface is prepared, and the second adhesive layer 5 a made of a room temperature solid heat-sensitive fusion resin is peeled off from the surface of the mirror surface imparting sheet 4. Possible protective sheets 6 are laminated in this order, and the first adhesive layer 3 is formed on the back surface.

  Next, as shown in FIG. 3, a thick plate made of a porous or absorbent material is prepared as the substrate 1, and the mirror surface imparting sheet 4 is provided on the surface of the substrate 1 with the first adhesive layer 3. It laminates | stacks by mounting and pressing so that the side of this may become the base 1 side. Thereby, the 1st adhesive agent 3 osmose | permeates near the surface of the base material 1. FIG.

  Next, as shown in FIG. 4, the periphery of the substrate 1 is polished or cut from the protective sheet 6 to the side surface, and the top surface portion and the substrate 1 formed by laminating the substrate 1 on the surface thereof are exposed. And forming into a three-dimensional shape including the side portion. Under the present circumstances, the thickness level difference in the end surface of the mirror surface provision sheet | seat 4 is eliminated because the thickness of the peripheral part of the mirror surface provision sheet | seat 4 is gradually decreased toward the outward from a center part.

  Then, as shown in FIG. 5, after forming the 2nd adhesive bond layer 5b just on the side part of the base material 1, the protective sheet 6 is peeled from the surface of the mirror surface provision sheet | seat 4 as shown in FIG. At this time, the surplus second adhesive layer for the side surface portion attached to the upper portion together with the protective sheet 6 is also removed. Thus, in the vicinity of the boundary between the top surface portion and the side surface portion of the substrate 1, the level difference due to the presence or absence of the mirror surface imparting sheet 4 is eliminated, and both the second adhesive layers 5 a and 5 b are in a continuous state.

  And as shown in FIG. 7, the decorative sheet 2 is stuck through two continuous second adhesive layers 5a and 5b. Here, a decorative sheet 2 is prepared by decorating a thermoplastic resin substrate sheet, the decorative sheet 2 is heated and softened, and the decorative sheet is used by vacuum suction from the substrate 1 side. 2 is made to adhere and laminate over the entire surface of the mirror surface imparting sheet 4 on the side surface portion and the top surface portion of the base material 1 while following the surface shapes of the side surface portion and the top surface portion of the base material 1.

  In the decorative material thus obtained, as shown in FIG. 7, the mirror surface imparting sheet 4 has a shape in which the peripheral edge gradually decreases in thickness from the top surface portion to the side surface portion, and the second adhesion. The agent layer 5 has a top surface portion and a side surface portion formed of separate adhesive layers 5a and 5b.

  Next, each part which comprises the decorative material of this invention is demonstrated in detail.

〔Base material〕
As a base material used in the present invention, a single plate, plywood, laminated wood, fiberboard (medium density fiberboard (MDF), pine, cedar, firewood, firewood, firewood, lawan, teak, melapy, etc. Hardwood, etc.) and woody materials such as particle board. In addition, earthenware, ceramics, foam glass, or cement materials such as pulp cement, slag cement, lightweight cellular concrete (ALC), calcium silicate, gypsum, and the like can be used.

As shown in FIG. 8, the shape of the base material 1 in the decorative material of the present invention includes a top surface portion 1 a and a side surface portion 1 b surrounding the periphery thereof, and a boundary portion between the top surface portion 1 a and the side surface portion 1 b is From the surface portion 1a to the side surface portion 1b, it is chamfered or curved into a curved solid shape. About the shape of a base material, there is no limitation in particular about other things. There are the following two types of the three-dimensional shape and the timing of laminating the mirror surface imparting sheet on the base material according to the two manufacturing procedures described above.
(A) A base material is made into said solid shape previously, and a mirror surface provision sheet | seat is laminated | stacked through a 1st adhesive bond layer after an appropriate time. In this case, in addition to making the flat base material into the above-mentioned three-dimensional shape by cutting or polishing, it is possible to make the above-mentioned three-dimensional shape from the beginning when the base material is formed. For example, the above three-dimensional wood fiber board is formed by press-molding wood powder with a mold.
(B) A mirror surface imparting sheet is previously laminated on the base material via the first adhesive layer, and then the base material is made into the above three-dimensional shape by cutting or polishing. As described in the manufacturing method of FIGS. 2 to 7, this method is preferable from the viewpoint of eliminating the step at the peripheral edge of the mirror surface imparting sheet.

[Decorative sheet]
The decorative sheet used in the present invention is a base sheet that is softened by heating, has a good three-dimensional (three-dimensional) formability, and has a sufficient specularity (flat smoothness). Materials include thermoplastic resins, especially polyolefin resins such as polyethylene, polypropylene, polybutene, and olefinic thermoplastic elastomers, polyethylene terephthalate, polybutylene terephthalate, ethylene glycol-terephthalic acid-isophthalic acid copolymer, terephthalic acid-ethylene glycol. Acrylic resins such as polyester resins such as 1,4-cyclohexanedimethanol copolymer, polymethyl (meth) acrylate, methyl (meth) acrylate-butyl (meth) acrylate copolymer, methyl (meth) acrylate-styrene copolymer ((Meth) acrylate means acrylate or methacrylate), ABS (acryl-butadiene-styrene copolymer) resin, polycarbonate resin, polyvinyl chloride, poly Styrene, and the like.

  The decorative treatment applied to the resin sheet as the base sheet includes: [a] coloring by adding pigment (transparent or opaque), [b] pattern printing, [c] embossing (heating press), uneven pattern by hairline processing, etc. There are shaping. FIG. 9 shows a decorative sheet produced by performing these decoration treatments.

  A decorative sheet S shown in FIG. 9A is obtained by adding a pigment 12 to a resin sheet 11 and coloring it. Examples of pigments include titanium white, zinc white, petal, vermilion, ultramarine, cobalt blue, titanium yellow, yellow lead, carbon black and other inorganic pigments, isoindolinone, Hansa Yellow A, quinacridone, permanent red 4R, phthalocyanine blue, Organic pigments (including dyes) such as Induslenbury RS and aniline black, metal pigments such as aluminum and brass, pearlescent pigments made of foil powder such as titanium dioxide-coated mica and basic lead carbonate, etc. Can be used. These are added and dispersed as powder or scaly foil pieces. Coloring by adding a pigment can be either transparent coloring or opaque (hiding) coloring.

  The decorative sheet S shown in FIG. 9B is obtained by forming an adhesive layer 13 on a resin sheet 11 and forming a pattern layer 14 thereon by printing. The pattern is printed by a known printing method such as gravure printing, offset printing, silk screen printing, ink jet printing, transfer printing from a transfer sheet, and the pattern is formed with ink (or paint). Examples of the pattern include a wood grain pattern, a stone pattern, a cloth pattern, a crest pattern, a geometric figure, a character, a symbol, or a solid surface. The pattern is provided on the front surface, back surface, both front and back surfaces, or between layers of the sheet. As ink (or paint), binder, chlorinated polyolefin such as chlorinated polyethylene, chlorinated polypropylene, polyester, polyurethane, acrylic resin, polyvinyl acetate, vinyl chloride / vinyl acetate copolymer, cellulose resin, etc. One type or a mixture of two or more types is used, and a known pigment as listed above is added thereto.

  The decorative sheet S shown in FIG. 9C is obtained by forming a concavo-convex pattern composed of the concave portions 15 on the resin sheet 11 by embossing (heating press), hairline processing, or the like. Embossing is a process in which the resin sheet 11 is heated and softened, pressed and shaped with an embossing plate, cooled and fixed to form a concavo-convex pattern, and can be performed using a known single-wafer or rotary embossing machine. it can. Examples of the uneven shape include a wood grain plate conduit groove, a stone plate surface unevenness (such as a granite cleaved surface), a cloth surface texture, a satin texture, a sand texture, a hairline, and a single line groove.

  Furthermore, as shown in FIG. 10, the colored ink 16 may be filled into the concave and convex portions 15 as necessary by a known wiping method (for example, see Japanese Patent Publication No. 58-14312). The same colored ink as described above can be used. However, it is preferable to use a two-component curable urethane resin as a binder in terms of wear resistance.

  Moreover, you may provide a metal thin film in a resin sheet as a decoration process. This metal thin film is formed by a method such as vacuum deposition or sputtering using a metal such as aluminum, chromium, gold, silver, copper, or tin. Alternatively, a combination thereof may be used. The metal thin film may be provided on the entire surface or partially in a pattern.

  The decorative sheet S shown in FIG. 9 and FIG. 10 is obtained by applying a decoration process to a single-layer resin sheet 11, but the decorative sheet S shown in FIG. 11 is formed by laminating resin sheets 11 a and 11 b. It has a layered structure.

  A decorative sheet S shown in FIG. 11A is obtained by forming a pattern layer 14 on one resin sheet 11a by printing and laminating another resin sheet 11b thereon. A decorative sheet S shown in FIG. 11 (b) is obtained by forming a patterned layer 14 on a resin sheet 11a colored by adding a pigment 12 and then laminating another resin sheet 11b thereon. The decorative sheet S shown in FIG. 11 (c) has a pattern layer 14 formed by printing on a resin sheet 11a colored by adding a pigment 12, and another resin sheet 11b is laminated thereon. A pattern 15 is formed.

  The decorative sheet shown in FIG. 12 is obtained by laminating a transparent resin sheet 17 on a resin sheet 11 with an adhesive layer 13 interposed therebetween. In this example, a patterned layer 14 is formed by printing on a resin sheet 11 colored by adding a pigment 12, and a transparent resin sheet 17 is dry-laminated via an adhesive layer 13 on the resin layer 11. 15 is formed.

  As a method for attaching the decorative sheet to the substrate, for example, as described in Japanese Patent Publication No. 56-45768, Japanese Patent Publication No. 60-58014, etc., the surface of the molded product is interposed between the adhesive layers. There is a so-called vacuum press lamination method in which a decorative sheet is placed or placed oppositely and the decorative sheet is laminated on the surface of the molded article by a pressure difference due to vacuum suction from the molded article side. Alternatively, as described in Japanese Patent Publication No. 61-5895, Japanese Patent Publication No. 3-2666, etc., a decorative sheet with an adhesive layer interposed in the major axis direction of a columnar substrate such as a cylinder or a polygonal column There is also a so-called wrapping method in which a decorative sheet is successively pressure-bonded and laminated on a plurality of side surfaces constituting a columnar body with a plurality of rollers having different directions while supplying the sheet.

  An example of a vacuum press apparatus is shown in FIG. This vacuum press apparatus P has an upper chamber member 21 that is driven in the vertical direction by a fluid pressure cylinder 20 and a fixed lower chamber member 22. The upper chamber member 21 has a box shape with an opening at the bottom, and a heat-resistant rubber film 23 is provided at the opening, thereby defining an upper chamber 24 having a sealed structure inside the upper chamber member 21. The A heater 25 is attached to the ceiling surface of the upper chamber member 21. On the other hand, the lower chamber 22 has a box shape with an upper opening, and a support base 26 for placing the substrate 1 is provided at the center. The upper chamber member 21 is provided with an upper port 27 for supplying and discharging air to the upper chamber 24, and the lower chamber member 22 is provided with a lower port 29 for supplying and discharging air to the lower chamber 28.

  The operation of this vacuum press apparatus P is as follows. First, as shown in the figure, the decorative sheet 2 is set on the base material 1 placed on the support base 26, and then the rubber film 23 is heated by energizing the heater 25 to generate heat. Next, the upper chamber member 21 is lowered by the fluid pressure cylinder 20 and brought into contact with the lower chamber member 22 as shown in the figure, and so-called mold clamping is performed. As a result, the heat-softened rubber film 23 is in close contact with the decorative sheet 2, the heat of the rubber film 23 is transmitted to the decorative sheet 2, and the decorative sheet 2 is softened by heating. Subsequently, after the air in the lower chamber 28 is exhausted to a vacuum state, pressurized air is supplied to the upper chamber 24 to pressurize it, and a differential pressure is generated between the upper chamber 24 and the lower chamber 28. Let Due to this differential pressure, the rubber film 23 is in close contact with the outer surface of the substrate 1 via the decorative sheet 2 so as to wrap it. Thereafter, the rubber film 23 is returned to the original state by returning the upper chamber 24 and the lower chamber 28 to atmospheric pressure. As a result, the decorative sheet 2 is adhered to the outer surface of the substrate 1.

[Mirror finish sheet]
As the material for the mirror surface imparting sheet, a sheet of resin, paper, resin-impregnated paper, metal or the like is used. However, it has good handling properties and processability (film formation, cutting, etc.), and heat distortion resistance (during lamination) Resin and resin-impregnated paper are preferable in terms of heat resistance (prevention of deformation and prevention of deformation) and heat insulation (preventing cooling of the decorative sheet heated and softened during molding and lamination). As the resin, either a thermosetting resin or a thermoplastic resin can be used, but a thermoplastic resin is usually used.

  The thermoplastic resin used for the mirror surface imparting sheet is preferably a thermoplastic resin having a relatively high melting point or softening point, hardly deformed, and hard (high elastic modulus). For example, polyester resins such as polyethylene terephthalate, polyethylene naphthalate, polybutylene terephthalate, ethylene glycol-terephthalic acid-isophthalic acid copolymer, terephthalic acid-ethylene glycol-1,4 cyclohexanedimethanol copolymer, polypropylene, polymethylpentene And the like, polyamide resins such as nylon 6, nylon 9, nylon 66, acrylic resin, polycarbonate resin, cellulose triacetate, rigid polyvinyl chloride, polyarylate and the like.

As the resin-impregnated paper, paper such as fine paper, thin paper, kraft paper, linter paper, sulfuric acid paper, Japanese paper, paraffin paper, etc. impregnated with urethane resin, melamine resin, acrylic resin, styrene-butadiene rubber or the like is used. A basis weight of about 30 to 100 g / m ² is used.

  When a resin sheet is used as the mirror surface imparting sheet, a resin sheet having at least a smooth and flat surface, preferably a smooth and flat resin sheet on both front and back surfaces is used. The front surface means a surface on the observer side of the decorative material, and the back surface means the opposite side, that is, the surface on the base material side. Here, a resin sheet having a smoothness of about 0.1 to 10 μm with a centerline average roughness (Ra) defined in “JIS-B0601” is used.

  And the thickness of the thermoplastic resin to be used is about 30-300 micrometers. When providing concealability as required, a colorant containing a high concealment pigment such as titanium dioxide or carbon black is added. If necessary, an extender pigment composed of particles such as calcium carbonate, barium sulfate, silicon dioxide, aluminum hydroxide, and kaolinite may be added for imparting heat resistance, preventing deformation, and hardening. Moreover, you may perform easy adhesion processes, such as a corona discharge process, an ozone process, and an easy adhesion primer process, to one side or both surfaces as needed.

  When applying a decorative sheet by the vacuum press lamination method described above, since the mirror surface imparting sheet on the substrate side is also heated, if the mirror surface imparting sheet is a thermoplastic resin, it is easy to soften during the vacuum press, and the mirror surface The state may not be maintained and may become uneven. Therefore, in such a case, it is preferable to use resin-impregnated paper as the mirror surface imparting sheet. Since this resin-impregnated paper is less deformable with respect to heat, it can be softened during vacuum pressing and maintain a mirror surface without the possibility of irregularities appearing on the surface.

[First adhesive]
The first adhesive is applied to the surface in contact with the top surface side of the substrate in the mirror surface imparting sheet. If it is applied to the substrate side, the substrate is made of a porous or absorbent material, and the texture is not uniform. It penetrates into the material and the surface of the adhesive becomes uneven. Therefore, even if a mirror surface imparting sheet is laminated thereon, the surface irregularities are picked up, and a complete mirror surface cannot be realized.

The first adhesive is preferably applied to the mirror surface imparting sheet by a system that can be applied with a uniform thickness (or coating amount) as much as possible. For example, roll coating, gravure (roll) coating, knife coating, comma coating, curtain flow coating, melt extrusion coating and the like are preferable. The coating amount is usually about 30 to 200 g / m ² .

  As the first adhesive, two-component curable urethane resin, epoxy resin, thermoplastic urethane resin, acrylic resin, polyvinyl acetate, vinyl chloride-vinyl acetate copolymer, ethylene vinyl-vinyl acetate copolymer, rubber, etc. Can be mentioned. Adhesives are applied in the form of a solution (or dispersion), solidified by drying of the solvent (or dispersion medium), bonded and cured by a crosslinking / curing reaction, heated and melted. Any of the methods of applying and bonding by cooling and solidification (so-called hot melt method) may be used, but the hot melt method is particularly preferable from the viewpoint of realizing a mirror surface and easy processing.

[Second adhesive]
A 2nd adhesive agent exists over the whole surface between a decorative sheet and a base material, and is for adhere | attaching a decorative sheet to a base material. Directly above the top surface portion, coating is performed with a mirror surface providing sheet interposed therebetween. Moreover, it coats directly on a board | substrate directly on a side part. The coating method and the coating amount are the same as those of the first adhesive.

  The same adhesive is applied to the second adhesive layer immediately above the top surface (referred to as the second adhesive layer for the mirror surface imparting sheet) and the second adhesive layer immediately above the side surface (referred to as the second adhesive layer for the side surface). It is also possible to apply an agent on the entire surface of the decorative sheet side or the substrate side at once, and to make both the second adhesive layers the same. In this case, the second adhesive layer may be applied on the back side of the decorative sheet, the surface side of the base material, or both the back side of the decorative sheet and the front side of the base material.

  However, in order to eliminate the level difference due to the presence or absence of the mirror surface imparting sheet in the vicinity of the boundary between the top surface portion and the side surface portion of the base material, as described with reference to FIGS. The second adhesive layer is preferably designed to be used separately. In this case, a heat-sensitive adhesive such as a thermoplastic urethane resin or vinyl chloride-vinyl acetate copolymer is used for the second adhesive layer for the mirror surface imparting sheet in a hot melt system. On the other hand, the second adhesive layer for the side surface portion may be a heat-sensitive melting type, a two-component curing type, a water-dispersed emulsion, or a moisture curing type.

[Protective sheet]
The protective sheet used in the production method of the present invention is laminated on the surface of the mirror surface imparting sheet so as to be peelable and removable to protect the mirror surface imparting sheet. That is, the mirror surface imparting sheet is laminated on the base material in a state where the protective sheet is laminated, and further, by cutting or polishing the periphery of the base material, the mirror surface imparting sheet is damaged when the mirror surface imparting sheet is laminated on the base material. Sticking can be prevented, and the cutting waste of the base material can be prevented from being mixed between the decorative sheet and the mirror surface imparting sheet.

  In addition to this, when adopting a form in which the second adhesive layer for the mirror surface imparting sheet is applied to the surface of the mirror surface imparting sheet in advance, the mirror surface imparting sheets may be stacked or rolled up When it does, there also exists an effect that this 2nd adhesive bond layer can prevent adhering with the back surface of a mirror surface provision sheet | seat (blocking).

  This protective sheet may be the same as the protective sheet used for protecting the surface of a decorative board or the like, and its thickness may be about 20 to 100 μm. Specifically, the back surface of a resin sheet such as polyethylene, polypropylene, nylon, or polyethylene terephthalate is coated with a pressure-sensitive adhesive that hardly transfers (adhesive residue) to the adherend side after peeling. Alternatively, the surface of the mirror surface imparting sheet may be formed into a protective sheet by forming a resin having releasability from the resin surface by solution coating, melt extrusion, etc. For example, polyethylene is coated on the mirror surface imparting sheet made of polyethylene terephthalate. The method of melt extrusion is mentioned.

  When applying a decorative sheet by the vacuum press lamination method described above, if the surface of the second adhesive layer is in a mirror state, air remains without being completely removed between the decorative sheet and the second adhesive layer. Sometimes. Therefore, if the surface of the second adhesive layer is matted, the occurrence of such residual air can be eliminated. The unevenness of the mat surface is preferably about 1 to 10 μm in center line average roughness (Ra). Such a matte surface can be formed as follows. That is, a protective sheet embossed with fine irregularities with a Ra of about 1 to 10 μm is used on the release surface, and the release sheet is applied to the second adhesive layer that has been semi-dried by coating with hot melt. By sticking them to face each other, the surface of the second adhesive layer after peeling off the protective sheet can be matted.

First, a 200 μm thick resin sheet made of unstretched polyethylene terephthalate with corona discharge treatment on both sides was prepared as a mirror surface imparting sheet, and a thermoplastic urethane resin adhesive was applied to the back surface thereof at 10 g / m ² by knife coating. The first adhesive layer was formed by coating.

Next, a plate-like MDF (medium density fiberboard) having a thickness of 15 mm formed by chamfering the peripheral edge portion of the surface with a curvature radius of 3 mm is prepared as a base material, and a mirror surface imparting sheet is provided only on the top surface portion of the base material. Was laminated such that the first adhesive layer side was the base material side, and was laminated by pressing with a roller. Next, an adhesive of thermoplastic urethane resin was applied at 10 g / m ² by spray coating over the upper surface of the mirror surface imparting sheet and the side surface of the base material to form a second adhesive layer.

  On the other hand, as a decorative sheet, a resin sheet having a thickness of 170 μm in which titanium white (pigment) is added to unstretched polyethylene terephthalate to give a color concealing property, ethylene glycol-1,4 hexagon is formed on both sides of the resin sheet. A decorative sheet having a thickness of 200 μm was prepared by coating methylene dimethanol-terephthalic acid copolymer with a thickness of 15 μm.

  And this decorative sheet was affixed on the base-material surface with the vacuum press apparatus as shown in FIG. That is, the decorative sheet is heated and softened in a state of being placed on the base material, and using the vacuum suction from the base material side, the decorative sheet is made to follow the surface shape of the side surface portion and the top surface portion of the base material, Adhesive lamination was performed over the entire surface of the mirror surface imparting sheet on the side surface portion and the top surface portion of the substrate. This vacuum forming was performed under the conditions of preheating of the decorative sheet: 120 ° C. × 120 seconds, vacuum pressure heating time: 120 ° C. × 120 seconds.

  The cosmetic material thus obtained was visually evaluated for surface specularity (flat smoothness). Under the same conditions, three decorative materials were prepared and evaluated, but the surface of each decorative material was a mirror surface, and irregularities and distortion of the reflected image were not recognized.

First, a 200 μm thick resin sheet made of unstretched polyethylene terephthalate was prepared as a mirror surface imparting sheet. And after applying the hot-melt-type adhesive agent which consists of a thermoplastic urethane resin to the surface of the mirror surface provision sheet | seat by 10 g / m < ² > by knife coating, the 2nd adhesive bond layer is formed. A 30 μm thick polyethylene sheet is laminated as a protective sheet, and a hot melt adhesive made of thermoplastic urethane resin is applied to the back surface of the mirror surface imparting sheet by knife coating at a rate of 10 g / m ² . An adhesive layer was formed.

  Next, prepare a MDF with a thickness of 15 mm as a base material, place the mirror surface imparting sheet on the surface of the base material so that the first adhesive layer side is the base material side, and heat and press with a heating roller Laminated with. After the mirror surface imparting sheet with the protective sheet was stuck on the surface of the substrate in this way, the sheet was cut into a predetermined size and then cut by a router so that the corners became 3 mmR. Thereby, a base material is shape | molded by the three-dimensional shape containing the top | upper surface part formed by laminating | stacking a mirror surface provision sheet | seat on the surface, and the side part which a base material exposes.

Next, a thermoplastic urethane resin adhesive was applied by spray coating at 10 g / m ² immediately above the side surface of the substrate to form a second adhesive layer, and then the protective sheet was peeled off from the surface of the mirror surface imparting sheet. .

  On the other hand, a resin sheet having a thickness of 170 μm, which is colored by adding titanium white (pigment) to unstretched polyethylene terephthalate, and ethylene glycol-1,4 hexamethylene dimethanol-terephthalic acid copolymer on both sides of the resin sheet. A decorative sheet with a thickness of 200 μm was prepared.

  And this decorative sheet was affixed on the base-material surface with the vacuum press apparatus as shown in FIG. That is, the decorative sheet is heated and softened in a state of being placed on the base material, and using the vacuum suction from the base material side, the decorative sheet is made to follow the surface shape of the side surface portion and the top surface portion of the base material, Adhesive lamination was performed over the entire surface of the mirror surface imparting sheet on the side surface portion and the top surface portion of the substrate. This vacuum forming was performed under the conditions of preheating of the decorative sheet: 120 ° C. × 120 seconds, vacuum pressure heating time: 120 ° C. × 120 seconds.

Those in Example 2, with changing the mirror imparting sheet acrylic resin impregnated paper having a basis weight of 30 g / m ^2, were laminated a release layer made of a polyethylene resin protective sheet on the surface of woodfree paper having a basis weight of 30 g / m ² Replaced. This release layer has a matte surface whose surface has a center line average roughness (Ra) of 6 μm. And the mat | matte surface of the protective sheet and the 2nd adhesive bond layer were made to oppose. Others were the same as in Example 2.

  The cosmetic material thus obtained was visually evaluated for surface specularity (flat smoothness). Under the same conditions, three decorative materials were prepared and evaluated, but the surface of each decorative material was a mirror surface, and irregularities and distortion of the reflected image were not recognized. In addition, in the vicinity of the boundary between the top surface portion and the side surface portion, there is no difference in level, and the surface is a smooth curved surface from the top surface portion to the side surface portion.

(Comparative example)
As a comparative example, a decorative sheet was attached by vacuum forming (vacuum press) without using a mirror surface imparting sheet. The procedure is as follows.

First, a plate-like MDF (medium density fiberboard) having a thickness of 15 mm formed by chamfering the peripheral edge of the surface with a curvature radius of 3 mm was prepared as a base material. Next, after spray-applying a water-dispersed urethane emulsion adhesive at 70 g / m ² on the base sheet surface of the decorative sheet similar to that in Example 1, the adhesive layer side of the decorative sheet faces the surface of the base. And laminated with a vacuum press as shown in FIG. 13 to produce a decorative material. This vacuum forming was performed under the conditions of preheating of the decorative sheet: 120 ° C. × 120 seconds, vacuum pressure heating time: 120 ° C. × 120 seconds.

  The cosmetic material thus obtained was visually evaluated for surface specularity (flat smoothness). Under the same conditions, three decorative materials were produced and evaluated, but the surface of each decorative material was found to have fine skin-like irregularities.

  The decorative material of the present invention is suitably used for top plates and doors of kitchen equipment, dining tables, desks, shelves, etc., and also has features such as handrails, baseboards, window frames, doors, door frames, etc. in buildings. It can also be used for members and joinery.

It is sectional drawing which shows typically an example of the decorative material which concerns on this invention. It is sectional drawing of the mirror surface provision sheet | seat which provided the 1st adhesive bond layer, the 2nd adhesive bond layer, and the protection sheet. It is sectional drawing which shows the state which laminated | stacked the mirror surface provision sheet | seat of FIG. 2 on the base material. It is sectional drawing which shows the state which chamfered the corner part in the laminated body of FIG. It is sectional drawing which shows the state which formed the 2nd adhesive bond layer just on the side part in the laminated body of FIG. It is sectional drawing which shows what peeled the protective sheet from the laminated body of FIG. It is sectional drawing which shows the state which stuck the decorative sheet to the laminated body of FIG. It is a perspective view which shows the shape of the base material in the decorative material of this invention. It is sectional drawing which shows an example of a decorative sheet. It is sectional drawing which shows the other example of a decorative sheet. It is sectional drawing which shows the other example of a decorative sheet. It is sectional drawing which shows the other example of a decorative sheet. It is a schematic block diagram which shows an example of a vacuum press apparatus.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Base material 1a Top surface part 1b Side surface part 2 Cosmetic sheet 3 1st adhesive layer 4 Mirror surface provision sheet 5 2nd adhesive layer 5a, 5b 2nd adhesive layer 6 Protection sheet 11 Resin sheet 11a, 11b Resin sheet 12 Pigment 13 Easy adhesion layer 14 Pattern layer 15 Concave portion 16 Colored ink 17 Transparent resin sheet 20 Fluid pressure cylinder 21 Upper chamber member 22 Lower chamber member 23 Rubber film 24 Upper chamber 25 Heater 26 Support base 27 Upper port 28 Lower chamber 29 Lower port C Cosmetic material P Vacuum press S S Cosmetic sheet

Claims (4)

A decorative material formed by sticking a decorative sheet on the surface of a thick plate-like base material made of a porous or absorbent material, the base material having a top surface portion and a side surface portion curved and connected thereto. And has a first adhesive layer partially infiltrated in the vicinity of the surface of the base material only on the top surface portion of the base material, and at least the viewer side of the front and back surfaces on the first adhesive layer It has a mirror surface imparting sheet made of a resin sheet having a flat and smooth surface , and has a second adhesive layer over the entire side surface of the base material and the mirror surface imparting sheet. A decorative material, wherein a decorative sheet obtained by applying a decorative treatment to a base material sheet of a thermoplastic resin is laminated on the agent layer following the surface shape of the top surface portion and the side surface portion.   The cosmetic material according to claim 1, wherein the thickness of the peripheral edge of the mirror surface imparting sheet gradually decreases from the top surface portion to the side surface portion.   The cosmetic material according to claim 1 or 2, wherein the second adhesive layer has a top surface portion and a side surface portion formed from separate adhesive layers. The method for manufacturing a cosmetic material according to claim 1, wherein the following steps are sequentially performed.
(1) A mirror surface imparting sheet comprising a resin sheet having a flat and smooth film formed on at least the viewer side of the front and back surfaces is prepared, and a room temperature solid heat-sensitive fusion resin is applied to the surface of the mirror surface imparting sheet. A first step of laminating a second adhesive layer and a peelable protective sheet in this order, and forming a first adhesive layer on the back surface.
(2) A thick plate made of a porous or absorptive material is prepared as a base material, and a mirror surface imparting sheet is placed on the surface of the base material so that the first adhesive layer side is the base material side. And the second step of laminating.
(3) The periphery of the base material is polished or cut from the protective sheet to the side surface, and the base material is formed into a three-dimensional shape including a top surface portion formed by laminating a mirror surface imparting sheet on the surface and a side surface portion formed by exposing the base material. 3rd process to shape | mold.
(4) A fourth step of forming a second adhesive layer directly on the side surface of the substrate.
(5) 5th process which peels a protective sheet from the surface of a mirror surface provision sheet | seat.
(6) A decorative sheet formed by decorating a thermoplastic resin base material sheet is prepared, the decorative sheet is heated and softened, and the decorative sheet is attached to the base material by vacuum suction from the base material side. A sixth step of adhering and laminating the entire surface of the mirror surface imparting sheet on the side surface portion of the substrate and the top surface portion of the base material while following the surface shapes of the side surface portion and the top surface portion.

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